light SUBARU FORESTER 2004 Service Repair Manual
[x] Cancel search | Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
Page 2420 of 2870
4AT-106
AUTOMATIC TRANSMISSION
Oil Pump Housing
2) Install the torque converter clutch case to trans-
mission case.
3) Install the reduction driven gear.
4) Install the reduction drive gear.
5) Align the transmission case and extension case.
6) Insert the inhibitor switch and transmission con-
nector to the stay.
7) Install the ATF cooler pipe.
8) Install the ATF charger pipe with O-ring.
9) Insert the input shaft with rotating it by hand
lightly, and then check the protrusion amount.
Normal protrusion A:
50 — 55 mm (1.97 — 2.17 in)
10) Install the torque converter clutch assembly.
11) Install the transmission assembly into the vehi-
cle.
1. OIL PUMP COVER
1) Remove four seal rings.
2) Remove the installing bolt, and then remove the
cover by lightly tapping the end of starter shaft.
3) Remove the oil pump inner and outer rotor.
(A) Transmission harness ASSY
(B) Inhibitor switch harness
AT-01351
(B)(A)
AT-00291
A
(A) Seal ring
(A) Oil pump cover
(B) Oil pump housing
(A) Oil pump inner rotor
(B) Oil pump outer rotor
AT-00189
(A)
AT-00190
(A)(B)
AT-01036
(A)(B)
Page 2426 of 2870
4AT-112
AUTOMATIC TRANSMISSION
Drive Pinion Shaft Assembly
9) Install the ATF charger pipe with O-ring.
10) Insert the input shaft with rotating it by hand
lightly, and then check the protrusion amount.
Normal protrusion A:
50 — 55 mm (1.97 — 2.17 in)
11) Install the torque converter clutch assembly.
12) Install the transmission assembly into the vehi-
cle.
C: DISASSEMBLY
1) Remove the caulking part of lock nut, and then
remove the lock nut with holding rear spline part of
drive pinion shaft using ST1 and ST2. Pull out the
drive pinion collar.
ST1 498937110 HOLDER
ST2 499787700 WRENCH
ST3 499787500 ADAPTER
2) Remove the O-ring.3) Separate the roller bearing and outer race from
drive pinion shaft using the press.
4) Separate the front roller bearing from drive pin-
ion shaft using the press and ST.
ST 498517000 REPLACER
D: ASSEMBLY
1) Measure the dimension “A” of drive pinion shaft
ST 398643600 GAUGE
AT-00291
A
AT-00197
ST1
ST3
ST2
(A) Outer race
(A) Front roller bearing
AT-00198
(A)
AT-00199
(A)
ST
A
AT-00200
Page 2428 of 2870
4AT-114
AUTOMATIC TRANSMISSION
Drive Pinion Shaft Assembly
10) Select three or less shims from following table.
E: INSPECTION
Make sure that all component parts are free of
harmful cut, gouges, and other faults.
Adjust the teeth alignment.
F: ADJUSTMENT
1) Remove the liquid gasket completely.
2) Install the oil pump housing assembly to torque
converter clutch case, and secure them with tight-
ening four bolts evenly.
NOTE:
Use an old gasket or an aluminum washer so as not
to damage the mating surface of housing.
Tightening torque:
41 N
⋅m (4.2 kgf-m, 30.4 ft-lb)
3) Rotate the drive pinion several times using ST1
and ST2.
ST1 498937110 HOLDER
ST2 499787700 WRENCH4) Adjust backlash between drive pinion and hy-
poid driven gear.
5) Apply red lead evenly to the surfaces of three or
four teeth on hypoid driven gear. Rotate the drive
pinion in the forward and reverse directions for sev-
eral times. Remove the oil pump housing, and
check the tooth contact pattern.
If the tooth contact is improper, readjust the back-
lash or shim thickness.
Correct tooth contact
Checking item: Tooth contact pattern is slightly
shifted toward to toe side under no-load
rotation. [When loaded, contact pattern moves
toward heel.]
Face contact
Checking item: Backlash is too large.
Contact pattern
Drive pinion shim
TOOL NUMBER Thickness mm (in)
31451AA050 0.150 (0.0059)
31451AA060 0.175 (0.0069)
31451AA070 0.200 (0.0079)
31451AA080 0.225 (0.0089)
31451AA090 0.250 (0.0098)
31451AA100 0.275 (0.0108)
AT-00205
AT-00206
ST2
ST1
(A) Toe side
(B) Heel side
AT-00207
(A)
(B)
AT-00208
Page 2432 of 2870
4AT-118
AUTOMATIC TRANSMISSION
Front Differential
6) Install the new seal pipe to torque converter
clutch case.
7) Install the torque converter clutch case to trans-
mission case.
8) Insert the inhibitor switch and transmission con-
nector to the stay.
9) Install the ATF cooler pipe.
10) Install the ATF charger pipe with O-ring.
lightly, and then check the protrusion amount.
Normal protrusion A:
50 — 55 mm (1.97 — 2.17 in)
12) Install the torque converter clutch assembly.
13) Install the transmission assembly into the vehi-
cle.
C: DISASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
1) Remove taper roller bearing using ST and press.
ST 498077000 REMOVER
(A) Seal pipe
(A) Transmission harness ASSY
(B) Inhibitor switch harness
AT-00176
AT-01351
(B)(A)
AT-00291
A
AT-00216
Page 2435 of 2870
4AT-121
AUTOMATIC TRANSMISSION
Front Differential
6) Using ST, install the taper roller bearing.
ST 398487700 INSTALLER
2. DIFFERENTIAL SIDE RETAINER
1) Install the bearing outer race to differential side
retainer.
2) Install a new oil seal using ST and plastic ham-
mer.
ST 18675AA000 DIFFERENTIAL OIL SEAL IN-
STALLER
3) Install a new O-ring.
E: INSPECTION
Check each component for harmful cuts, dam-
age and other faults.
Measure the backlash, and then adjust it within
specification.
F: ADJUSTMENT
1) Using ST, screw-in the differential side retainer
until light contact is felt.
NOTE:
Screw-in the RH side slightly deeper than the LH
side.
ST 499787000 WRENCH ASSY
2) Remove the oil pump housing.
3) Remove the liquid gasket completely.
4) Install the oil pump housing assembly to torque
converter clutch case, and secure them with tight-
ening four bolts evenly.
NOTE:
Use an old gasket or an aluminum washer so as not
to damage the mating surface of housing.
Tightening torque:
41 N
⋅m (4.2 kgf-m, 30.4 ft-lb)
5) Rotate the drive pinion several times using ST1
and ST2.
ST1 498937110 HOLDER
ST2 499787700 WRENCH
(A) Taper roller bearing
AT-00225
AT-00226
ST
AT-00219
AT-00227
ST
AT-00205
AT-00206
ST2
ST1
Page 2445 of 2870
4AT-131
AUTOMATIC TRANSMISSION
AT Main Case
35) Install the oil pump housing assembly with a
new gasket.
36) Install the torque converter clutch case assem-
bly into transmission case assembly.
Case.>
37) Insert the inhibitor switch and transmission
connector to the stay.
38) Install the air breather hose.
39) Install the ATF cooler pipe.
40) Install the ATF charger pipe with O-ring.
41) Insert the input shaft with rotating it by hand
lightly, and then check the protrusion amount.
Normal protrusion A:
50 — 55 mm (1.97 — 2.17 in)
42) Install the torque converter clutch assembly.
43) Install the transmission assembly into the vehi-
cle.
1. HIGH CLUTCH AND REVERSE CLUTCH
1) Remove the snap ring, and then take out the re-
taining plate, drive plate and driven plate.
2) Remove the snap ring, and then take out the re-
taining plate, drive plate and driven plate.
3) Using ST1 and ST2, remove the snap ring.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
(A) Transmission harness
(B) Inhibitor switch harness
AT-01351
(B)(A)
AT-00291
A
(A) Snap ring
(A) Snap ring
(A) Snap ring
AT-00236
(A)
AT-00237
(A)
AT-00238
(A)
ST1
ST2
Page 2457 of 2870
4AT-143
AUTOMATIC TRANSMISSION
Transmission Control Device
2) Insert the range select lever, and then tighten
the bolt.
Tightening torque:
6 N
⋅m (0.6 kgf-m, 4.4 ft-lb)
3) Insert the manual plate and parking rod.
4) Insert the spring pin to manual plate.
5) Install the oil pan and control valve assembly.
6) Turn over the transmission case to its original
position.
7) Install the pitching stopper bracket.
Tightening torque:
41 N
⋅m (4.2 kgf-m, 30.4 ft-lb)
8) Install and adjust the inhibitor switch.
nector to the stay.
10) Install the air breather hose.
11) Insert the input shaft with rotating it by hand
lightly, and then check the protrusion amount.
Normal protrusion A:
50 — 55 mm (1.97 — 2.17 in)
12) Install the torque converter clutch assembly.
13) Install the transmission assembly into the vehi-
cle.
C: INSPECTION
Make sure the manual lever and detention spring
are not worn or otherwise damaged.
(A) Bolt
(B) Range select lever
(C) Manual plate
(D) Parking rod
AT-00308
AT-00306
AT-00305
(A) Transmission harness
(B) Inhibitor switch harness
AT-01351
(B)(A)
AT-00291
A
Page 2460 of 2870
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)
4AT(H4SO)
Page
1. Basic Diagnostic Procedure ........................................................................2
2. Check List for Interview ...............................................................................4
3. General Description ....................................................................................5
4. Electrical Components Location..................................................................8
5. Transmission Control Module (TCM) I/O Signal .......................................12
6. Subaru Select Monitor...............................................................................17
7. Read Diagnostic Trouble Code (DTC) ......................................................20
8. Inspection Mode ........................................................................................22
9. Clear Memory Mode..................................................................................23
10. Power Indicator Light Display....................................................................24
11. Diagnostic Procedure for Subaru Select Monitor Communication ............32
12. List of Diagnostic Trouble Code (DTC) .....................................................35
13. Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....................36
14. Diagnostic Procedure without Diagnostic Trouble Code (DTC) ................84
15. Symptom Related Diagnostic ..................................................................110
Page 2461 of 2870
4AT(H4SO)-2
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Basic Diagnostic Procedure
1. Basic Diagnostic Procedure
A: PROCEDURE
Step Check Yes No
1 CHECK PRE-INSPECTION.
1) Ask the customer when and how trouble
occurred using interview checklist.
2) Before performing the diagnosis, inspect
following items which might influence the AT
problems.
General inspection
Disconnection of harness connector
Visually check the damage of harness
Oil leak
Stall speed test
Line pressure test
Transfer clutch pressure test
Time lag test
Road test
Inhibitor switch
AT problem normal?Go to step 2.Repair or replace
each item.
2 CHECK POWER INDICATOR LIGHT.
Turn the ignition switch to ON.Does the POWER indicator
light illuminate?Go to step 4.Go to step 3.
3 CHECK POWER INDICATOR LIGHT.
1) Turn the ignition switch to OFF.
2) Repair the POWER indicator light circuit or
power supply and ground line circuit.
3) Turn the ignition switch to ON.Is the POWER indicator light
illuminate?Go to step 4.Go to step 5.
4 CHECK INDICATION OF DTC.
Calling up the DTC.
Without Subaru Select Monitor
Diagnostic Trouble Code (DTC).>
With Subaru Select Monitor
Diagnostic Trouble Code (DTC).>
NOTE:
If the communication function of select monitor
cannot be executed normally, check the communi-
cation circuit.
Diagnostic Procedure for Subaru Select Monitor
Communication.>Is the DTC displayed? Go to step 6.
NOTE:
Record all DTC.Go to step 5.
Page 2463 of 2870
4AT(H4SO)-4
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Check List for Interview
2. Check List for Interview
A: CHECK
Check the following items when problem has occurred.
NOTE:
Use copies of this page for interviewing customers.
Customer’s name
Date of purchase
Date of repair
Trans. model TRANSMISSION VIN
Odometer readingkm/h (miles)
Frequency❏ Continuous ❏ Intermittent ( times a day)
Weather❏ Fine ❏ Cloudy ❏ Rainy ❏ Snowy
❏ Others
()
Place❏ High ❏ Suburbs ❏ Inner city ❏ Uphill ❏ Rough road
❏ Others
()
Outdoor temperature❏ Hot ❏ Wa r m ❏ Cool ❏ Cold
Vehicle speedkm/h (MPH)
AT warning light (POWER indicator
light)❏ Continuously lit❏ Not lit
Select lever position❏ P ❏ R ❏ N ❏ D ❏ 3 ❏ 2 ❏ 1
Driving condition❏ Not affected
❏ At racing
❏ While decelerating❏ At starting
❏ While accelerating
❏ While turning (❏ RH/❏
LH)❏ While idling
❏ While cruising
POWER switch❏ ON ❏ OFF
HOLD switch❏ ON ❏ OFF
Symptoms❏ No up-shift
❏ No down-shift
❏ No kick down
❏ Vehicle does not move (❏ Any position ❏ Particular position)
❏ Lock-up malfunction
❏ Noise or vibration
❏ Shift shock or slip
❏ Select lever does not move
❏ Others
()