torque SUBARU FORESTER 2004 Service Repair Manual

CS-21
CONTROL SYSTEM
MT Gear Shift Lever
3) Mount each part; boot, O-ring, bushing A, spac-
er, bushing B, bushing and spring pin on the gear
shift lever.
NOTE:
 Always use new O-rings.
 Apply grease [SUNLIGHT 2 (Part No. 003602010)
or equivalent] to the inner and side surfaces of the
bush when installing the spacer.
4) Insert the gear shift lever into boot hole.
5) Install the snap ring and stay to bushing B.6) Tighten with a lock wire to the extent that the
boot will not come off.
NOTE:
Always use new lock wire.
7) Insert the rod into boot hole.
8) Connect the rod to gear shift lever.
Tightening torque:
12 N·m (1.2 kgf-m, 8.7 ft-lb)
(A) Boot
(B) O-ring
(C) Bushing
(D) Spacer
(E) Bushing A
(F) Bushing B
(G) Spring pin
(H) O-ring
(A) Snap ring
(B) Bushing B
CS-00062
(F)(D)(C)
(E)
(G)
(H)
(B)
(A)
CS-00165
(A)(B)
(A) Lock wire
(B) Stay
(A) Rod
(B) Gear shift lever
(C) Stay
CS-00055
(B)
(A)
CS-00056
(A)
(B)
(C)

CS-22
CONTROL SYSTEM
MT Gear Shift Lever
E: INSPECTION
1) Check each part (bushing, cushion rubber, spacer,
boot, stay, rod, etc.) for deformation, damage and
wear. Repair or replace any defective part. Determine
defective parts by comparing with new parts.
2) Check the swing torque of the rod connected to
gear shift lever.
If the torque exceeds specification, replace the
bushing or retighten nuts.
Swing torque:
3.7 N (0.38 kgf, 0.83 lb) or less3) Check that there is no excessive play and that
parts move smoothly.
(A) Bushing
(B) Cushion rubber
(C) Spacer
(D) Boot
(E) Stay
(F) Rod
(A) Center of rotation
(B) Swing torque
(C)
(D)(A) (F) (A)
CS-00064
(E)(B)
CS-00065
(A)
(B)

CS-23
CONTROL SYSTEM
MT Drive Select Lever
6. MT Drive Select Lever
A: REMOVAL
1) Apply parking brake and place chocks to hold
wheels.
2) Disconnect the ground cable from battery.
3) Shift the drive select lever to HI position.
4) Remove the knob.
5) Remove the console box. MOVAL, Console Box.>
6) Remove the bolt installing drive select lever as-
sembly on body.
7) Remove the flange nut and clip, and then dis-
connect the cable from lever assembly.
B: INSTALLATION
1) Install the drive select cable to lever assembly,
and then fasten it with a clip.
2) Install the drive select lever.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
3) Shift the drive select lever to HI position.
4) Insert the cable eye end bolt into lever arm slit.
5) Tighten the nut where cable eye end bolt comes
to a stop.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
(A) Flange nut
(B) Lever ASSY
(C) Clip
CS-00102
CS-00067
(C)(A)(B)
(A) Flange nut
(B) Lever ASSY
(C) Clip
(A) HI position
(A) Cable eye end bolt
(B) Lever arm
CS-00067
(C)(A)(B)
CS-00068
(A)
CS-00069
(A) (B)

CS-24
CONTROL SYSTEM
MT Drive Select Lever
6) Install in the reverse order of removal.
C: DISASSEMBLY
1) Remove the spring.
2) Remove the lever, cushion and bushing.
D: ASSEMBLY
1) Assemble in the reverse order of disassembly.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
2) Make sure the select lever moves smoothly.
E: INSPECTION
1) Make sure the select lever moves smoothly. If it
does not move smoothly, repair or replace it.
2) Make sure the drive select lever is not damaged.
If it is damaged, repair or replace it.
(A) Spring
(A) Washer
(B) Bushing
(C) Plate ASSY
(D) Cushion
(E) Lever ASSY
CS-00070
(A)
CS-00071
(E)(C)
(D)(B)(A)

CS-25
CONTROL SYSTEM
Drive Select Cable
7. Drive Select Cable
A: REMOVAL
1) Remove the drive select lever. REMOVAL, MT Drive Select Lever.>
2) Remove the intake duct. REMOVAL, Air Intake Duct.>
3) Remove the air cleaner case. 6, REMOVAL, Air Cleaner Case.>
4) Remove the snap pin and clevis pin.
5) Loosen the nut and disconnect the cable from
cable bracket.
6) Disconnect the cable from transmission clamp.
7) Remove the cable from the under side of vehi-
cle.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Make sure the drive select lever operates prop-
erly.
C: INSPECTION
1) Shift the transmission to HI or LO position by
moving the drive select lever. If it does not move,
adjust the cable. Drive Select Cable.>
2) Make sure the cable moves smoothly. If it catch-
es or fails to work properly, repair or replace it.
3) Check the cable for damage.
D: ADJUSTMENT
1) Shift the drive select lever to HI position.
2) Remove the drive select lever knob.
3) Remove the console box. MOVAL, Console Box.>
4) Remove the nut.
5) Make sure the transmission is in HI position. If it is
not, pull the cable to put transmission in HI position.
6) Tighten the nut in the location where cable end
bolt stops naturally.
Tightening torque:
18 N·m (1. 8 kgf-m, 13.0 ft-lb)
7) Shift the transmission to HI or LO position by
moving the drive select lever. If it does not move,
readjust the cable.
(A) Snap pin
(B) Clevis pin
(C) Nut
CS-00103(A) (B) (C)
CS-00073
CS-00104
CS-00104

AUTOMATIC TRANSMISSION
4AT
Page
1. General Description ....................................................................................2
2. Automatic Transmission Fluid ...................................................................30
3. Differential Gear Oil...................................................................................31
4. Road Test..................................................................................................32
5. Stall Test ...................................................................................................33
6. Time Lag Test ...........................................................................................35
7. Line Pressure Test ....................................................................................36
8. Transfer Clutch Pressure Test ..................................................................38
9. Automatic Transmission Assembly ...........................................................39
10. Transmission Mounting System ................................................................47
11. Extension Case Oil Seal ...........................................................................49
12. Differential Side Retainer Oil Seal.............................................................50
13. Inhibitor Switch ..........................................................................................51
14. Front Vehicle Speed Sensor .....................................................................55
15. Rear Vehicle Speed Sensor ......................................................................59
16. Torque Converter Turbine Speed Sensor .................................................60
17. Control Valve Body ...................................................................................61
18. Air Bleeding of Control Valve ....................................................................70
19.
Shift Solenoids, Duty Solenoids and ATF Temperature Sensor.........................71
20. Transfer Duty Solenoid and Valve Body ...................................................73
21. ATF Filter ..................................................................................................76
22. Transmission Control Module (TCM) ........................................................77
23. Dropping Resistor .....................................................................................78
24. ATF Cooler Pipe and Hose .......................................................................79
25. ATF Cooler (With Warmer Function).........................................................84
26. Air Breather Hose......................................................................................87
27. Oil Charger Pipe........................................................................................88
28. Torque Converter Clutch Assembly ..........................................................89
29. Extension Case .........................................................................................90
30. Transfer Clutch..........................................................................................92
31. Reduction Driven Gear..............................................................................97
32. Reduction Drive Gear................................................................................99
33. Parking Pawl ...........................................................................................101
34. Torque Converter Clutch Case ...............................................................102
35. Oil Pump Housing ...................................................................................105
36. Drive Pinion Shaft Assembly ...................................................................111
37. Front Differential......................................................................................117
38. AT Main Case .........................................................................................123
39. Transmission Control Device ..................................................................142

4AT-2
AUTOMATIC TRANSMISSION
General Description
1. General Description
A: SPECIFICATION
1. TORQUE CONVERTER CLUTCH
2. OIL PUMP
3. TRANSMISSION CONTROL ELEMENT
4. TRANSMISSION GEAR RATIO5. PLANETARY GEAR AND PLATE
Model2.0 L
Non-
turbo2.5 L
Non-
turbo2.0 L
Tu r b o2.5 L
Tu r b o
Ty p eSymmetric, 3 element, single stage, 2 phase
torque converter
Stall torque
ratio2.0 —
2.21.9 —
2.11.85 —
2.152.05 —
2.35
Nominal
diameter246 mm (9.69 in)
Stall speed
(at sea level)2,000 —
2,500
rpm2,100 —
2,600
rpm2,600 —
3,300
rpm2,700 —
3,200
rpm
One-way
clutchSprague type one-way clutch
Type Pracoid constant-displacement pump
Driving method Driven by engine
Number of teethInner rotor 9
Outer rotor 10
Ty p e4-forward, 1-reverse, double-row plan-
etary gears
Multi-plate clutch 3 sets
Multi-plate brake 2 sets
One-way clutch
(sprague type)1 sets
Gear ratio
1st 2.785
2nd 1.545
3rd 1.000
4th 0.694
Rev 2.272
Model2.0 L Non-
turbo2.5 L Non-
turboTu r b o
Tooth num-
ber of front
sun gear33
Front pinion
number of
teeth21
Front inter-
nal gear
number of
teeth75
Tooth num-
ber of rear
sun gear42
Rear pinion
number of
teeth17
Tooth num-
ber of rear
internal gear75
Drive &
driven plate
number of
high clutch45
Drive &
driven plate
number of
low clutch467
Drive &
driven plate
number of
reverse
clutch2
Drive &
driven plate
number of 2-
4 brake34
Drive &
driven plate
number of
low &
reverse
brake467

4AT-5
AUTOMATIC TRANSMISSION
General Description
B: COMPONENT
1. TORQUE CONVERTER CLUTCH AND CASE
(1) Pitching stopper bracket (11) Torque converter clutch ASSYTightening torque: N⋅m (kgf-m, ft-lb)
(2) O-ring (12) Differential gear oil
Drain plugT1: 18 (1.8, 13.0)
(3) Differential oil level gaugeT2: 41 (4.2, 30.4)
(4) Stay (13) GasketT3: 44 (4.5, 32.5)
(5) Seal pipe (14) Oil sealT4: 33 (3.4, 24.3)
(6) Oil pump shaft (15) Clip (Turbo model)T5: 21 (2.1, 15.5)
(7) Clip (16) Torque converter clutch caseT6: 23 (2.3, 17.0)
(8) Rubber seal (17) ATF cooler (with warmer function)
(if equipped)
(9) Input shaft
(10) O-ring
AT-01862
T2
T2
T2T2
T3
T1
(8)
(11) (1)
(2)
(3)
(4)
(7)(5)
(6)
(10)(9)
(14)
(16)
(12)
(13)
(15)
T5 T4T6(17)

4AT-6
AUTOMATIC TRANSMISSION
General Description
2. OIL PUMP
(1) Oil pump rotor (11) Gasket (21) Lock nuts
(2) Oil pump cover (12) O-ring
(3) Seal ring (13) Test plugTightening torque: N
⋅m (kgf-m, ft-lb)
(4) Thrust needle bearing (14) Stud boltT1: 7 (0.7, 5.1)
(5) Drive pinion shaft (15) O-ringT2: 13 (1.3, 9.4)
(6) Roller bearing (16) O-ringT3: 18 (1.8, 13.0)
(7) Drive pinion shim (17) Oil seal retainerT4: 25 (2.5, 18.1)
(8) Oil pump housing (18) Oil sealT5: 40 (4.1, 29.5)
(9) Nipple (19) O-ringT6: 42 (4.3, 31)
(10) Air breather hose (20) Drive pinion collarT7: 116 (11.8, 85)
AT-00003

4AT-8
AUTOMATIC TRANSMISSION
General Description
(1) ATF level gauge (19) Oil filter (41) Transmission case
(2) ATF charger pipe (20) Oil filter stud bolt (42) Plate ASSY
(3) O-ring (21) Drain plug (ATF) (43) Washer
(4) Transfer valve plate (22) Gasket (44) Bushing (turbo model)
(Non-turbo model) (23) Oil pan (45) ATF cooler inlet pipe (model with
ATF cooler (with warmer func-
tion)) (5) Transfer valve ASSY (24) Magnet
(Non-turbo model) (25) Stud bolt (Short)
(6) Transfer clutch seal
(Non-turbo model)(26) Stud bolt (Long) (46) ATF cooler outlet pipe (model
with ATF cooler (with warmer
function)) (27) Parking rod
(7) Transfer duty solenoid (non-turbo
model)(28) Manual plate
(29) Spring pin
(8) Straight pin (30) Detention springTightening torque: N
⋅m (kgf-m, ft-lb)
(9) Return spring (31) BallT1: 3.4 (0.35, 2.6)
(10) Shaft (32) SpringT2: 5 (0.5, 3.6)
(11) Parking pawl (33) GasketT3: 6 (0.6, 4.4)
(12) Parking support (34) ATF cooler outlet pipe (model
without ATF cooler (with warmer
function))T4: 8 (0.8, 6)
(13) Inlet filter (Non-turbo model)T5: 12 (1.2, 8.7)
(14) GasketT6: 13 (1.3, 10)
(15) ATF cooler inlet pipe (model with-
out ATF cooler (with warmer func-
tion))(35) Union screwT7: 14 (1.4, 10)
(36) Oil sealT8: 18 (1.8, 13)
(37) Range select leverT9: 25 (2.5, 18.1)
(16) Union screw (38) Inhibitor switch ASSYT10: 45 (4.6, 33.2)
(17) O-ring (39) NippleT11: 21 (2.1, 15.5)
(18) Test plug (40) Air breather hose