torque SUBARU FORESTER 2004 Service Repair Manual

4AT-71
AUTOMATIC TRANSMISSION
Shift Solenoids, Duty Solenoids and ATF Temperature Sensor
19.Shift Solenoids, Duty Sole-
noids and ATF Temperature
Sensor
A: REMOVAL
1. SHIFT SOLENOID AND DUTY SOLE-
NOID
1) Lift-up the vehicle.
2) Clean the transmission exterior.
3) Drain the ATF completely.
4) Replace the gasket with new one, and then tight-
en the drain plug (ATF).
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
5) Remove the oil pan.
6) Disconnect the solenoid and duty solenoid con-
nectors.7) Remove the solenoid and duty solenoid.
2. ATF TEMPERATURE SENSOR
For removal procedure of the ATF temperature
sensor, refer to “Front Vehicle Speed Sensor”.
Sensor.>
B: INSTALLATION
1. SHIFT SOLENOID AND DUTY SOLE-
NOID
1) Insert the solenoid and duty solenoid into the
specified position.
(A) Oil pan
(B) Drain plug (ATF)
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
(H) Transfer duty solenoid (Brown)
AT-00080
(A)(B)
AT-02122
(A) (B) (C) (D) (E)
(H)
(F)
(G)
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
AT-02124
(E)
(F)(G)
(D)(C)
(B)(A)
AT-02124
(E)
(F)(G)
(D)(C)
(B)(A)

4AT-72
AUTOMATIC TRANSMISSION
Shift Solenoids, Duty Solenoids and ATF Temperature Sensor
2) Tighten the bolt and nut.
Tightening torque:
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
3) Connect the harness connectors.
Connect the connectors of same color, and con-
nect the connectors to control valve body using
clips.4) Apply proper amount of liquid gasket to the en-
tire oil pan mating surface.
Liquid gasket:
THREE BOND 1217B (Part No. K0877YA020)
5) Fill liquid gasket to holes except for bolt holes
(three) of transmission case.
Liquid gasket:
THREE BOND 1217B (Part No. K0877YA020)
6) Install the oil pan with equally tighten the bolts.
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
7) Pour ATF from the ATF charge pipe. 4AT-30, Automatic Transmission Fluid.>
8) Check the ATF level. ic Transmission Fluid.>
2. ATF TEMPERATURE SENSOR
For installation procedure of the ATF temperature
sensor, refer to “Front Vehicle Speed Sensor”.
Speed Sensor.>
Bolt length mm (in)
(A) 12 (0.47)
(B) 40 (1.57)
(C) 45 (1.77)
(D) 62 (2.44)
(E) 73 (2.87)
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
(H) Transfer duty solenoid (Brown)
AT-02126
E
AD
EE
D
D
B
CC
AT-02122
(A) (B) (C) (D) (E)
(H)
(F)
(G)
AT-00051
AT-02123

4AT-74
AUTOMATIC TRANSMISSION
Transfer Duty Solenoid and Valve Body
14) Remove the select cable nut.
15) Move the gear select cable so that extension
case securing bolts can be removed.
16) Remove the bolt.
17) Remove the extension case.
NOTE:
Use a container to catch oil flowing from extension.
18) Disconnect the transfer duty solenoid connec-
tor.
19) Remove the transfer duty solenoid and transfer
valve body.B: INSTALLATION
1) Install the transfer duty solenoid and transfer
valve body.
(1) Install the transfer duty solenoid and trans-
fer valve body.
Tightening torque:
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
(2) Connect the transfer duty solenoid connec-
tor.
2) Replace the gasket with a new one, and then in-
stall the extension case to transmission case.
(1) Tighten eleven bolts.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
(2) Adjust the select cable. JUSTMENT, Select Cable.>
3) Install the rear vehicle speed sensor.
Tightening torque:
7 N
⋅m (0.7 kgf-m, 5.1 ft-lb)
(A) Transfer valve body
(B) Transfer duty solenoid connector
(C) Transfer duty solenoid
AT-00083
AT-00084
AT-00085
(A)
(C)
(B)
(A) Transfer valve body
(B) Transfer duty solenoid connector
(C) Transfer duty solenoid
AT-00086
(A)
(C)
(B)
TT
AT-00087
T

4AT-75
AUTOMATIC TRANSMISSION
Transfer Duty Solenoid and Valve Body
4) Install the transmission rear crossmember.
(1) Tighten the bolt.
Tightening torque:
T1: 35 N
⋅m (3.6 kgf-m, 26 ft-lb)
T2: 70 N
⋅m (7.1 kgf-m, 51 ft-lb)
(2) Remove the transmission jack.
5) Install the propeller shaft.

6) Install the front, center, rear exhaust pipes and
muffler. (Non-turbo model)
haust Pipe.> TION, Rear Exhaust Pipe.> INSTALLATION, Muffler.>
7) Install the center, rear exhaust pipe and muffler.
(Turbo model)
Exhaust Pipe.> STALLATION, Rear Exhaust Pipe.> EX(H4DOTC)-16, INSTALLATION, Muffler.>
8) Connect the transmission harness connector.9) Install the pitching stopper.
Tightening torque:
T1: 50 N
⋅m (5.1 kgf-m, 37 ft-lb)
T2: 58 N
⋅m (5.9 kgf-m, 43 ft-lb)
10) Install the air cleaner case. (Non-turbo model)
Case.>
11) Install the intercooler. (Turbo model)
cooler.>
12) Pour ATF from the ATF charge pipe. 4AT-30, Automatic Transmission Fluid.>
13) Check the ATF level. matic Transmission Fluid.>
AT-00088
T2T2T1
AT-00089
AT-00025
T1
T2

4AT-76
AUTOMATIC TRANSMISSION
ATF Filter
21.ATF Filter
A: REMOVAL
NOTE:
The ATF filter is maintenance free.
1) Lift-up the vehicle.
2) Using ST, remove the ATF filter.
ST 498545400 OIL FILTER WRENCH
B: INSTALLATION
1) Apply a thin coat of ATF to the oil seal part of
new ATF filter.
2) Install the ATF filter. Turn it by hand, being care-
ful not to damage oil seal.
3) Tighten the ATF filter using ST.
Calculate the ATF filter tightening torque using fol-
lowing formula.
T2 = L2/ (L1+L2) ×T1
T1: 14 N⋅m (1.4 kgf-m, 10.1 ft-lb)
[Required torque setting]
T2: Tightening torque
L1: ST length 78 mm (3.07 in)
L2: Torque wrench length
Example:
NOTE:
Align the ST with torque wrench while tightening
the ATF filter.
ST 498545400 OIL FILTER WRENCH
4) Fill ATF.
5) Check the level of the ATF. tomatic Transmission Fluid.>
C: INSPECTION
 Replace the part if any defect is found from the
inspection.
 Check for rust, hole, ATF leaks and other dam-
age.
(A) ATF filter
Torque wrench length
mm (in)Tightening torque
N⋅m (kgf-m, ft-lb)
100 (3.94) 7.7 (0.79, 5.7)
150 (5.91) 9.0 (0.92, 6.7)
200 (7.87) 9.8 (1.0, 7.2)
AT-00091
(A)ST

4AT-77
AUTOMATIC TRANSMISSION
Transmission Control Module (TCM)
22.Transmission Control Mod-
ule (TCM)
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the lower cover and then disconnect
the connector.
3) Disconnect the connectors from TCM.
 LHD model
 RHD model
4) Remove the TCM.
B: INSTALLATION
1) Install the TCM.
 LHD model
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
 RHD model
Tightening torque:
18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
2) Connect the connectors to TCM.
3) Install in the reverse order of removal.
(A) Transmission control module (TCM)
(B) Brake pedal
(A) Transmission control module (TCM)
(B) Steering column
AT-00041
(A)
(B)
AT-00748
AT-00749
(A)(B)
(A) Transmission control module (TCM)
(B) Brake pedal
(A) Transmission control module (TCM)
(B) Steering column
(A)
(B)
AT-00748
AT-00749
(A)(B)

4AT-78
AUTOMATIC TRANSMISSION
Dropping Resistor
23.Dropping Resistor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector from dropping resis-
tor.
3) Remove the dropping resistor.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
6.4 N
⋅m (0.65 kgf-m, 4.7 ft-lb)
C: INSPECTION
(A) Dropping resistor
AT-00041
AT-00313
(A)
(A) Dropping resistor
AT-00313
(A)
Step Check Yes No
1 CHECK RESISTOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from dropping
resistor.
3) Measure the resistance between dropping
resistors.
Te r m i n a l s
No. 1 — No. 2:Is the resistance 9 — 15 Ω? Go to step 2.Replace the drop-
ping resistor. to 4AT-78, Drop-
ping Resistor.>
2 CHECK RESISTOR.
Measure the resistance between dropping
resistors.
Te r m i n a l s
No. 3 — No. 4:Is the resistance 9 — 15 Ω? Dropping resistor
is normal.Replace the drop-
ping resistor. to 4AT-78, Drop-
ping Resistor.>

4AT-81
AUTOMATIC TRANSMISSION
ATF Cooler Pipe and Hose
B: INSTALLATION
1. EXCEPT WITH ATF COOLER MODEL
(WITH WARMER FUNCTION)
1) Install the ATF oil cooler inlet pipe and outlet
pipe with new washer.
Tightening torque:
T1: 25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
T2: 45 N
⋅m (4.6 kgf-m, 33.2 ft-lb)
2) Install the ATF cooler pipe to frame.3) Connect the ATF cooler hose to pipe on trans-
mission side.
NOTE:
 Install so that the hose is not folded over, exces-
sively bent, or twisted.
 Be careful to insert the hose to the specified po-
sition.
4) Connect the ATF cooler hose to pipe on radiator
side. (Non-turbo model)
NOTE:
 Install so that the hose is not folded over, exces-
sively bent, or twisted.
 Be careful to insert the hose to the specified po-
sition.
5) Connect the ATF cooler hose to pipe on radiator
side. (Turbo model)
LATION, Radiator.>
6) Install the under cover.
7) Install the battery and washer tank.
8) Fill ATF. sion Fluid.>
NOTE:
Make sure there are no ATF leaks in joints between
the transmission, radiator, pipes, and hoses.
AT-00805
T1
T1
T2
AT-00456
AT-00450
AT-00455

4AT-82
AUTOMATIC TRANSMISSION
ATF Cooler Pipe and Hose
2. WITH ATF COOLER MODEL (WITH
WARMER FUNCTION)
1) Install the ATF cooler inlet and outlet pipe with
new washer.
Tightening torque:
T1: 25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
T2: 41 N
⋅m (4.2 kgf-m, 30.4 ft-lb)
T3: 45 N
⋅m (4.6 kgf-m, 33.2 ft-lb)
T4: 21 N
⋅m (2.1 kgf-m, 15.5 ft-lb)2) Install the ATF cooler assembly to transmission.
Tightening torque:
T1: 21 N
⋅m (2.1 kgf-m, 15.5 ft-lb)
T2: 23 N
⋅m (2.3 kgf-m, 17.0 ft-lb)
T3: 33 N
⋅m (3.4 kgf-m, 24.3 ft-lb)
3) Install the oil charger pipe. STALLATION, Oil Charger Pipe.>
4) Install the inlet and outlet hoses.
5) Install the inhibitor switch and transmission har-
ness connector to the stay, and connect the har-
ness connector.
6) Install the air breather hose. STALLATION, Air Breather Hose.>
7) Install the air cleaner case. INSTALLATION, Air Cleaner Case.>
(A) ATF cooler outlet pipe
(B) ATF cooler inlet pipe
AT-01871
T1
T2
T3
T4T2
(B)
(A)
(A)(B)
(A) Inlet hose
(B) Outlet hose
AT-01869
T2
T1T3
AT-01866(A)(B)

4AT-85
AUTOMATIC TRANSMISSION
ATF Cooler (With Warmer Function)
B: INSTALLATION
1) Connect the hose to lower side of ATF cooler
(with warmer function), and then install the ATF
cooler (with warmer function) to transmission body.
NOTE:
Insert the tip of ATF cooler bracket into hole of
torque converter case.
Tightening torque:
T1: 21 N
⋅m (2.1 kgf-m, 15.5 ft-lb)
T2: 23 N
⋅m (2.3 kgf-m, 17.0 ft-lb)
T3: 33 N
⋅m (3.4 kgf-m, 24.3 ft-lb)
2) Connect the engine coolant inlet hose to cylinder
block and the engine coolant outlet hose to upper
side of engine.3) Connect the hose to pipe on transmission side.
4) Install the harness to bracket.
5) Install the air cleaner case. REMOVAL, Air Cleaner Case.>
6) Fill with engine coolant. REPLACEMENT, Engine Coolant.>
(A) Outlet hose
(B) Inlet hose
AT-01869
T2
T1T3
AT-02113
(A)
(B)
(A) Inlet pipe
(B) Outlet pipe
AT-01866(A)(B)
AT-01867