torque SUBARU FORESTER 2004 Service Repair Manual

4AT-86
AUTOMATIC TRANSMISSION
ATF Cooler (With Warmer Function)
C: DISASSEMBLY
1) Disconnect each connector from ATF cooler
(with warmer function).
2) Remove the ATF cooler (with warmer function)
from bracket.
D: ASSEMBLY
Assemble in the reverse order of disassembly.
CAUTION:
When connecting hose, be careful of its direc-
tion.
Tightening torque:
T1: 23 N
⋅m (2.3 kgf-m, 17.0 ft-lb)T2: 33 N
⋅m (3.4 kgf-m, 24.3 ft-lb)
E: INSPECTION
Check the ATF cooler (with warmer function) for
damage.
(A) ATF Outlet hose
(B) ATF Inlet hose
(C) Engine coolant inlet hose
(D) Engine coolant outlet hose
AT-02114
(A) (B)(C)
(D)
AT-02115
(A) ATF Inlet hose
(B) ATF Outlet hose
(C) Engine coolant outlet hose
(D) Engine coolant inlet hose
(A) ATF Inlet
(B) ATF Outlet
(C) Engine coolant outlet
(D) Engine coolant inlet
(E) Forward
AT-02116
T1
T2
(B)
(D) (C)
(A)
AT-02117
(D)(B)(A)
(C)
(E)

4AT-88
AUTOMATIC TRANSMISSION
Oil Charger Pipe
27.Oil Charger Pipe
A: REMOVAL
1) Remove the air cleaner case. (Non-turbo mod-
el).
Case.>
2) Remove the intercooler. (Turbo model)
er.>
3) Remove the ATF charger pipe, and then remove
the O-ring from flange side.
 Model without ATF warmer
 Model with ATF warmer
B: INSTALLATION
1) Install the ATF charger pipe with a new O-ring.
Tightening torque:
41 N
⋅m (4.2 kgf-m, 30.4 ft-lb)
 Model without ATF warmer
 Model with ATF warmer
2) Install the air cleaner case. (Non-turbo model).
Case.>
3) Install the intercooler. (Turbo model)
cooler.>
C: INSPECTION
Make sure the ATF charger pipe is not deformed or
damaged.
(A) ATF level gauge
(B) ATF charger pipe
(A) ATF level gauge
(B) ATF charger pipe
AT-00808
(A)
(B)
AT-01872
(B)
(A)
(A) ATF level gauge
(B) ATF charger pipe
(A) ATF level gauge
(B) ATF charger pipe
AT-00808
(A)
(B)
AT-01872
(B)
(A)

4AT-89
AUTOMATIC TRANSMISSION
Torque Converter Clutch Assembly
28.Torque Converter Clutch As-
sembly
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle. mission Assembly.>
2) Pull out the torque converter clutch assembly
and oil pump shaft horizontally.
CAUTION:
Be sure not to scratch the inside of bush in oil
pump shaft.
3) Remove the input shaft.
NOTE:
When the torque converter clutch assembly is re-
moved, the input shaft is also removed.
4) Remove the clips from torque converter clutch
assembly.
B: INSTALLATION
1) Install the clip to torque converter clutch case.
2) Install the oil pump shaft to torque converter
clutch assembly, and then make sure that the clip is
secured on groove.3) 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)
4) With holding the torque converter clutch assem-
bly by hands, carefully install to the torque convert-
er clutch case. Take care not to damage the
bushing. Not to contact the oil pump shaft bush and
starter shaft part of oil pump cover inappropriately.
5) Lightly rotating the oil pump shaft by hands to
engage the spline securely, and then check the di-
mension A of torque converter clutch case and
torque converter clutch assembly.
Dimension A:
2.0 L NON-TURBO MODEL
−1.3 — −1.1 mm (−0.015 — −0.043 in)
EXCEPT FOR 2.0 L NON-TURBO MODEL
2.7 — 2.9 mm (0.106 — 0.114 in)
6) Install the transmission assembly into the vehi-
cle. Transmission Assembly.>
C: INSPECTION
Make sure the ring gear and protrusion of torque
converter clutch end is not deformed or damaged.
AT-00113
AT-00114
(A) Dimension A
AT-00291
A
AT-00311
(A)

4AT-90
AUTOMATIC TRANSMISSION
Extension Case
29.Extension Case
A: REMOVAL
1) Remove the transmission assembly.
sion Assembly.>
2) Remove the rear vehicle speed sensor.
 Non-turbo model
 Turbo model
3) Separate the transmission case and extension
case part.
B: INSTALLATION
1) Apply the vaseline to selected thrust needle
bearing and attach it to the end surface of reduction
driven gear. Transfer Clutch.>
NOTE:
Install the thrust needle bearing in correct direction.
2) Install a new gasket.
3) Install the extension case to transmission case.
4) Tighten bolts to secure the extension case.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
5) Install the rear vehicle speed sensor.
Tightening torque:
7 N
⋅m (0.7 kgf-m, 5.1 ft-lb)
 Non-turbo model
(A) Rear vehicle speed sensor
(B) Front vehicle speed sensor
(A) Rear vehicle speed sensor
AT-00116
(B)
(A)
AT-01338
(A)
AT-00118
(A) Rear vehicle speed sensor
(B) Front vehicle speed sensor
AT-00118
AT-00116
(B)
(A)

4AT-92
AUTOMATIC TRANSMISSION
Transfer Clutch
30.Transfer Clutch
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle. mission Assembly.>
2) Remove the extension case, and then remove
the transfer clutch assembly. MOVAL, Extension Case.> ASSEMBLY, Extension Case.>
B: INSTALLATION
1) Select the thrust needle bearing. 95, ADJUSTMENT, Transfer Clutch.>
2) Install the transfer clutch assembly to the case.
3) Tighten bolts to secure the case.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
4) Install the transmission assembly into the vehi-
cle. Transmission Assembly.>
C: DISASSEMBLY
1) Remove the seal ring.
2) Remove ball bearing using ST and press.
ST 498077600 REMOVER
3) Remove the snap ring, and then take out the
pressure plate, drive plate and driven plate using
flat tip screw driver and etc.
(A) Transfer clutch ASSY
(B) Extension case
AT-00125
(A)
(B)
AT-00118
(A) Seal ring
(B) Rear drive shaft
(A) Snap ring
(B) Rear drive shaft
AT-00127
AT-00128
AT-00129

4AT-97
AUTOMATIC TRANSMISSION
Reduction Driven Gear
31.Reduction Driven Gear
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle. mission Assembly.>
2) Remove the rear vehicle speed sensor, and then
separate the extension case from transmission
case. Case.>
3) Set the range select lever to “P” range.
4) Remove the caulking part, and then remove the
lock nut.
5) Using the ST1 and ST2, extract the reduction
driven gear assembly.
ST1 499737000 PULLER
ST2 899524100 PULLER SET
B: INSTALLATION
1) Set the range select lever to “P” range.
2) Using a plastic hammer, install the reduction
driven gear assembly and new washer, and tighten
new lock nut.
Tightening torque:
100 N
⋅m (10.2 kgf-m, 73.8 ft-lb)
3) After tightening, stake the lock nut securely.
4) Combine the transmission case with the exten-
sion case, and then install the rear vehicle speed
sensor. sion Case.>
5) Install the transmission assembly into the vehi-
cle. Transmission Assembly.>
C: DISASSEMBLY
1) Remove the snap ring from reduction driven
gear.
(A) Reduction driven gear
(B) Reduction drive gear
(A) Reduction driven gear ASSY
(B) Reduction drive gear ASSY
AT-00153
(A) (B)
AT-00154
(A) (B)
ST1
ST2
(A) Reduction driven gear ASSY
(B) Reduction drive gear ASSY
(A) Snap ring
AT-00153
(A) (B)
AT-00156
(A)

4AT-102
AUTOMATIC TRANSMISSION
Torque Converter Clutch Case
34.Torque Converter Clutch
Case
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle. mission Assembly.>
2) Pull out the torque converter clutch assembly.
Clutch Assembly.>
3) Remove the input shaft.
4) Lift-up the lever on rear side of transmission har-
ness connector, and then disconnect it from the
stay.
5) Disconnect the inhibitor switch connector from
the stay.
6) Remove the air breather hose. REMOVAL, Air Breather Hose.>
7) Remove the ATF charger pipe. REMOVAL, Oil Charger Pipe.>
8) Remove the ATF cooler inlet and outlet pipes.
Hose.>9) Remove the torque converter clutch case align-
ing bolt, and then separate the transmission case
and torque converter clutch case by lightly tapping
with plastic hammer.
CAUTION:
 Be careful not to damage the oil seal and
bush inside the torque converter clutch case by
the oil pump cover.
 Do not loosen the rubber seal.
10) Remove the seal pipe.
11) Remove the differential assembly. 4AT-117, REMOVAL, Front Differential.>
12) Remove the oil seal from torque converter
clutch case.
(A) Transmission harness ASSY
(B) Inhibitor switch harness
AT-00114
AT-01351
(B)(A)
(A) Seal pipe
AT-00175
AT-00176

4AT-103
AUTOMATIC TRANSMISSION
Torque Converter Clutch Case
B: INSTALLATION
1) Check the appearance of each component and
clean them.
2) Press-fit the new oil seal to torque converter
clutch case using ST.
ST 398437700 DRIFT
3) Install the differential assembly to case. 4AT-117, INSTALLATION, Front Differential.>
4) Install the left and right side retainers. 4AT-121, ADJUSTMENT, Front Differential.>
5) Install the new seal pipe to torque converter
clutch case.
6) Install the new rubber seal to torque converter
clutch case.7) Apply proper amount of liquid gasket to the en-
tire matching surface of torque converter clutch
case.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007)
8) Install the torque converter clutch case assem-
bly without damaging bushing and oil seal.
Tightening torque:
41 N
⋅m (4.2 kgf-m, 30.4 ft-lb)
9) Insert the inhibitor switch connector and trans-
mission connector to the stay.
10) Install the air breather hose. INSTALLATION, Air Breather Hose.>
11) Install the ATF cooler pipe. STALLATION, ATF Cooler Pipe and Hose.>
12) Install the ATF charger pipe with O-ring. to 4AT-88, INSTALLATION, Oil Charger Pipe.>
(A) Seal pipe
(A) Rubber seal
AT-00177
AT-00176
AT-00178
(A)
(A) THREE BOND 1215
(B) Rubber seal
(B)
(A)
AT-00179
AT-00175

4AT-104
AUTOMATIC TRANSMISSION
Torque Converter Clutch Case
13) 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)
14) Install the torque converter clutch assembly.
er Clutch Assembly.>
15) Install the transmission assembly into the vehi-
cle. Transmission Assembly.>
C: INSPECTION
Measure the backlash, and then adjust it within
specification. Drive Pinion Shaft Assembly.>
AT-00291
A

4AT-105
AUTOMATIC TRANSMISSION
Oil Pump Housing
35.Oil Pump Housing
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle. mission Assembly.>
2) Pull out the torque converter clutch assembly.
Clutch Assembly.>
3) Remove the input shaft.
4) Lift-up the lever on rear side of transmission har-
ness connector, and then disconnect it from the
stay.
5) Disconnect the inhibitor switch connector from
the stay.
6) Remove the ATF charger pipe. REMOVAL, Oil Charger Pipe.>
7) Remove the ATF cooler inlet and outlet pipes.
Hose.>
8) Separate the torque converter clutch case and
transmission case part. MOVAL, Torque Converter Clutch Case.>
9) Separate the transmission case and extension
case part. Case.>
10) Remove the reduction drive gear. 99, REMOVAL, Reduction Drive Gear.>
11) Remove the reduction driven gear. 4AT-97, REMOVAL, Reduction Driven Gear.>
12) Loosen the oil pump housing mounting bolts.13) Place two wooden blocks on the workbench,
and stand the transmission case with its rear end
facing down.
CAUTION:
Be careful not to scratch the rear mating sur-
face of transmission case.
NOTE:
Check the height of wooden blocks to avoid dam-
aging the protrudes that on the mating surface of
parking rod and drive pinion.
14) Remove the oil pump housing and adjusting
thrust washer.
B: INSTALLATION
1) Secure the oil pump housing with two nuts and a
bolt.
Tightening torque:
42 N
⋅m (4.3 kgf-m, 31 ft-lb)
AT-00114
AT-01034
(A) Oil pump housing
(A) Oil pump housing
AT-00181
(2.17in)55mm
AT-00182
(A)
AT-01035
(A)