torque 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 2421 of 2870
4AT-107
AUTOMATIC TRANSMISSION
Oil Pump Housing
2. OIL SEAL RETAINER
1) Remove the oil seal retainer.
2) Remove the O-ring.
3) Remove the oil seal from oil seal retainer.
D: ASSEMBLY
1. OIL PUMP COVER
1) Install the oil pump rotor assembly to oil pump
housing.
2) Align both pivots with the pivot holes of cover,
and then install the oil pump cover being careful not
to apply excessive force to the pivots.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
3) After assembling, turn the oil pump shaft to
check the smooth rotation of rotor.
(A) Oil seal retainer
(B) Drive pinion shaft
(A) O-ring
(A) Oil seal
(B) Oil seal retainer
AT-00183
(A)(B)
AT-00186
(A)
AT-00185
(A)
(B)
(A) Oil pump inner rotor
(B) Oil pump outer rotor
(A) Oil pump cover
(B) Oil pump housing
AT-01036
(A)(B)
AT-00190
(A)(B)
Page 2422 of 2870
4AT-108
AUTOMATIC TRANSMISSION
Oil Pump Housing
4) Install the oil seal retainer and new seal rings.
After installing, adjust the tooth contact and back-
lash of drive pinion.
CAUTION:
There are two kinds of seal rings and those are
identified by color. Be sure to install proper po-
sitions with referring figure.
2. OIL SEAL RETAINER
1) Install two new oil seals to oil seal retainer in
proper direction using ST.
ST 499247300 INSTALLER
2) Install a new O-ring to oil seal retainer using va-
seline.3) Install the oil seal and secure it using three bolts
being careful not to damage oil seal lip.
Tightening torque:
7 N
⋅m (0.7 kgf-m, 5.1 ft-lb)
E: INSPECTION
1) Check seal ring and oil seal for breaks or dam-
ages.
2) Check other parts for dents or abnormalities.
3) Selection of oil pump rotor assembly
(1) Tip clearance
Install the oil pump inner rotor and oil pump out-
er rotor to oil pump. With rotor gears facing each
other, measure crest-to-crest clearance.
Tip clearance:
0.02 — 0.15 mm (0.0008 — 0.0059 in)(A) Seal ring (Black)
(B) Seal ring (Brown)
(A) Oil seal
(B) Oil seal retainer
(A) O-ring
AT-01307
(A)
(B)
AT-00185
(A)
(B)
AT-00186
(A)
(A) Oil seal retainer
(B) Drive pinion shaft
(A) Thickness gauge
(B) Oil pump inner rotor
(C) Oil pump outer rotor
AT-00183
(A)(B)
AT-01038
(B)(C) (A)
Page 2425 of 2870
4AT-111
AUTOMATIC TRANSMISSION
Drive Pinion Shaft Assembly
36.Drive Pinion Shaft Assembly
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle.
2) Pull out the torque converter 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) Disconnect the air breather hose.
7) Remove the ATF charger pipe.
8) Remove the ATF cooler inlet and outlet pipes.
9) Separate the torque converter clutch case and
transmission case part.
10) Separate the transmission case and extension
case part.
11) Remove the reduction drive gear.
12) Remove the reduction driven gear.
and remove the drive shaft assembly from oil pump
housing.
B: INSTALLATION
1) Assemble the drive pinion assembly to oil pump
housing.
NOTE:
Be careful not to bend the shim.
Be careful not to press-fit the pinion into housing
bore.
Tightening torque:
40 N
⋅m (4.1 kgf-m, 29.5 ft-lb)
2) Combine the torque converter case with 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 air breather hose.
8) Install the ATF cooler inlet and outlet pipes.
AT-00114
AT-01252
AT-01252
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 2427 of 2870
4AT-113
AUTOMATIC TRANSMISSION
Drive Pinion Shaft Assembly
2) Using a press, press-fit the new roller bearing
into specified position.
NOTE:
If excessive force is applied to roller bearing, the
roller bearing will not turn easily.
3) After fitting a new O-ring to the drive pinion shaft,
attach the drive pinion collar to the drive pinion
shaft.
4) Install the lock washer to drive pinion shaft in
proper direction.
5) Tighten the new lock nuts using ST1, ST2 and
ST3.
Calculate the lock washer and lock nut specifica-
tions using following formula.
T2 = L2/ (L1+L2) ×T1
T1: 116 N⋅m (11.8 kgf-m, 85.3 ft-lb)
[Required torque setting]
T2: Tightening torque
L1: ST2 length 0.072 m (2.83 in)
L2: Torque wrench length
Example:
ST1 498937110 HOLDER
ST2 499787700 WRENCH
ST3 499787500 ADAPTERNOTE:
Install ST2 to torque wrench as straight as possi-
ble.
6) Measure the starting torque of bearing. Make
sure the starting torque is within the specified
range. If the torque is not within specified range, re-
place the roller bearing.
Starting torque:
7.6 — 38.1 N (0.776 — 3.88 kgf, 1.7 — 3.88 kg)
7) Stake the lock nut at two points.
8) Measure the dimension “B” of drive pinion shaft
ST 398643600 GAUGE
9) Calculate the thickness “t” (mm) of drive pinion
shim.
t = 6.5±0.0625− (B−A)
(A) Drive pinion shaft
(B) Roller bearing
Torque wrench length
m (in)Tightening torque
N⋅m (kgf-m, ft-lb)
0.4 (15.75) 98 (10.0, 72.3)
0.45 (17.72) 100 (10.2, 73.5)
0.5 (19.69) 101 (10.3, 74.6)
0.55 (21.65) 102 (10.4, 75.4)
AT-00201
(B)
(A)
ST1
AT-00202
L1 [m (in)]
L2 [m (in)]
ST2
ST3
AT-00203
B
AT-00204
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 2430 of 2870
4AT-116
AUTOMATIC TRANSMISSION
Drive Pinion Shaft Assembly
6) If tooth contact is correct, mark the differential
side retainer position and loosen it. After fitting a
new O-ring and oil seal, screw in the differential
side retainer to the marked position. Tighten the
lock plate with specified torque.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
(A) Lock plate
AT-00214
(A)
Page 2431 of 2870
4AT-117
AUTOMATIC TRANSMISSION
Front Differential
37.Front Differential
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle.
2) Pull out the torque converter 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 from the stay.
6) Remove the ATF charger pipe.
7) Remove the ATF cooler inlet and outlet pipes.
8) Separate the torque converter clutch case and
transmission case.
9) Remove the seal pipe.
10) Remove the differential side retainers using
ST.
NOTE:
Hold the differential case assembly by hand to
avoid damaging retainer mounting hole of torque
converter clutch case.
ST 499787000 WRENCH ASSY
11) Remove the differential assembly without dam-
aging installation part of retainer.
B: INSTALLATION
1) Install the differential assembly to torque con-
verter clutch case.
CAUTION:
Do not damage the inside of torque converter
clutch case (especially the mating surface of
differential side retainer).
2) Install the O-ring to left and right differential side
retainer.
3) Install the side retainers using ST.
ST 499787000 WRENCH ASSY
4) Adjust the front differential backlash.
5) Install the lock plate.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
AT-00114(A) Differential ASSY
(A) Lock plate
AT-00215
(A)
AT-00214
(A)
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