automatic transmission SUBARU FORESTER 2004 Service Manual PDF

4AT-41
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
20) Lift-up the vehicle.
21) Remove the under cover.
22) Remove the front, center, rear, exhaust pipes
and muffler. (Non-turbo model).
Pipe.> Exhaust Pipe.> AL, Muffler.>
23) Remove the center, rear exhaust pipe and muf-
fler. (Turbo model)
haust Pipe.> AL, Rear Exhaust Pipe.> 16, REMOVAL, Muffler.>
24) Remove the heat shield cover. (If equipped)
25) Remove the drain plug (ATF) to drain ATF.
26) Disconnect the ATF cooler hoses from pipes of
transmission side, and remove the ATF level gauge
guide. (without ATF cooler (with warmer function))
27) Remove the propeller shaft.

28) Remove the shift select cable.
29) Disconnect the stabilizer link from the trans-
verse link.
30) Remove the bolt securing ball joint of trans-
verse link to housing.
31) Pull out the front drive shaft from transmission.
(1) Face the letter of “AT” to the transmission
side.
ST 28399SA000 DRIVE SHAFT REMOVER
(A) Oil pan
(B) Drain plug (ATF)
AT-00080
(A)(B)
AT-00683
(A) Letter “AT”
AT-00107
AT-00115
AT-00461
(A)

4AT-42
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
(2) Insert ST between the transmission and
front drive shaft.
NOTE:
Set the protrusion portion of ST to the torque con-
verter clutch housing.
ST 28399SA000 DRIVE SHAFT REMOVER
(3) Hold the joint portion of front drive shaft
(AARi) by hand and extract the housing from the
transmission by pressing it outside.
32) Remove the bolts which hold lower side of
transmission to engine.
33) Place the transmission jack under transmis-
sion.
NOTE:
Make sure that the support plates of transmission
jack don’t touch the oil pan.34) Remove the transmission rear crossmember
from the vehicle.
35) Slightly lowering the transmission jack, fully
contract the engine support and tilt the engine
backward.
36) Remove the transmission.
CAUTION:
Remove the transmission and torque converter
as a unit from the engine.
37) Remove the rear cushion rubber from transmis-
sion.
(A) Protrusion portion of ST
(B) Torque converter clutch case
AT-00444
ST
(A)
(B)
AT-00108
AT-00024
AT-00109

4AT-43
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
B: INSTALLATION
1) Replace the differential side oil seal with a new
one. tial Side Retainer Oil Seal.>
2) Install the rear cushion rubber to the transmis-
sion.
Tightening torque:
39 N
⋅m (4.0 kgf-m, 29 ft-lb)
3) Install the ST to torque converter clutch case.
ST 498277200 STOPPER SET
4) Install the transmission onto the engine.
(1) Lift up the transmission gradually using a
transmission jack.
(2) Engage them at splines.
(3) Slightly raising the transmission jack, turn
the screws of engine support and tilt the engine
forward.5) Install the transmission rear crossmember.
Tightening torque:
T1: 35 N
⋅m (3.6 kgf-m, 26 ft-lb)
T2: 70 N
⋅m (7.1 kgf-m, 51 ft-lb)
6) Take off the transmission jack.
7) Tighten the bolts which hold lower side of trans-
mission to engine.
Tightening torque:
50 N
⋅m (5.1 kgf-m, 36.9 ft-lb)
8) Lower the lift.
9) Connect the engine and transmission.
(1) Remove the ST from torque converter clutch
case.
NOTE:
When removing ST, be careful not to drop it into
torque converter clutch case.
ST 498277200 STOPPER SET
(2) Install the starter.
er.>AT-00103
ST
AT-00109
AT-00026
T2T2
T1
AT-00108

4AT-44
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
(3) Tighten the bolts which hold right upper side
of transmission to engine.
Tightening torque:
50 N
⋅m (5.1 kgf-m, 36.9 ft-lb)
10) Install the torque converter clutch assembly to
drive plate.
(1) Tighten the bolts which hold torque convert-
er clutch assembly to drive plate.
(2) Using ST, remove all bolts with slightly rotat-
ing crank sprocket.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
(3) Fit the plug to the service hole.
11) Remove the ST.12) 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)
13) Lift-up the vehicle.
14) Replace the snap ring of front drive shaft with a
new one.
15) Apply grease to the oil seal lips.
16) Install ST to side retainer.
ST 28399SA010 OIL SEAL PROTECTOR
17) Align the serration of front differential shaft to
that of differential bevel gear for insertion, and re-
move them using ST.
ST 28399SA010 OIL SEAL PROTECTOR
18) Insert the front drive shaft into transmission se-
curely by pressing the front housing.
19) Install the ball joint onto front housing.
AT-00106
AT-00102
AT-00105
ST
AT-00025
T1
T2
AT-00110ST
AT-00111

4AT-45
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
20) Tighten the attachment bolts.
Tightening torque:
49 N
⋅m (5.0 kgf-m, 36 ft-lb)
21) Install the stabilizer link from the transverse
link.
Tightening torque:
45 N
⋅m (4.6 kgf-m, 33.2 ft-lb)
22) Install the shift select cable onto select lever.

23) Connect the ATF cooler hoses to the pipe. (with
ATF cooler (with warmer function))
24) Install the ATF level gauge guide.
25) Install the propeller shaft.

26) Install the heat shield cover. (If equipped)27) Install the rear exhaust pipe and muffler as-
sembly.
(Non-turbo model)
haust Pipe.> TION, Muffler.>
(Turbo model)
Exhaust Pipe.> STALLATION, Muffler.>
28) Install the front and center exhaust pipe. (Non-
turbo model)
haust Pipe.>
29) Install the center exhaust pipe. (Turbo model)
Exhaust Pipe.>
30) Install the under cover.
31) Lower the lift.
32) Install the ATF cooler assembly bracket to
transmission body. (with ATF cooler (with warmer
function))
NOTE:
Insert the end of ATF cooler bracket to the hole of
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)
AT-00115
AT-00107
AT-00450
AT-01869
T2
T1T3

4AT-46
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
33) Connect the ATF cooler hoses to pipes on
transmission side, and then install the oil charge
pipe. (with ATF cooler (with warmer function))
34) Install the ATF level gauge guide.
35) Connect the following connectors.
(1) Transmission harness connectors
(2) Transmission ground terminal
36) Install the harness to bracket.
37) Install the air cleaner case stay. (Non-turbo
model)
Tightening torque:
16 N
⋅m (1.6 kgf-m, 11.6 ft-lb)38) Install the air cleaner case and air intake duct.
(Non-turbo model).
Case.> Intake Duct.>
39) Install the intercooler. (Turbo model)
cooler.>
40) Connect the battery ground cable to battery.
41) Pour ATF from the oil charge pipe. 4AT-30, Automatic Transmission Fluid.>
42) Check the ATF level. matic Transmission Fluid.>
43) Take off the vehicle from a lift.
44) Check the select lever operation.

45) Execute the learning control promotion. (Turbo
model) OF LEARNING CONTROL, OPERATION, Subaru
Select Monitor.>
46) Perform the road test.

(A) Inlet hose
(B) Outlet hose
AT-01866(A)(B)
AT-00693
AT-01867

4AT-47
AUTOMATIC TRANSMISSION
Transmission Mounting System
10.Transmission Mounting Sys-
tem
A: REMOVAL
1. PITCHING STOPPER
1) Disconnect the ground cable from battery.
2) Remove the air cleaner case. (Non-turbo mod-
el).
Case.>
3) Remove the intercooler. (Turbo model)
er.>
4) Remove the pitching stopper.
2. TRANSMISSION REAR CROSSMEMBER
& REAR CUSHION RUBBER
1) Disconnect the ground cable from battery.
2) Jack-up the vehicle and support it with study
racks.
3) Remove the front, center, rear exhaust pipes
and muffler. (Non-turbo model).
Pipe.> Exhaust Pipe.> AL, Muffler.>
4) Remove the center, rear exhaust pipe and muf-
fler. (Turbo model)
haust Pipe.> AL, Rear Exhaust Pipe.> 16, REMOVAL, Muffler.>
5) Remove the heat shield cover. (If equipped)
6) Set the transmission jack under the transmis-
sion.
NOTE:
Make sure that the support plate of transmission
jack does not touch the oil pan.7) Remove the transmission rear crossmember.
8) Remove the rear cushion rubber.
B: INSTALLATION
1. PITCHING STOPPER
1) 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)
2) Install the air cleaner case. (Non-turbo model).
Case.>
3) Install the intercooler. (Turbo model)
cooler.>
AT-00023
AT-00024
AT-00025
T1
T2

4AT-48
AUTOMATIC TRANSMISSION
Transmission Mounting System
2. TRANSMISSION REAR CROSSMEMBER
& REAR CUSHION RUBBER
1) Install the rear cushion rubber.
Tightening torque:
39 N
⋅m (4.0 kgf-m, 29 ft-lb)
2) Install the transmission rear crossmember.
Tightening torque:
T1: 35 N
⋅m (3.6 kgf-m, 26 ft-lb)
T2: 70 N
⋅m (7.1 kgf-m, 51 ft-lb)
3) Remove the transmission jack.
4) Install the heat shield cover. (If equipped)
5) Install the front, center, rear exhaust pipes and
muffler. (Non-turbo model).
haust Pipe.> TION, Rear Exhaust Pipe.> INSTALLATION, Muffler.>
6) Install the center, rear exhaust pipe and muffler.
(Turbo model)
Exhaust Pipe.> STALLATION, Rear Exhaust Pipe.> EX(H4DOTC)-16, INSTALLATION, Muffler.>
C: INSPECTION
Perform the following inspection procedures and
repair or replace the parts if defective.
1. PITCHING STOPPER
Make sure that the pitching stopper is not bent or
damaged. Ensure there are no cracks, hardening,
or damage on rubbers.
2. TRANSMISSION REAR CROSSMEMBER
& REAR CUSHION RUBBER
Make sure that the crossmember is not bent or
damaged. Ensure there are no cracks, breakage or
damage on cushion rubbers.
AT-00026
T2T2
T1

FUJI HEAVY INDUSTRIES LTD. G8080GE5
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
TRANSMISSION SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.CONTROL SYSTEM CS
AUTOMATIC TRANSMISSION 4AT
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4SO)
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4DOTC)
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4DOTC 2.5)
MANUAL TRANSMISSION AND
DIFFERENTIAL5MT
CLUTCH SYSTEM CL

4AT-49
AUTOMATIC TRANSMISSION
Extension Case Oil Seal
11.Extension Case Oil Seal
A: INSPECTION
Make sure that the ATF does not leak from the joint
of transmission and propeller shaft. If so, replace
the oil seal. tension Case Oil Seal.>
B: REPLACEMENT
1) Clean the transmission exterior.
2) Drain the ATF completely.
NOTE:
Tighten the drain plug (ATF) after draining the ATF.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
3) Remove the rear exhaust pipe and muffler.
(Non-turbo model).
Pipe.> fler.>
(Turbo model)
haust Pipe.> AL, Muffler.>
4) Remove the heat shield cover. (If equipped)
5) Remove the propeller shaft. MOVAL, Propeller Shaft.>
6) Using ST, install the oil seal.
ST 398527700 PULLER ASSY
7) Using the ST, install the oil seal.
ST 498057300 INSTALLER
8) Install the propeller shaft.

9) Install the heat shield cover. (If equipped)10) Install the rear exhaust pipe and muffler.
(Non-turbo model).
haust Pipe.> TION, Muffler.>
(Turbo model)
Exhaust Pipe.> STALLATION, Muffler.>
11) Pour ATF and check the ATF level. 4AT-30, Automatic Transmission Fluid.>
(A) Oil pan
(B) Drain plug (ATF)
(C) Differential gear oil drain plug
AT-00016
(A) (B)
(C)