automatic transmission fluid 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 720 of 2870
RM-5
RECOMMENDED MATERIAL
Recommended Materials
4. FLUID
Use the fluids specified in the table below. Do not mix two different kinds or makes of fluid.
5. COOLANT
Use genuine coolant to protect the engine.
6. REFRIGERANT
Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants.
Also, do not use any air compressor oil except for ZXL200PG.
7. GREASE
Use the grease and supplementary lubricants shown in the table below.
SAE viscosity No. and applicable temperature SAE J300
Manual transmission oil, front differential oil and rear differential oil
Fluid Recommended Alternative Remarks
Automatic transmission fluid DEXRON III — —
Power steering fluid DEXRON III — —
Brake fluid FMVSS No. 116 DOT3 FMVSS No. 116 DOT4 —
Clutch fluid FMVSS No. 116 DOT3 FMVSS No. 116 DOT4 —
Coolant Recommended Item number Alternative
Coolant SUBARU coolant 000016218 None
Water for dilution Distilled water — Tap water (Soft water)
Air conditioner Recommended Item number Alternative
Refrigerant HFC134a — None
Compressor oil ZXL200PG — None
Grease Application point Recommended Item number Alternative
Supplementary lubricants Oxygen sensor
Bolts, etc.SUBARU CRC 004301003 —
RM-00004 ( F)–22 –4 14 50 68 86 104 ( C)–30 –20 –100
10 20 30 40
85W
75W-9080W90
32
Page 763 of 2870
PM-26
PERIODIC MAINTENANCE SERVICE
ATF
16.ATF
A: INSPECTION
CAUTION:
The level of ATF varies with fluid temperature.
Pay attention to the fluid temperature when
checking ATF level.
1) Raise the ATF temperature by driving a distance
of 5 to 10 km (3 to 6 miles). Otherwise, idle the en-
gine to raise ATF temperature to 70 — 80°C (158
— 176°F) on Subaru Select Monitor.
TION, Subaru Select Monitor.>
2) Make sure the vehicle is level.
3) After selecting all positions (P, R, N, D, 3, 2, 1),
set the select lever in “P” range. Measure the ATF
level with the engine idling for one or two minutes.
4) Make sure that ATF level is above the center of
upper and lower level.
NOTE:
When the transmission is hot, the level should be
above the center of upper and lower marks, and
when it is cold, the level should be found below the
center of these two marks.
5) If the ATF level is below the center between up-
per and lower marks, add the recommended ATF
until the ATF level is found above the center be-
tween upper and lower marks.
CAUTION:
Use care not to exceed the upper limit level.
Remember that the addition of ATF to the up-
per limit mark when the transmission is cold
will result in overfilling of ATF, causing a trans-
mission failure.
6) Check ATF level after raising ATF temperature
to 70 — 80°C (158 — 176°F) by running the vehicle
or by idling the engine again.7) Check the ATF for leaks.
Check for leaks in the transmission. If there are
leaks, it is necessary to repair or replace gasket, oil
seals, plugs or other parts.
B: REPLACEMENT
1. AUTOMATIC TRANSMISSION FLUID
1) Drain the ATF by removing drain plug.
NOTE:
Before starting work, cool off ATF well.
2) Replace the gasket with a new one, and then
tighten the specified torque.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
3) Fill ATF up to the middle of the “COLD” side on
level gauge by using the gauge hole.
Recommended fluid:
Dexron III type automatic transmission fluid
Fluid capacity:
Fill the same amount drained from ATF drain
plug hole.
(A) Level gauge
(B) Check position when “HOT”
(C) Upper level
(D) Lower level
(E) Check position when “COLD”
PI-00105
COLD
LFHOT LF
(A)
(C)
(D)
(C)
(D)
(E)
(B)(A) Front differential drain plug
(B) ATF drain plug
PM-00032
(B)
(A)
Page 1014 of 2870
CO(H4SO)-31
COOLING
Radiator
4) Attach the power steering hose to radiator.
5) Connect the radiator inlet hose.
6) Install the reservoir tank.
Tightening torque:
4.9 N
⋅m (0.50 kgf-m, 3.6 ft-lb)
7) Connect the overflow hose.
8) Lift-up the vehicle.
9) Connect the ATF cooler hoses. (AT model)10) Connect the radiator outlet hose.
11) Connect the connectors to radiator main fan
motor (A) and sub fan motor (B).
12) Install the under cover.
13) Lower the vehicle.
14) Connect the battery ground cable to battery.
15) Fill engine coolant.
MENT, Engine Coolant.>
16) Check the ATF level.
CO-00037
CO-00035
CO-00015
CO-00034
CO-00076
CO-00013
(A)(B)
FU-00009
Page 1016 of 2870
CO(H4SO)-33
COOLING
Radiator
12) Connect the oil cooler hose. (MT model with oil
cooler)
13) Connect the radiator outlet hose.
14) Connect the connectors to radiator main fan
motor (A) and sub fan motor (B).
15) Install the under cover.
16) Lower the vehicle.
17) Connect the battery ground cable to battery.
18) Fill engine coolant.
MENT, Engine Coolant.>19) Check the ATF level.
C: INSPECTION
1) Remove the radiator cap, top off radiator, and
then attach the tester (A) to radiator in place of cap.
NON-TURBO MODEL
TURBO MODEL
2) Apply a pressure of 157 kPa (1.6 kg/cm
2, 23 psi)
to the radiator to check if:
(1) Engine coolant leaks at/around radiator.
(2) Engine coolant leaks at/around hoses or
connections.
CAUTION:
Inspection must be carried out at the side of
coolant filler tank, not at the side of radiator.
Engine should be off.
Wipe engine coolant from check points in ad-
vance.
Be careful to prevent engine coolant from
spurting out when removing the tester.
Be careful also not to deform the filler neck of
radiator when installing or removing tester.
CO-00034
CO-00030
CO-00013
(A)(B)
FU-00009
CO-00042
(A)
CO-00043
(A)
Page 1101 of 2870
EN(H4SO)-3
ENGINE (DIAGNOSTIC)
Basic Diagnostics Procedure
2. AUTOMATIC TRANSMISSION
When the DTC about automatic transmission is
shown on display, carry out the following basic
check. After that, carry out the replacement or re-
pair work.
1) ATF level check
2) Differential gear oil level check
3) ATF leak check
4) Differential gear oil level check
5) Stall Test
6) Line Pressure Test
7) Transfer Clutch Pressure Test
8) Time Lag Test
9) Road Test
10) Shift characteristics
Page 1633 of 2870
EN(H4DOTC)-3
ENGINE (DIAGNOSTIC)
Basic Diagnostics Procedure
2. AUTOMATIC TRANSMISSION
When the DTC about automatic transmission is
shown on display, carry out the following basic
check.After that, carry out the replacement or re-
pair work.
1) ATF level check
2) Differential gear oil level check
3) ATF leak check
4) Differential gear oil leak check
5) Stall Test
6) Line Pressure Test
7) Transfer Clutch Pressure Test
8) Time Lag Test
9) Road Test
10) Shift characteristics
Page 2313 of 2870
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
Page 2315 of 2870
4AT-3
AUTOMATIC TRANSMISSION
General Description
6. SELECTOR POSITION
7. HYDRAULIC CONTROL AND LUBRICA-
TION
8. COOLING AND HARNESS9. TRANSFER
P (Park)Transmission in neutral, output member immov-
able, and engine start possible
R
(Reverse)Transmission in reverse
N (Neu-
tral)Transmission in neutral and engine start possi-
ble
D (Drive)Automatic gear change 1st
←
→ 2nd ←
→ 3rd ←
→
4th
3 (3rd)Automatic gear change 1st
←
→ 2nd ←
→ 3rd ←
4th
2 (2nd)Automatic gear change 1st
←
→ 2nd ← 3rd ←
4th
1 (1st)1st gear locked (Deceleration possible 1st ←
2nd ← 3rd ← 4th)
Control
methodWire cable type
Ty p eElectronic/hydraulic control
[Four forward speed
changes by electrical signals
of vehicle speed and accel-
erator (throttle) opening]
FluidDEXRON III type automatic
transmission fluid
Fluid capac-
ity2.0 L Non-
turbo model8.4 — 8.72 (8.9 — 9.2 US
qt, 7.4 — 7.7 Imp qt)
Except for
2.0 L Non-
turbo model9.3 — 9.62 (9.8 — 10.1 US
qt, 8.2 — 8.4 Imp qt)
Lubrication systemForced feed lubrication with
oil pump
OilAutomatic transmission fluid
(above mentioned)
Cooling SystemLiquid-cooled cooler incorpo-
rated in radiator
Inhibitor switch 12 poles
Transmission harness 20 poles
Model2.0 L Non-
turbo2.5 L Non-
turboTu r b o
Transfer
typeMulti-plate transfer (MPT)
Drive &
driven plate
number of
transfer
clutch456
Control
methodElectronic, hydraulic type
LubricantThe same Automatic transmission fluid used
in automatic transmission
Reduction
gear ratio1.000 (53/53)
Page 2321 of 2870
4AT-9
AUTOMATIC TRANSMISSION
General Description
4. CONTROL VALVE AND HARNESS ROUTING
A Non-turbo model B Turbo model
(1) Stay (11) Accumulator piston (23) 2-4 brake duty solenoid
(2) Transmission harness ASSY (12) Accumulator spring (24) Line pressure duty solenoid
(3) O-ring (13) Side plate (25) Low clutch timing solenoid
(4) O-ring (14) Upper separate plate (26) Lock-up duty solenoid
(5) Torque converter turbine speed
sensor(15) Middle control valve body (27) Oil strainer
(16) Separate plate (28) Control valve ASSY
(6) O-ring (17) Fluid filter (29) Rear vehicle speed sensor (turbo
model)
(7) Front vehicle speed sensor (18) Fluid filter
(8) O-ring (19) Lower control valve body
(9) Rear vehicle speed sensor (non-
turbo model)(20) Shift solenoid 2Tightening torque: N
⋅m (kgf-m, ft-lb)
(21) Shift solenoid 1T1: 7 (0.7, 5.1)
(10) Upper control valve body (22) 2-4 brake timing solenoidT2: 8 (0.8, 5.8)
AT-01864
T1T2
T2
T2
T2
T2
T2
T2T2
T2
T1
(1)(2)
(3)(4)
(5)
(6)
(7)
(10)
(11)
(12)
(14)
(13)(15)
(16)
(17)
A(24)(19)
(18)
(20)
(21)
(22)
(23) (26) (25)
(27)
(28)
B
T1
(8)
(9)
T1
(8)
(29)
Page 2342 of 2870
4AT-30
AUTOMATIC TRANSMISSION
Automatic Transmission Fluid
2. Automatic Transmission Flu-
id
A: INSPECTION
NOTE:
The level of ATF varies with fluid temperature. Pay
attention to the ATF temperature when checking
ATF level.
1) Raise the ATF temperature by driving a distance
of 5 to 10 km (3 to 6 miles). Otherwise, idle the en-
gine to raise ATF temperature to 70 — 80°C (158
— 176°F) on Subaru Select Monitor.
TION, Subaru Select Monitor.>
2) Make sure the vehicle is level.
3) After selecting all positions (P, R, N, D, 3, 2, 1),
set the select lever in “P” range. Measure the ATF
level with engine idling for one or two minutes.
4) Make sure that ATF level is above the center of
upper level and lower level at HOT side.
If the ATF level is below the lower level, check for
leaks in the transmission. If there are leaks, it is
necessary to repair or replace gasket, oil seals,
plugs or other parts.
5) If the ATF level is below the center between up-
per level and lower level, add the recommended
ATF until the fluid level is found above the center
between upper level and lower level marks.
CAUTION:
Use care not to exceed the upper level.
Remember that the addition of ATF to the up-
per limit mark when the transmission is cold
will overfilling of ATF, causing a transmission
failure.
6) Check ATF level after raising ATF temperature
to 70 — 80°C (158 — 176°F) by running the vehicle
or by idling the engine again.
B: REPLACEMENT
1) Lift-up the vehicle.2) Drain the ATF completely.
CAUTION:
Directly after the engine has been running, the
ATF is hot. Be careful not to burn yourself.
3) 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)
4) Lower the vehicle.
5) Pour ATF from the ATF charge pipe.
Recommended fluid:
DEXRON III type automatic transmission flu-
id
Capacity:
Fill the same amount of ATF drained from
drain plug hole.
CAPACITY WHEN TRANSMISSION IS OVER-
HAULED:
2.0 L NON-TURBO MODEL
8.4 — 8.72 (8.9 — 9.2 US qt, 7.4 — 7.7 Imp
qt)
EXCEPT 2.0 L NON-TURBO MODEL
9.3 — 9.62 (9.8 — 10.1 US qt, 8.2 — 8.4 Imp
qt)
6) Check the level and leaks of ATF.
(A) ATF level gauge
(B) Upper level
(C) Lower level
AT-00674
COLD
LFHOT LF
(C)
(C)
(B)
(B)
(A)(A) Oil pan
(B) Drain plug (ATF)
(C) Differential gear oil drain plug
AT-00016
(A) (B)
(C)