2004 SUBARU FORESTER starter

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-51
AUTOMATIC TRANSMISSION
Inhibitor Switch
13.Inhibitor Switch
A: INSPECTION
When the driving condition or starter motor opera-
tion is erroneous, first check the shift linkage for im-
proper operation. If the shift linkage is functioning
properly, check the inhibitor switch.
1) Disconnect the inhibitor switch connector.
2) Check continuity in inhibitor switch circuits with
the select lever moved to each position.
NOTE:
 Also check that continuity in ignition circuit does
not exist when the select lever is in “R”, “D”, “3”, “2”
and “1” ranges.
 If the inhibitor switch is inoperative, check for
poor contact of connector on transmission side.3) Check if there is continuity at equal points when
the select lever is turned 1.5° in both directions
from the “N” range to “R” range or “D” range
If there is continuity in one direction and the conti-
nuity in the other or if there is continuity at unequal
points, adjust the inhibitor switch. ADJUSTMENT, Inhibitor Switch.>
4) Repeat the above checks at other ranges. If
there are abnormalities, adjust the select cable.

Signal sent to TCMRange Pin No.
P4 — 3
R4 — 2
N4 — 1
D4 — 8
34 — 7
24 — 6
14 — 5
Ignition circuit P/N 12 — 11
Back-up light circuit R 10 — 9
(A) Inhibitor switch connector
AT-00030
(4)(3)(2) (1)
(5) (6) (7) (8)
(9)
(10) (11) (12)
(A)
(A) Continuity does not exist.
(B) Continuity exists.
(C) 1.5°
(C) (A) (C) (A)
(B)
AT-00452
P
R
N
D
3
2
1

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-106
AUTOMATIC TRANSMISSION
Oil Pump Housing
2) Install the torque converter clutch case to trans-
mission case. Torque Converter Clutch Assembly.>
3) Install the reduction driven gear. 97, INSTALLATION, Reduction Driven Gear.>
4) Install the reduction drive gear. INSTALLATION, Reduction Drive Gear.>
5) Align the transmission case and extension case.
Case.>
6) Insert the inhibitor switch and transmission con-
nector to the stay.
7) Install the ATF cooler pipe. STALLATION, ATF Cooler Pipe and Hose.>
8) Install the ATF charger pipe with O-ring. 4AT-88, INSTALLATION, Oil Charger Pipe.>
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.
er Clutch Assembly.>
11) Install the transmission assembly into the vehi-
cle. Transmission Assembly.>C: DISASSEMBLY
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)

4AT(H4SO)-110
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Symptom Related Diagnostic
15.Symptom Related Diagnostic
A: INSPECTION
Symptom Problem parts
Starter does not rotate when select lever is in “P” or “N” range;
starter rotates when select lever is in “R”, “D”, “3” or “2” range. Inhibitor switch
 Select cable
 Select lever
 Starter motor and harness
Abnormal noise when select lever is in “P” or “N” range. Strainer
 Transfer duty solenoid
 Oil pump
Drive plate
 ATF level too high or too low
Hissing noise occurs during standing start. Strainer
 ATF level too high or too low
Noise occurs while driving in “D1”.  Final gear
 Planetary gear
 Reduction gear
 Differential gear oil level too high or too low Noise occurs while driving in “D2”.
Noise occurs while driving in “D3”. Final gear
 Low & reverse brake
 Reduction gear
 Differential gear oil level too high or too low
Noise occurs while driving in “D4”. Final gear
 Low & reverse brake
 Planetary gear
 Reduction gear
 Differential gear oil level too high or too low
Engine stalls while shifting from “1” range to another. Control valve
 Lock-up damper
 Engine performance
 Input shaft
Vehicle moves when select lever is in “N” range.  Low clutch
Shock occurs when select lever is moved from “N” to “D” range.TCM
Harness
 Control valve
 ATF deterioration
Excessive time lag occurs when select lever is moved from “N”
to “D” range. Control valve
 Low clutch
 Line pressure duty solenoid
 Seal ring
 Front gasket transmission case
Shock occurs when select lever is moved from “N” to “R” range.TCM
Harness
 Control valve
 ATF deterioration
Excessive time lag occurs when select lever is moved from “N”
to “R” range. Control valve
 Low & reverse clutch
 Reverse clutch
 Line pressure duty solenoid
 Seal ring
 Front gasket transmission case
Vehicle does not start in any shift range (engine stalls). Parking brake mechanism
 Planetary gear

4AT(H4DOTC)-126
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Symptom Related Diagnostic
15.Symptom Related Diagnostic
A: INSPECTION
Symptom Problem parts
Starter does not rotate when select lever is in “P” or “N” range,
starter rotates when select lever is in “R”, “D”, “3” or “2” range. Inhibitor switch
 Select cable
 Select lever
 Starter motor and harness
Abnormal noise when select lever is in “P” or “N” range. Strainer
 Transfer duty solenoid
 Oil pump
Drive plate
 ATF level too high or too low
Hissing noise occurs during standing start. Strainer
 ATF level too high or too low
Noise occurs while driving in “D1”.  Final gear
 Planetary gear
 Reduction gear
 Differential gear oil level too high or too low Noise occurs while driving in “D2”.
Noise occurs while driving in “D3”. Final gear
 Low & reverse brake
 Reduction gear
 Differential gear oil level too high or too low
Noise occurs while driving in “D4”. Final gear
 Low & reverse brake
 Planetary gear
 Reduction gear
 Differential gear oil level too high or too low
Engine stalls while shifting from “1” range to another. Control valve
 Lock-up damper
 Engine performance
 Input shaft
Vehicle moves when select lever is in “N” range. Select cable
 Inhibitor switch
TCM
 Low clutch
Shock occurs when select lever is shifted from “N” to “D” range. Accelerator pedal position sensor
 ATF temperature sensor
 Line pressure linear solenoid
 Low clutch duty solenoid
 Low clutch
TCM
Harness
 Control valve
 ATF deterioration
Excessive time lag occurs when select lever is shifted from “N”
to “D” range. Control valve
 Low clutch
 Line pressure duty solenoid
 Seal ring
 Front gasket of transmission case
Shock occurs when select lever is shifted from “N” to “R” range. Accelerator pedal position sensor
 ATF temperature sensor
 Line pressure linear solenoid
TCM
Harness
 Control valve
 ATF deterioration

5MT-32
MANUAL TRANSMISSION AND DIFFERENTIAL
Manual Transmission Assembly
3. Manual Transmission As-
sembly
A: REMOVAL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Drain the transmission gear oil completely. to 5MT-31, REPLACEMENT, Transmission Gear
Oil.>
4) Open the front hood fully, and support with stay.
5) Remove the air intake duct and air cleaner case.
(Non-turbo model) AL, Air Intake Duct.> MOVAL, Air Cleaner Case.>
6) Remove the air cleaner case stay. (Non-turbo
model)
7) Remove the intercooler. (Turbo model) IN(H4DOTC)-10, REMOVAL, Intercooler.>
8) Disconnect the following connectors and trans-
mission cable.
(1) Neutral position switch connector
(2) Back-up light switch connector
(3) High-low switch connector (Dual-range
model)
 Non-turbo model Turbo model
(4) Vehicle speed sensor
9) Remove the snap pin and pin from drive select
cable.
10) Remove the drive select cable on transmission.
(Dual-range model)
11) Remove the starter. MOVAL, Starter.>
ME-00062
MT-00063
(A) Snap pin
(B) Clevis pin
(C) Drive select cable
MT-00064
MT-00065
MT-00066
(A)
(B)
(C)

5MT-36
MANUAL TRANSMISSION AND DIFFERENTIAL
Manual Transmission Assembly
B: INSTALLATION
1) Replace the differential side retainer oil seal with
a new one. ferential Side Retainer Oil Seal.>
NOTE:
When pulling out the front drive shaft, always re-
place the differential side retainer oil seal.
2) Install the rear cushion rubber to transmission
assembly.
Tightening torque:
35 N·m (3.57 kgf-m, 25.8 ft-lb)
3) Install the clutch release lever and bearing onto
transmission. (Turbo model) STALLATION, Release Bearing and Lever.>
4) Install the transmission onto engine.
(1) Gradually raise the transmission with trans-
mission jack.
(2) Engage them at splines.
NOTE:
Be careful not to strike the main shaft against clutch
cover.
5) Install the transmission rear crossmember.
Tightening torque:
T1: 70 N·m (7.1 kgf-m, 51 ft-lb)
T2: 140 N·m (14.3 kgf-m, 103 ft-lb)
6) Take off the transmission jack.
7) Tighten the nuts which hold lower side of trans-
mission to engine.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)8) Connect the engine and transmission.
(1) Install the starter.
er.>
(2) Tighten the bolts which holds right upper
side of transmission to engine.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
9) Remove the ST.
10) Install the pitching stopper.
Tightening torque:
T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)
T2: 58 N·m (5.9 kgf-m, 43 ft-lb)
11) Lift-up the vehicle.
12) Install the front drive shaft into transmission.
Shaft.>
ST 28399SA010 FRONT DRIVE SHAFT OIL
SEAL PROTECTOR
MT-00081
T2T2
T1T1
MT-00077
MT-00073
MT-00070
ST
AT-00025
T1
T2