2004 SUBARU FORESTER check oil

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. MENT, Oil Pump Housing.>
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)

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. ADJUSTMENT, Drive Pinion Shaft Assembly.>
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. MENT, Front Differential.>
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. JUSTMENT, Front Differential.>
 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

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. Torque Converter Clutch Case.>
8) Insert the inhibitor switch and transmission con-
nector to the stay.
9) Install the ATF cooler pipe. STALLATION, ATF Cooler Pipe and Hose.>
10) Install the ATF charger pipe with O-ring. to 4AT-88, INSTALLATION, Oil Charger Pipe.>11) 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)
12) Install the torque converter clutch assembly.
er Clutch Assembly.>
13) Install the transmission assembly into the vehi-
cle. Transmission Assembly.>
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

4AT-121
AUTOMATIC TRANSMISSION
Front Differential
6) Using ST, install the taper roller bearing.
ST 398487700 INSTALLER
2. DIFFERENTIAL SIDE RETAINER
1) Install the bearing outer race to differential side
retainer.
2) Install a new oil seal using ST and plastic ham-
mer.
ST 18675AA000 DIFFERENTIAL OIL SEAL IN-
STALLER
3) Install a new O-ring.
E: INSPECTION
 Check each component for harmful cuts, dam-
age and other faults.
 Measure the backlash, and then adjust it within
specification.
tial.>
F: ADJUSTMENT
1) Using ST, screw-in the differential side retainer
until light contact is felt.
NOTE:
Screw-in the RH side slightly deeper than the LH
side.
ST 499787000 WRENCH ASSY
2) Remove the oil pump housing.
3) Remove the liquid gasket completely.
4) 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)
5) Rotate the drive pinion several times using ST1
and ST2.
ST1 498937110 HOLDER
ST2 499787700 WRENCH
(A) Taper roller bearing
AT-00225
AT-00226
ST
AT-00219
AT-00227
ST
AT-00205
AT-00206
ST2
ST1

4AT-131
AUTOMATIC TRANSMISSION
AT Main Case
35) Install the oil pump housing assembly with a
new gasket.
36) Install the torque converter clutch case assem-
bly into transmission case assembly. 103, INSTALLATION, Torque Converter Clutch
Case.>
37) Insert the inhibitor switch and transmission
connector to the stay.
38) Install the air breather hose. INSTALLATION, Air Breather Hose.>
39) Install the ATF cooler pipe. STALLATION, ATF Cooler Pipe and Hose.>
40) Install the ATF charger pipe with O-ring. to 4AT-88, INSTALLATION, Oil Charger Pipe.>
41) 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)
42) Install the torque converter clutch assembly.
er Clutch Assembly.>
43) Install the transmission assembly into the vehi-
cle. Transmission Assembly.>C: DISASSEMBLY
1. HIGH CLUTCH AND REVERSE CLUTCH
1) Remove the snap ring, and then take out the re-
taining plate, drive plate and driven plate.
2) Remove the snap ring, and then take out the re-
taining plate, drive plate and driven plate.
3) Using ST1 and ST2, remove the snap ring.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
(A) Transmission harness
(B) Inhibitor switch harness
AT-01351
(B)(A)
AT-00291
A
(A) Snap ring
(A) Snap ring
(A) Snap ring
AT-00236
(A)
AT-00237
(A)
AT-00238
(A)
ST1
ST2

4AT-141
AUTOMATIC TRANSMISSION
AT Main Case
3) Set the one way clutch inner race to low clutch
drum. Make sure that the forward clutch is free in
the clockwise direction and locked in the counter
clockwise direction, as viewed from the front of the
vehicle.
E: INSPECTION
1. HIGH CLUTCH AND REVERSE CLUTCH
Check the following items:
 Drive plate facing for wear and damage
 Snap ring for wear, return spring for setting and
breakage, and snap ring retainer for deformation
 Lip seal and D-ring for damage
 Piston and drum check ball for operation
 Adjust total end play. JUSTMENT, Oil Pump Housing.>
2. PLANETARY GEAR AND LOW CLUTCH
Check the following items:
 Drive plate facing for wear and damage
 Snap ring for wear, return spring for setting and
breakage, and spring retainer for deformation
 Lip seal and D-ring for damage
 Piston check ball for operation
 Measure the total end play and adjust it within
specifications. Oil Pump Housing.>
3. 2-4 BRAKE
Check the following items:
 Drive plate facing for wear and damage
 Snap ring for wear and spring retainer for defor-
mation
 Lip seal and D-ring for damage
 Measure the total end play and adjust it within
specifications. Oil Pump Housing.>
4. ONE-WAY CLUTCH
 Make sure the snap ring is not worn and the seal
rings are not deformed.
 Measure the total end play and adjust it within
specifications. Oil Pump Housing.>
5. LOW AND REVERSE BRAKE
Check the following:
 Drive plate facing for wear and damage
 Snap ring for wear and spring retainer for defor-
mation
(A) Locked
(B) Free
AT-00282
(B) (A)

4AT-143
AUTOMATIC TRANSMISSION
Transmission Control Device
2) Insert the range select lever, and then tighten
the bolt.
Tightening torque:
6 N
⋅m (0.6 kgf-m, 4.4 ft-lb)
3) Insert the manual plate and parking rod.
4) Insert the spring pin to manual plate.
5) Install the oil pan and control valve assembly.
Body.>
6) Turn over the transmission case to its original
position.
7) Install the pitching stopper bracket.
Tightening torque:
41 N
⋅m (4.2 kgf-m, 30.4 ft-lb)
8) Install and adjust the inhibitor switch. 4AT-51, Inhibitor Switch.>9) Insert the inhibitor switch and transmission con-
nector to the stay.
10) Install the air breather hose. INSTALLATION, Air Breather Hose.>
11) 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)
12) Install the torque converter clutch assembly.
er Clutch Assembly.>
13) Install the transmission assembly into the vehi-
cle. Transmission Assembly.>
C: INSPECTION
Make sure the manual lever and detention spring
are not worn or otherwise damaged.
(A) Bolt
(B) Range select lever
(C) Manual plate
(D) Parking rod
AT-00308
AT-00306
AT-00305
(A) Transmission harness
(B) Inhibitor switch harness
AT-01351
(B)(A)
AT-00291
A

4AT(H4SO)-2
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Basic Diagnostic Procedure
1. Basic Diagnostic Procedure
A: PROCEDURE
Step Check Yes No
1 CHECK PRE-INSPECTION.
1) Ask the customer when and how trouble
occurred using interview checklist. 4AT(H4SO)-4, Check List for Interview.>
2) Before performing the diagnosis, inspect
following items which might influence the AT
problems.
 General inspection INSPECTION, General Description.>
 Disconnection of harness connector
 Visually check the damage of harness
 Oil leak
 Stall speed test
 Line pressure test Pressure Test.>
 Transfer clutch pressure test 38, Transfer Clutch Pressure Test.>
 Time lag test Te s t . >
 Road test
 Inhibitor switch Switch.>Is the unit that might influence
AT problem normal?Go to step 2.Repair or replace
each item.
2 CHECK POWER INDICATOR LIGHT.
Turn the ignition switch to ON.Does the POWER indicator
light illuminate?Go to step 4.Go to step 3.
3 CHECK POWER INDICATOR LIGHT.
1) Turn the ignition switch to OFF.
2) Repair the POWER indicator light circuit or
power supply and ground line circuit.
Indicator Light Display.>
3) Turn the ignition switch to ON.Is the POWER indicator light
illuminate?Go to step 4.Go to step 5.
4 CHECK INDICATION OF DTC.
Calling up the DTC.
Without Subaru Select Monitor
SELECT MONITOR, OPERATION, Read
Diagnostic Trouble Code (DTC).>
With Subaru Select Monitor
SELECT MONITOR, OPERATION, Read
Diagnostic Trouble Code (DTC).>
NOTE:
If the communication function of select monitor
cannot be executed normally, check the communi-
cation circuit. NICATION FOR INITIALIZING IMPOSSIBLE,
Diagnostic Procedure for Subaru Select Monitor
Communication.>Is the DTC displayed? Go to step 6.
NOTE:
Record all DTC.Go to step 5.