2004 SUBARU FORESTER automatic transmission

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-132
AUTOMATIC TRANSMISSION
AT Main Case
4) Take out the clutch cover, spring retainer, high
clutch piston and reverse clutch piston.
5) Remove the D-ring and lip seal from high clutch
piston and reverse clutch piston.
2. PLANETARY GEAR AND LOW CLUTCH
1) Remove the snap ring from low clutch drum.2) Take out the front planetary carrier.
3) Take out the rear sun gear.
4) Take out the rear planetary carrier, washer and
thrust needle bearing.
(A) Reverse clutch piston
(B) Clutch cover
(C) Return spring
(A) High clutch piston
(B) Reverse clutch piston
(A) Snap ring
(B) Low clutch drum
AT-00239
(A)(B)
(C)
AT-00240
(A)
(B)
AT-00259
(A)
(B)
(A) Front planetary carrier
(B) Low clutch drum
(A) Rear sun gear
(B) Rear planetary carrier
(A) Rear planetary carrier
(B) Low clutch drum
AT-00260
(B) (A)
AT-00261
(B)(A)
AT-00262
(B)
(A)

4AT-133
AUTOMATIC TRANSMISSION
AT Main Case
5) Take out the rear internal gear.
6) Remove the snap ring from low clutch drum.
7) Compress the spring retainer of low & reverse
brake, and remove the snap ring from low clutch
drum using ST1 and ST2.
ST1 498627100 SEAT
ST2 398673600 COMPRESSOR
8) Remove the one-way clutch. REMOVAL, AT Main Case.>9) Install the one-way clutch inner race to low
clutch drum, and then apply compressed air to re-
move the low clutch piston.
10) Remove the one-way clutch inner race.
11) Remove the one-way clutch after taking out the
snap ring.
12) Remove the needle bearing after taking out the
snap ring.
(A) Rear internal gear
(B) Low clutch drum
(A) Snap ring
(B) Low clutch drum
(A) Snap ring
(B) Low clutch drum
AT-00263
(B)
(A)
AT-00264
(B)
(A)
AT-00265
(B)(A)
ST1
ST2
(A) Apply compressed air.
(B) One-way clutch inner race
(A) Snap ring
(B) Plate
(C) One-way clutch
(A) Needle bearing
(B) Snap ring
AT-00266
(B) (A)
AT-00267
(A)(C)
(B)
AT-00268
(B)(A)

4AT-134
AUTOMATIC TRANSMISSION
AT Main Case
3. 2-4 BRAKE
Separate the 2-4 brake piston and piston retainer.
4. ONE-WAY CLUTCH INNER RACE
1) Remove the seal ring.
2) Remove the needle bearing using ST.
ST 398527700 PULLER ASSY
5. ONE-WAY CLUTCH OUTER RACE
1) Remove the one-way clutch after taking out the
snap ring.2) Remove the needle bearing after taking out the
snap ring.
D: ASSEMBLY
1. HIGH CLUTCH AND REVERSE CLUTCH
1) Install the new D-ring and lip seal to high clutch
piston and reverse clutch piston.
2) Install the high clutch piston to reverse clutch
piston.
3) Install the reverse clutch ASSY to high clutch
drum. Align the groove on reverse clutch piston
with the groove on high clutch drum during installa-
tion.
(A) 2-4 brake piston
(B) 2-4 brake piston retainer
(A) One-way clutch inner race
(B) Seal ring
(A) Snap ring
(B) Plate
(C) One-way clutch
AT-00288
(A)(B)
AT-00298(B)(A)
AT-00267
(A)(C)
(B)
(A) Needle bearing
(B) Snap ring
(A) High clutch piston
(B) Reverse clutch piston
(A) Reverse clutch piston
(B) High clutch drum
AT-00268
(B)(A)
AT-00240
(A)
(B)
AT-00241
(A)
(B)

4AT-135
AUTOMATIC TRANSMISSION
AT Main Case
4) Install the spring retainer to high clutch piston.
5) Install ST to high clutch piston.
ST 498437000 HIGH CLUTCH PISTON
GUIDE
6) Install the cover to high clutch piston without
folding the high clutch piston seal.
7) Install the snap ring using ST1 and ST2.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 498437000 HIGH CLUTCH PISTON
GAUGE8) Install the thickest driven plate to piston side,
and then install the driven plate, drive plate, retain-
ing plate to high clutch drum.
9) Install the snap ring to high clutch drum.
10) Apply compressed air intermittently to check for
operation.
11) Measure the clearance between the retaining
plate of high clutch and snap ring.
At this time, do not press down the retaining plate.
Initial standard:
0.8 — 1.1 mm (0.031 — 0.043 in)
Limit thickness:
1.5 mm (0.059 in)
(A) Return spring
(B) High clutch drum
AT-00242
(B)
(A)
AT-00243
ST
AT-00244
ST1
ST3
ST2
(A) Thickness gauge
AT-00245
AT-00246
AT-00249
(A)

4AT-136
AUTOMATIC TRANSMISSION
AT Main Case
If the specified tolerance limits are exceeded, se-
lect a suitable retaining plate.
12) Install the driven plate, drive plate, retaining
plate and snap ring.
13) Apply compressed air intermittently to check for
operation.14) Measure the clearance between the retaining
plate of reverse clutch and snap ring.
At this time, do not press down the retaining plate.
Initial standard:
0.5 — 0.8 mm (0.020 — 0.031 in)
Limit thickness:
1.2 mm (0.047 in)
If the specified tolerance limits are exceeded, se-
lect a suitable retaining plate.
2. PLANETARY GEAR AND LOW CLUTCH
1) Install new D-ring to low clutch piston.
2) Install the low clutch piston to low clutch drum.
Retaining plate
TOOL NUMBER Thickness mm (in)
31567AA710 4.7 (0.185)
31567AA720 4.8 (0.189)
31567AA730 4.9 (0.193)
31567AA740 5.0 (0.197)
31567AA670 5.1 (0.201)
31567AA680 5.2 (0.205)
31567AA690 5.3 (0.209)
31567AA700 5.4 (0.213)
AT-00247
AT-00248
(A) Thickness gauge
Retaining plate
TOOL NUMBER Thickness mm (in)
31567AA910 4.0 (0.157)
31567AA920 4.2 (0.165)
31567AA930 4.4 (0.173)
31567AA940 4.6 (0.181)
31567AA950 4.8 (0.189)
31567AA960 5.0 (0.197)
31567AA970 5.2 (0.205)
31567AA980 5.4 (0.213)
(A) Low clutch piston
(B) Low clutch drum
AT-00250
(A)
AT-00269
(B) (A)

4AT-137
AUTOMATIC TRANSMISSION
AT Main Case
3) Install the spring retainer to low clutch piston.
4) Install the ST to low clutch drum.
ST 498437100 LOW CLUTCH PISTON
GUIDE
5) Set the cover on the piston with a press using
ST1 and ST2, and attach the snap ring. At this time,
be careful not to fold the cover seal during installa-
tion.
ST1 498627100 SEAT
ST2 398673600 COMPRESSOR
ST3 498437100 LOW CLUTCH PISTON
GUIDE6) Install the dish plate, driven plate and retaining
plate, and then secure them with snap ring.
7) Check the low clutch for operation.
(1) Remove the one-way clutch. 123, REMOVAL, AT Main Case.>
(2) Set the one-way clutch inner race, and apply
compressed air for checking.
(A) Spring retainer
(B) Low clutch drum
AT-00270
(A)
(B)
AT-00271
ST
AT-00272
ST2
ST3
ST1
(A) Snap ring
(B) Low clutch drum
(C) Dish plate
(D) Low clutch piston side
(A) Apply compressed air.
(B) Low clutch drum
AT-00273
(B)
(A)
(C)
(D)
AT-00274
(B) (A)

4AT-138
AUTOMATIC TRANSMISSION
AT Main Case
8) Check the low clutch clearance.
(1) Place the same thickness of shim on both
sides to prevent pressure plate from tilting.
(2) Check the clearance between retaining
plate and low clutch operation.
Initial standard:
0.7 — 1.1 mm (0.028 — 0.043 in)
Limit thickness:
1.6 mm (0.063 in)
If the clearance is out of the specified range, select
a proper retaining plate so that the standard clear-
ance can be obtained.
9) Install the washer to rear internal gear.10) Install the rear internal gear.
11) Install the thrust needle bearing in correct di-
rection.
12) Install the washer by aligning protrusion of
washer and hole of rear planetary carrier.
(A) Thickness gauge
(B) Low clutch drum
Retaining plate
Tool number Thickness mm (in)
31567AA830 3.8 (0.150)
31567AA840 4.0 (0.157)
31567AA850 4.2 (0.165)
31567AA860 4.4 (0.173)
31567AA870 4.6 (0.181)
(A) Rear internal gear
(B) Washer
AT-00283
(A)
(B)
AT-00275
(A)(B)
(A) Rear internal gear
(B) Low clutch drum
(A) Thrust needle bearing
(B) Low clutch drum
(A) Washer
(B) Rear planetary carrier
AT-00276
(B)
(A)
AT-00277
(B)
(A)
AT-00278
(A)
(B)