2004 SUBARU FORESTER transmission

4AT-124
AUTOMATIC TRANSMISSION
AT Main Case
15) Remove the snap ring and thrust needle bear-
ing.
16) Take out the retaining plate, drive plate and
driven plate of 2-4 brake.
17) Take out the thrust needle bearing, planetary
gear assembly and low clutch assembly.
18) Remove the 2-4 brake seal.19) Remove the snap ring.
20) Take out the 2-4 brake spring retainer.
21) Remove the 2-4 brake piston and 2-4 brake
piston retainer without damaging.
(A) Snap ring
(B) Thrust needle bearing
AT-00253
(A)(B)
AT-00254
AT-00255
AT-00284
(A) Snap ring
(B) 2-4 brake piston
(A) 2-4 brake piston
(B) 2-4 brake piston retainer
AT-00285
(B)
(A)
AT-00286
AT-00287
(A)
(B)

4AT-125
AUTOMATIC TRANSMISSION
AT Main Case
22) Pull out the leaf spring of low & reverse brake
without folding.
23) Remove the snap ring.
24) Take out the retaining plate of low & reverse
brake, drive plate, driven plate and dish plate.
25) Turn the transmission case upside down, and
then take out the socket bolts while holding the
one-way clutch inner race with hand.26) Remove the spring retainer.
27) Take out the return spring.
28) Apply compressed air.
29) Take out the low & reverse brake piston.
(A) Leaf spring
(A) Snap ring
AT-00293
(A)
AT-00294
(A)
AT-00295
AT-00296
AT-00302
AT-00301
AT-00297
AT-00300

4AT-126
AUTOMATIC TRANSMISSION
AT Main Case
B: INSTALLATION
1) Install the low & reverse piston.
CAUTION:
Be careful not to damage the lip seal.
2) Install the return spring.
3) Install the spring retainer.
4) Install the one-way clutch inner race.
5) Tighten the socket head bolts evenly from the
rear side of transmission case.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)6) Place the front side of transmission body up.
7) Install the thrust needle bearing.
8) Place the dish plate, driven plate, drive plate and
retaining plate neatly in this order on surface table.
9) Set the micro gauge to clutch, and read its scale.
NOTE:
The value, which is read in the gauge at this time, is
zero point.
10) Scale and record the weight “Z” of a flat board
which will be put on plates.
NOTE:
Use a stiff flat board which does not bend against
load.
Use a flat board of its weight less than 83 N (8.5
kgf, 18.7 lb).
11) Put the flat plate on retaining plate.
12) Using the following formula, calculate “N” indi-
cated on the push/pull gauge
N = 83 N (8.5 kgf, 18.7 lb) − Z
N: Value indicated on push/pull gauge
83 N (8.5 kgf, 18.7 lb): Load applied to clutch plate
Z: Flat plate weight
13) Press the center of retaining plate with applying
force of N, and then measure and record the height
A. Make more than three measurements at even
distance and take the average value.
AT-00300
AT-00301
AT-00302
AT-00296
AT-01720

4AT-127
AUTOMATIC TRANSMISSION
AT Main Case
NOTE:
If three points, measure the height every 120°. If
four points, measure the height every 90°.
14) Installation of the low & reverse brake:
Install the dish plate, driven plate and retaining
plate, and then secure them with snap ring.
NOTE:
Pay attention to the orientation of dish plate.15) Apply compressed air intermittently to check for
operation.
16) Measure the clearance.
Place the same thickness of shim on both sides to
prevent pressure plate from tilting, and then mea-
sure the clearance B and note it.
(A) Dish plate
(B) Driven plate
(C) Drive plate
(D) Retaining plate
(A) Snap ring
AT-01721
(B)
(D)
(C)
(A)
A
AT-00294
(A)
AT-00297
AT-01722
B

4AT-128
AUTOMATIC TRANSMISSION
AT Main Case
17) Calculation of piston stroke
Calculate from noted dimension A and B, and then
select the retaining plate to adjust it within specifi-
cation. If the calculated value exceed the limit, re-
place the drive plate with a new one to adjust it
within specification.
T = A+B
T: Piston stroke
A: Collapsing amount of drive plate
B: Clearance between retaining plate and snap ring
TURBO model
Initial standard:
2.7 — 3.2 mm (0.106 — 0.126 in)
Limit thickness:
4.2 mm (0.165 in)
NON-TURBO model
Initial standard:
2.4 — 2.9 mm (0.094 — 0.114 in)
Limit thickness:
3.9 mm (0.154 in)
18) Install the leaf spring of low & reverse brake.19) Install the 2-4 brake piston and 2-4 brake re-
tainer by aligning hole of 2-4 brake retainer and
hole of transmission case.
20) Install the 2-4 brake piston spring retainer to
transmission case.
21) Position the snap ring in transmission. Using
ST, press the snap ring into specified place.
ST 498677100 COMPRESSOR
Retaining plate
TOOL NUMBER Thickness mm (in)
31667AA320 4.1 (0.161)
31667AA330 4.4 (0.173)
31667AA340 4.7 (0.185)
31667AA350 5.0 (0.197)
31667AA360 5.3 (0.209)
31667AA370 5.6 (0.220)
31667AA380 5.9 (0.232)
(A) Leaf spring
AT-00293
(A)
(A) 2-4 brake piston
(B) 2-4 brake piston retainer
AT-00287
(A)
(B)
AT-00286
AT-00289
ST

4AT-129
AUTOMATIC TRANSMISSION
AT Main Case
22) Install the planetary gear and low clutch as-
sembly to transmission case.
CAUTION:
When install the low clutch and planetary gear
assembly with rotating them, rotate them slow-
ly and paying attention not to damage the seal
ring.
23) Install the pressure rear plate, drive plate of 2-
4 brake, driven plate, retaining plate and snap ring.
24) Install a new 2-4 brake seal to transmission
case.25) After all 2-4 brake component parts have been
installed, blow in air intermittently and confirm the
operation of brake.
26) Check the clearance between the retaining
plate and snap ring.
NOTE:
Select a retaining plate with a suitable value from
following table, so that the clearance becomes
within specified value.
Initial standard:
0.8 — 1.2 mm (0.031 — 0.047 in)
Limit thickness:
1.5 mm (0.059 in)
AT-00255
AT-00254
AT-00284
Retaining plate
TOOL NUMBER Thickness mm (in)
31567AA612 5.6 (0.220)
31567AA622 5.8 (0.228)
31567AA632 6.0 (0.236)
31567AA642 6.2 (0.244)
31567AA652 6.4 (0.252)
31567AA662 6.6 (0.260)
AT-00290
AT-00292

4AT-130
AUTOMATIC TRANSMISSION
AT Main Case
27) Install the leaf spring of 2-4 brake.
CAUTION:
Do not install in the wrong place.
28) Install the thrust needle bearing in correct di-
rection.
29) Install the front sun gear and thrust needle
bearing.
30) Attach the thrust needle bearing to high clutch
hub using vaseline, and then install the high clutch
hub by correctly engaging the splines of the front
planetary carrier.31) Install the thrust needle bearing in correct di-
rection.
32) Install the high clutch assembly and reverse
clutch assembly.
33) Adjust total end play. JUSTMENT, Oil Pump Housing.>
34) Install the thrust needle bearing in correct di-
rection.
(A) Leaf spring
(B) Retaining plate
(A) Snap ring
(B) Thrust needle bearing
(C) Upside
(D) Downside
(A) Front sun gear
(B) Thrust needle bearing
AT-00252
(A)
(B)
AT-00256
(A)
(B) (C)
(D)
AT-00251
(A)
(B)
(A) High clutch hub
(B) Thrust needle bearing
(C) Upside
(D) Downside
(E) Outside
(A) High clutch and reverse clutch ASSY
(A) High clutch and reverse clutch ASSY
(B) Thrust needle bearing
(C) Upside
(D) Downside
(E) Outside
AT-00234
AT-00235
(A)
AT-00312

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