Page 2409 of 2870
![SUBARU FORESTER 2004 Service Repair Manual 4AT-96
AUTOMATIC TRANSMISSION
Transfer Clutch
3) Calculation formula:
NOTE:
Calculation of “T”:
T = A−B+35.4 mm
[T = A−B+1.3937 in]
T: Thrust needle bearing thickness
A: Distance from the end SUBARU FORESTER 2004 Service Repair Manual 4AT-96
AUTOMATIC TRANSMISSION
Transfer Clutch
3) Calculation formula:
NOTE:
Calculation of “T”:
T = A−B+35.4 mm
[T = A−B+1.3937 in]
T: Thrust needle bearing thickness
A: Distance from the end](/manual-img/17/57426/w960_57426-2408.png)
4AT-96
AUTOMATIC TRANSMISSION
Transfer Clutch
3) Calculation formula:
NOTE:
Calculation of “T”:
T = A−B+35.4 mm
[T = A−B+1.3937 in]
T: Thrust needle bearing thickness
A: Distance from the end of extension case to end
of rear drive shaft
B: Distance from the end of transmission case to
end of reduction drive gear
Example:
When A = 33.6 mm (1.3228 in), B = 65.05 mm
(2.5610 in)
T = 33.6−65.05+35.4 = 3.95
[T = 1.3228−2.5610+1.3937 = 0.1555]
After calculation, the value of “T” becomes 3.95,
therefore select bearing thickness of 3.8.
NOTE:
Calculation formula for “T” is applied when measur-
ing using ST (398643600 GAUGE, 499577000
GAUGE). When not using ST, apply
T = (A−α+0.45 mm) − (B−β) −H
[T = (A−α+0.0177 in) − (B−β) −H]
T: Thrust needle bearing thickness
A: Distance from the end of extension case to end
of reduction drive shaft
B: Distance from the end of transmission case to
end of rear drive shaft
α: Collar thickness used when measuring “A”
β: Collar thickness used when measuring “B”
0.45: Gasket thickness (mm)
H: Shim clearance
Thrust needle bearing
TOOL NUMBER Thickness mm (in)
806536020 3.8 (0.150)
806535030 4.0 (0.157)
806535040 4.2 (0.165)
806535050 4.4 (0.173)
806535060 4.6 (0.181)
806535070 4.8 (0.189)
806535090 5.0 (0.197)
Page 2410 of 2870

FUJI HEAVY INDUSTRIES LTD. G8080GE5
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
TRANSMISSION SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.CONTROL SYSTEM CS
AUTOMATIC TRANSMISSION 4AT
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4SO)
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4DOTC)
AUTOMATIC TRANSMISSION
(DIAGNOSTIC)4AT(H4DOTC 2.5)
MANUAL TRANSMISSION AND
DIFFERENTIAL5MT
CLUTCH SYSTEM CL
Page 2411 of 2870

4AT-97
AUTOMATIC TRANSMISSION
Reduction Driven Gear
31.Reduction Driven Gear
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle.
mission Assembly.>
2) Remove the rear vehicle speed sensor, and then
separate the extension case from transmission
case.
Case.>
3) Set the range select lever to “P” range.
4) Remove the caulking part, and then remove the
lock nut.
5) Using the ST1 and ST2, extract the reduction
driven gear assembly.
ST1 499737000 PULLER
ST2 899524100 PULLER SET
B: INSTALLATION
1) Set the range select lever to “P” range.
2) Using a plastic hammer, install the reduction
driven gear assembly and new washer, and tighten
new lock nut.
Tightening torque:
100 N
⋅m (10.2 kgf-m, 73.8 ft-lb)
3) After tightening, stake the lock nut securely.
4) Combine the transmission case with the exten-
sion case, and then install the rear vehicle speed
sensor.
sion Case.>
5) Install the transmission assembly into the vehi-
cle.
Transmission Assembly.>
C: DISASSEMBLY
1) Remove the snap ring from reduction driven
gear.
(A) Reduction driven gear
(B) Reduction drive gear
(A) Reduction driven gear ASSY
(B) Reduction drive gear ASSY
AT-00153
(A) (B)
AT-00154
(A) (B)
ST1
ST2
(A) Reduction driven gear ASSY
(B) Reduction drive gear ASSY
(A) Snap ring
AT-00153
(A) (B)
AT-00156
(A)
Page 2412 of 2870
4AT-98
AUTOMATIC TRANSMISSION
Reduction Driven Gear
2) Remove the ball bearing from reduction driven
gear using ST.
ST 498077600 REMOVER
D: ASSEMBLY
1) Install the new ball bearing to reduction driven
gear using press.
2) Install the snap ring to reduction driven gear.
E: INSPECTION
Make sure the ball bearing and gear is not de-
formed or damaged.
(A) Ball bearing
(A) Ball bearing
(A) Snap ring
AT-00157
(A)ST
AT-00158
(A)
AT-00156
(A)
Page 2413 of 2870

4AT-99
AUTOMATIC TRANSMISSION
Reduction Drive Gear
32.Reduction Drive Gear
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle.
mission Assembly.>
2) Remove the rear vehicle speed sensor, and then
separate the extension case from transmission
case.
Case.>
3) Remove the reduction driven gear.
97, REMOVAL, Reduction Driven Gear.>
4) Using ST, extract the reduction drive gear as-
sembly.
ST1 499737100 PULLER SET
ST2 899524100 PULLER SET
B: INSTALLATION
1) Install the reduction drive gear assembly.
NOTE:
Press-fit it to the bottom of bearing shoulder com-
pletely.
2) Install the reduction driven gear.
97, INSTALLATION, Reduction Driven Gear.>
3) Combine the transmission case with the exten-
sion case, and then install the rear vehicle speed
sensor.
sion Case.>4) Install the transmission assembly into the vehi-
cle.
Transmission Assembly.>
C: DISASSEMBLY
1) Take out the seal ring.
2) Remove ball bearing using ST.
ST 498077600 REMOVER
3) Using press, remove the reduction drive gear.
(A) Reduction drive gear ASSY
(A) Reduction drive gear ASSY
AT-00159
(A)
ST2
ST1
AT-00160
(A)
(A) Seal ring
(B) Reduction drive shaft
(A) Ball bearing
(B) Reduction drive gear
(A) Reduction drive gear
AT-00161
(A)
(B)
AT-00162
(A)
(B)ST
AT-00163
(A)
Page 2414 of 2870
4AT-100
AUTOMATIC TRANSMISSION
Reduction Drive Gear
D: ASSEMBLY
1) Press-fit the reduction drive gear to shaft.
2) Press-fit the new ball bearing into reduction drive
gear.
3) Apply vaseline to outer surface of new seal ring
and shaft groove.
4) Install the seal ring.
E: INSPECTION
Rotate the bearing by hand, make sure it rotates
smoothly.
Make sure that each component is free of harm-
ful gouges, cuts or dust.
Measure the extension end play and adjust it to
specification.
Transfer Clutch.>
(A) Seal ring
(B) Reduction drive shaft
AT-00161
(A)
(B)
Page 2415 of 2870
4AT-101
AUTOMATIC TRANSMISSION
Parking Pawl
33.Parking Pawl
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle.
mission Assembly.>
2) Remove the rear vehicle speed sensor, and then
separate the extension case from transmission
case.
Case.>
3) Remove the reduction drive gear.
99, REMOVAL, Reduction Drive Gear.>
4) Remove the parking pawl, return spring and
shaft.
B: INSTALLATION
1) Install the parking pawl, return spring and shaft.
2) Install the reduction drive gear.
INSTALLATION, Reduction Drive Gear.>
3) Install the extension case and rear vehicle speed
sensor.
sion Case.>
4) Install the transmission assembly into the vehi-
cle.
Transmission Assembly.>
C: INSPECTION
Make sure that the tab of parking pawl on reduction
gear is not worn or otherwise damaged.
(A) Return spring
(B) Parking pawl
(A) Return spring
(B) Parking pawl
AT-00171
(B)(A)
AT-00171
(B)(A)
Page 2416 of 2870

4AT-102
AUTOMATIC TRANSMISSION
Torque Converter Clutch Case
34.Torque Converter Clutch
Case
A: REMOVAL
1) Remove the transmission assembly from vehi-
cle.
mission Assembly.>
2) Pull out the torque converter clutch assembly.
Clutch Assembly.>
3) Remove the input shaft.
4) Lift-up the lever on rear side of transmission har-
ness connector, and then disconnect it from the
stay.
5) Disconnect the inhibitor switch connector from
the stay.
6) Remove the air breather hose.
REMOVAL, Air Breather Hose.>
7) Remove the ATF charger pipe.
REMOVAL, Oil Charger Pipe.>
8) Remove the ATF cooler inlet and outlet pipes.
Hose.>9) Remove the torque converter clutch case align-
ing bolt, and then separate the transmission case
and torque converter clutch case by lightly tapping
with plastic hammer.
CAUTION:
Be careful not to damage the oil seal and
bush inside the torque converter clutch case by
the oil pump cover.
Do not loosen the rubber seal.
10) Remove the seal pipe.
11) Remove the differential assembly.
4AT-117, REMOVAL, Front Differential.>
12) Remove the oil seal from torque converter
clutch case.
(A) Transmission harness ASSY
(B) Inhibitor switch harness
AT-00114
AT-01351
(B)(A)
(A) Seal pipe
AT-00175
AT-00176