2004 SUBARU FORESTER height

ME(H4DOTC)-106
MECHANICAL
Cylinder Block
2.0 L MODEL
Standard diameter:
A: 92.005 — 92.015 mm (3.6222 — 3.6226 in)
B: 91.995 — 92.005 mm (3.6218 — 3.6222 in)
2.5 L MODEL
Standard diameter:
A: 99.505 — 99.515 mm (3.9175 — 3.9179 in)
B: 99.495 — 99.505 mm (3.9171 — 3.9175 in)
2) How to measure the inner diameter of each cyl-
inder:
Measure the inner diameter of each cylinder in both
the thrust and piston pin directions at the heights
shown in the figure, using a cylinder bore gauge.
NOTE:
Measurement should be performed at a tempera-
ture of 20°C (68°F).
Taper:
Standard
0.015 mm (0.0006 in)
Limit
0.050 mm (0.0020 in)Out-of-roundness:
Standard
0.010 mm (0.0004 in)
Limit
0.050 mm (0.0020 in)
3) When the piston is to be replaced due to general
or cylinder wear, determine a suitable sized piston
by measuring the piston clearance.
4) How to measure the outer diameter of each pis-
ton:
Measure the outer diameter of each piston at the
height shown in the figure. (Thrust direction)
NOTE:
Measurement should be performed at a tempera-
ture of 20°C (68°F).
(A) Main journal size mark
(B) Cylinder block (RH)-(LH) combination mark
(C) #1 cylinder bore size mark
(D) #2 cylinder bore size mark
(E) #3 cylinder bore size mark
(F) #4 cylinder bore size mark
ME-00170 #5
#4
#3
#2
#1(A)(B)
(F)
(D)
A BA B
5 45 4
(C) (E)
(A) Piston pin direction
(B) Thrust direction
H1: 10 mm (0.39 in)
H2: 45 mm (1.77 in)
H3: 80 mm (3.15 in)
H4: 115 mm (4.53 in)
ME-00171
(A)
(B)
H2 H1
H3
H4

4AT-25
AUTOMATIC TRANSMISSION
General Description
499787700 WRENCH Used for removing and installing drive pinion lock
nut.
499787500 ADAPTER Used for removing and installing drive pinion lock
nut.
398643600 GAUGE Used for measuring total end play, extension end
play and drive pinion height.
498627100 SEAT Used for holding low clutch piston retainer spring
when installing snap ring. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-499787700
ST-499787500
ST-398643600
ST-498627100

4AT-105
AUTOMATIC TRANSMISSION
Oil Pump Housing
35.Oil Pump Housing
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 ATF charger pipe. REMOVAL, Oil Charger Pipe.>
7) Remove the ATF cooler inlet and outlet pipes.
Hose.>
8) Separate the torque converter clutch case and
transmission case part. MOVAL, Torque Converter Clutch Case.>
9) Separate the transmission case and extension
case part. Case.>
10) Remove the reduction drive gear. 99, REMOVAL, Reduction Drive Gear.>
11) Remove the reduction driven gear. 4AT-97, REMOVAL, Reduction Driven Gear.>
12) Loosen the oil pump housing mounting bolts.13) Place two wooden blocks on the workbench,
and stand the transmission case with its rear end
facing down.
CAUTION:
Be careful not to scratch the rear mating sur-
face of transmission case.
NOTE:
Check the height of wooden blocks to avoid dam-
aging the protrudes that on the mating surface of
parking rod and drive pinion.
14) Remove the oil pump housing and adjusting
thrust washer.
B: INSTALLATION
1) Secure the oil pump housing with two nuts and a
bolt.
Tightening torque:
42 N
⋅m (4.3 kgf-m, 31 ft-lb)
AT-00114
AT-01034
(A) Oil pump housing
(A) Oil pump housing
AT-00181
(2.17in)55mm
AT-00182
(A)
AT-01035
(A)

4AT-109
AUTOMATIC TRANSMISSION
Oil Pump Housing
(2) Side clearance
Set depth gauge to oil pump housing, then mea-
sure oil pump housing-to-oil pump rotor clear-
ance.
Side clearance:
0.02 — 0.04 mm (0.0008 — 0.0016 in)
(3) If the depth and/or side clearance are not
within the specifications, replace the oil pump
rotor assembly.
Measure the total end play and adjust it within
specifications. MENT, Oil Pump Housing.>
F: ADJUSTMENT
1) Using ST, measure length “L”, which is from
mating surface of transmission case to concave
side of high clutch drum.
ST 398643600 GAUGE2) Using ST, measure the length from oil pump
housing mating surface to top surface of oil pump
cover with thrust needle bearing.
ST 398643600 GAUGE
3) Calculation of total end play
Select the suitable thrust needle bearing from
among those listed in this table so that clearance C
within 0.25 to 0.55 mm (0.0098 to 0.0217 in).
C = (L+G) −2
(A) DEPTH GAUGE
(B) Oil pump inner rotor
(C) Oil pump outer rotor
Oil pump rotor ASSY
TOOL NUM-
BERThickness mm (in)
15008AA060 11.37 — 11.38 (0.4476 — 0.4480)
15008AA070 11.38 — 11.39 (0.4480 — 0.4484)
15008AA080 11.39 — 11.40 (0.4484 — 0.4488)
AT-01039
(A)
(B)
(C)
AT-00194
L
ST
CClearance between concave portion of high
clutch and end of clutch drum support
LLength from transmission case mating surface
to concave portion of high clutch
G Gasket thickness [0.28 mm (0.0110 in)]
2Height from oil pump housing mating surface to
upper surface of oil pump cover with thrust nee-
dle bearing
Thrust needle bearing
TOOL NUMBER Thickness mm (in)
806528050 4.1 (0.161)
806528060 4.3 (0.169)
806528070 4.5 (0.177)
806528080 4.7 (0.185)
806528090 4.9 (0.193)
806528100 5.1 (0.201)
AT-00195
ST
AT-00196
G
L

4AT-115
AUTOMATIC TRANSMISSION
Drive Pinion Shaft Assembly
Corrective action: Increase thickness of pinion
height adjusting washer in order to bring drive pin-
ion shaft close to hypoid driven gear.
 Flank contact
Checking item: Backlash is too small.
Contact pattern
Corrective action: Reduce thickness of pinion
height adjusting washer in order to bring drive pin-
ion shaft away from hypoid driven gear.
 Toe contact (inside end contact)
Checking item: Contact areas is small
Contact patternCorrective action: Reduce thickness of pinion
height adjusting washer in order to bring drive pin-
ion shaft away from hypoid driven gear.
 Heel contact (outside end contact)
Checking item: Contact areas is small
Contact pattern
Corrective action: Increase thickness of pinion
height adjusting washer in order to bring drive pin-
ion shaft close to hypoid driven gear.
AT-00212
AT-00209
AT-00213
AT-00210
AT-00213
AT-00211
AT-00212

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

5MT-27
MANUAL TRANSMISSION AND DIFFERENTIAL
General Description
398527700 PULLER ASSY  Used for removing extension case roller bear-
ing.
 Used for removing front differential side
retainer bearing outer race.
 Used for removing front differential side
retainer oil seal.
398643600 GAUGE Used for measuring total end play, extension end
play and drive pinion height.
398177700 INSTALLER  Used for installing bearing cone of transfer
driven gear (transfer case side).
 Used for installing ball bearing of transfer drive
gear.
398507703 DUMMY COLLAR  Used for installing input shaft holder oil seal.
 For dual-range model. ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST-398527700
ST-398643600
ST-398177700
ST-398507703