2004 SUBARU FORESTER differential

4AT-31
AUTOMATIC TRANSMISSION
Differential Gear Oil
3. Differential Gear Oil
A: INSPECTION
1) Park the vehicle on a level surface.
2) Remove the oil level gauge and wipe it clean.
3) Reinsert the level gauge all the way. Be sure that
the level gauge is correctly inserted and in the
proper orientation.
4) Remove the oil level gauge again, and check the
level. If the differential gear oil level is below the “L”
line, add oil to bring the level up to the “F” line.
5) To prevent overfilling the differential gear oil, do
not add oil above the “F” line.
B: REPLACEMENT
1) Lift-up the vehicle.
2) Remove the differential gear oil drain plug using
TORX
® BIT T70, and drain the differential gear oil
completely.
CAUTION:
 Directly after driving the vehicle, the differen-
tial gear oil is hot. Be careful not to burn your-
self.
 Be careful not to spill the differential gear oil
on exhaust pipe to prevent it from emitting
smoke or fire. When the differential gear oil is
spilled on exhaust pipe, wipe it away complete-
ly.3) Replace the gasket with new ones, and then
tighten the differential gear oil drain plug using
TORX
® BIT T70.
Tightening torque:
44 N
⋅m (4.5 kgf-m, 32.5 ft-lb)
4) Lower the vehicle.
5) Pour differential gear oil into the differential from
gauge hole.
Recommended gear oil:
Use GL-5 (SAE: 75 W-90) or equivalent.
Differential gear oil capacity:
1.1 — 1.32 (1.2 — 1.4 US qt, 1.0 — 1.1 Imp qt)
6) Check the level of the differential gear oil.
Oil.>
(A) Upper level
(B) Lower level
AT-00017
(A)
(B)
LF
(A) Oil pan
(B) Drain plug (ATF)
(C) Differential gear oil drain plug
AT-00016
(A) (B)
(C)

4AT-33
AUTOMATIC TRANSMISSION
Stall Test
5. Stall Test
A: INSPECTION
NOTE:
The stall test is of extreme importance in diagnos-
ing the condition of the automatic transmission and
the engine. It should be conducted to measure the
engine stall speeds in “R” and “2” ranges (when
HOLD switch is ON).
Purposes of the stall test:
 To check the operation of the automatic trans-
mission clutch.
 To check the operation of the torque converter
clutch.
 To check engine performance.
1) Check that the throttle valve opens fully.
2) Check that the engine oil level is correct.
3) Check that the coolant level is correct.
4) Check that the ATF level is correct.
5) Check that the differential gear oil level is cor-
rect.
6) Increase ATF temperature to 70 — 80°C (158 —
176°F) by idling the engine for approximately 30
minutes (with select lever set to “N” or “P”).
7) Place the wheel chocks at the front and rear of
all wheels and engage the parking brake.
8) Shift the manual linkage to ensure it operates
properly, then shift the select lever to the “2” range
and turn the HOLD switch to ON.
9) While forcibly depressing the foot brake pedal,
gradually depress the accelerator pedal until the
engine operates at full throttle.
10) When the engine speed is stabilized, record
that speed quickly and release the accelerator ped-
al.
11) Shift the select lever to “N” range, and cool
down the engine by idling it for more than one
minute.12) If the stall speed in “2” range (with HOLD switch
ON) is higher than specifications, low clutch slip-
ping and “2-4 brake slipping” may occur. To identify
it, conduct the same test as above in “R” range.
13) Perform the stall tests with the select lever in
the “D” range.
NOTE:
 Do not continue the stall test for more than five
seconds at a time (from closed throttle, fully open
throttle to stall speed reading). Failure to follow this
instruction causes the engine oil and ATF to deteri-
orate and the clutch and brake to be adversely af-
fected.
 Be sure to cool down the engine for at least one
minute after each stall test with the select lever set
in the “P” or “N” range and with the idle speed lower
than 1,200 rpm.
 If the stall speed is higher than the specified
range, attempt to finish the stall test in as short a
time as possible, in order to prevent the automatic
transmission from sustaining damage.
Stall speed (at sea level):
2.0 L NON-TURBO MODEL
2,000 — 2,500 rpm
2.0 L TURBO MODEL
2,600 — 3,300 rpm
2.5 L NON-TURBO MODEL
2,100 — 2,600 rpm
2.5 L TURBO MODEL
2,700 — 3,200 rpm
(A) Brake pedal
(B) Accelerator pedal
(A) (B)
P
R
N
D
3
2
1
AT-00449

4AT-43
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
B: INSTALLATION
1) Replace the differential side oil seal with a new
one. tial Side Retainer Oil Seal.>
2) Install the rear cushion rubber to the transmis-
sion.
Tightening torque:
39 N
⋅m (4.0 kgf-m, 29 ft-lb)
3) Install the ST to torque converter clutch case.
ST 498277200 STOPPER SET
4) Install the transmission onto the engine.
(1) Lift up the transmission gradually using a
transmission jack.
(2) Engage them at splines.
(3) Slightly raising the transmission jack, turn
the screws of engine support and tilt the engine
forward.5) Install the transmission rear crossmember.
Tightening torque:
T1: 35 N
⋅m (3.6 kgf-m, 26 ft-lb)
T2: 70 N
⋅m (7.1 kgf-m, 51 ft-lb)
6) Take off the transmission jack.
7) Tighten the bolts which hold lower side of trans-
mission to engine.
Tightening torque:
50 N
⋅m (5.1 kgf-m, 36.9 ft-lb)
8) Lower the lift.
9) Connect the engine and transmission.
(1) Remove the ST from torque converter clutch
case.
NOTE:
When removing ST, be careful not to drop it into
torque converter clutch case.
ST 498277200 STOPPER SET
(2) Install the starter.
er.>AT-00103
ST
AT-00109
AT-00026
T2T2
T1
AT-00108

4AT-44
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
(3) Tighten the bolts which hold right upper side
of transmission to engine.
Tightening torque:
50 N
⋅m (5.1 kgf-m, 36.9 ft-lb)
10) Install the torque converter clutch assembly to
drive plate.
(1) Tighten the bolts which hold torque convert-
er clutch assembly to drive plate.
(2) Using ST, remove all bolts with slightly rotat-
ing crank sprocket.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
(3) Fit the plug to the service hole.
11) Remove the ST.12) Install the pitching stopper.
Tightening torque:
T1: 50 N
⋅m (5.1 kgf-m, 37 ft-lb)
T2: 58 N
⋅m (5.9 kgf-m, 43 ft-lb)
13) Lift-up the vehicle.
14) Replace the snap ring of front drive shaft with a
new one.
15) Apply grease to the oil seal lips.
16) Install ST to side retainer.
ST 28399SA010 OIL SEAL PROTECTOR
17) Align the serration of front differential shaft to
that of differential bevel gear for insertion, and re-
move them using ST.
ST 28399SA010 OIL SEAL PROTECTOR
18) Insert the front drive shaft into transmission se-
curely by pressing the front housing.
19) Install the ball joint onto front housing.
AT-00106
AT-00102
AT-00105
ST
AT-00025
T1
T2
AT-00110ST
AT-00111

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

4AT-49
AUTOMATIC TRANSMISSION
Extension Case Oil Seal
11.Extension Case Oil Seal
A: INSPECTION
Make sure that the ATF does not leak from the joint
of transmission and propeller shaft. If so, replace
the oil seal. tension Case Oil Seal.>
B: REPLACEMENT
1) Clean the transmission exterior.
2) Drain the ATF completely.
NOTE:
Tighten the drain plug (ATF) after draining the ATF.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
3) Remove the rear exhaust pipe and muffler.
(Non-turbo model).
Pipe.> fler.>
(Turbo model)
haust Pipe.> AL, Muffler.>
4) Remove the heat shield cover. (If equipped)
5) Remove the propeller shaft. MOVAL, Propeller Shaft.>
6) Using ST, install the oil seal.
ST 398527700 PULLER ASSY
7) Using the ST, install the oil seal.
ST 498057300 INSTALLER
8) Install the propeller shaft.

9) Install the heat shield cover. (If equipped)10) Install the rear exhaust pipe and muffler.
(Non-turbo model).
haust Pipe.> TION, Muffler.>
(Turbo model)
Exhaust Pipe.> STALLATION, Muffler.>
11) Pour ATF and check the ATF level. 4AT-30, Automatic Transmission Fluid.>
(A) Oil pan
(B) Drain plug (ATF)
(C) Differential gear oil drain plug
AT-00016
(A) (B)
(C)

4AT-50
AUTOMATIC TRANSMISSION
Differential Side Retainer Oil Seal
12.Differential Side Retainer Oil
Seal
A: INSPECTION
Check the leakage of gear oil from differential side
retainer oil seal part.
If there is oil leakage, replace the oil seal.
B: REPLACEMENT
1) Lift-up the vehicle.
2) Remove the front exhaust pipe and center ex-
haust pipe.
(Non-turbo model)
Pipe.>
(Turbo model)
haust Pipe.>
3) Drain the differential gear by removing differen-
tial gear oil drain plug.
4) Replace new gasket and tighten the differential
oil drain plug.
Tightening torque:
44 N
⋅m (4.5 kgf-m, 32.5 ft-lb)
5) Separate the front drive shaft from transmission.

6) Remove the differential side retainer oil seal us-
ing driver which wrapped with vinyl tape or etc.7) Using ST, install the differential side retainer oil
seal by slightly tapping with hammer.
ST 18675AA000 DIFFERENTIAL SIDE OIL
SEAL INSTALLER
8) Apply oil to the oil seal lips.
9) Using the ST, install the front drive shaft. to DS-34, INSTALLATION, Front Drive Shaft.>
ST 28399SA010 OIL SEAL PROTECTOR
10) Install the front exhaust pipe and center ex-
haust pipe.
(Non-turbo model)
haust Pipe.>
(Turbo model)
Exhaust Pipe.>
11) Lower the vehicle.
12) Pour differential gear oil into the gauge hole.
Recommended gear oil:
GL-5 (SAE: 75 W-90) or equivalent
Differential gear oil capacity:
1.1 — 1.32 (1.3 — 1.4 US qt, 1.0 — 1.1 Imp qt)
13) Check the gear oil amount. INSPECTION, Differential Gear Oil.>
(A) Oil pan
(B) Drain plug (ATF)
(C) Differential gear oil drain plug
AT-00016
(A) (B)
(C)
AT-00029
ST

4AT-55
AUTOMATIC TRANSMISSION
Front Vehicle Speed Sensor
14.Front Vehicle Speed Sensor
A: REMOVAL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Remove the air cleaner case. (Non-turbo mod-
el).
Case.>
4) Remove the intercooler. (Turbo model)
er.>
5) Disconnect the transmission connector.
6) Remove the pitching stopper. REMOVAL, Transmission Mounting System.>
7) Remove the transmission connector from the
stay.
8) Lift-up the vehicle.9) Clean the transmission exterior.
10) Drain the ATF completely.
NOTE:
Tighten the drain plug (ATF) after draining the ATF.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
11) Remove the front, center, rear, exhaust pipes
and muffler. (Non-turbo model).
Pipe.> Exhaust Pipe.> AL, Muffler.>
12) Remove the center, rear exhaust pipe and muf-
fler. (Turbo model)
haust Pipe.> AL, Rear Exhaust Pipe.> 16, REMOVAL, Muffler.>
13) Remove the heat shield cover. (If equipped)
14) Remove the propeller shaft.

15) Place the transmission jack under transmis-
sion.
NOTE:
Make sure that the support plate of transmission
jack does not touch the oil pan.
16) Remove the transmission rear crossmember
bolt.
(A) Transmission connector
AT-00041
AT-00042
(A)
(A) Oil pan
(B) Drain plug (ATF)
(C) Differential gear oil drain plug
AT-00016
(A) (B)
(C)
AT-00043