2004 SUBARU FORESTER length

4AT-66
AUTOMATIC TRANSMISSION
Control Valve Body
3) Remove the upper and lower control valve body
installing bolt.
NOTE:
While assembling, safekeeping the bolt to identify
bolt position, because the bolt length is different.
4) Remove the lower control valve body.
5) Remove the oil filter and separate plate.
6) Remove the six steel balls from middle control
valve body.
7) Remove the middle control valve body.8) Remove the upper separator plate from middle
control valve body.
9) Remove the four steel balls and accumulator
spring from upper control valve body.
10) Put the cloth to removing part of piston.
11) Remove the accumulator piston with slowly ap-
ply compressed air to each hole.
12) Remove the seal ring from accumulator piston.
(A) Oil filter
(B) Separate plate
(A) Steel ball
(B) Middle control valve body
AT-02125
B
B
BB D
C
B
D
AA
AA
AT-00068(A)(B)
AT-00069
(A)(B)
(A) Upper separate plate
(B) Side plate
AT-00070
(A)
(B)
AT-00071
AT-00072

4AT-68
AUTOMATIC TRANSMISSION
Control Valve Body
8) Install the lower separate plate to lower control
valve body.
9) Temporarily assemble the valve body.
NOTE:
Be careful not to drop the oil filter of lower control
valve body or steel balls in middle control valve
body and upper control valve body.
10) Tighten the bolt.NOTE:
Install the bolt (D) from upper control valve body
side.
Tightening torque:
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
11) Insert solenoid and duty solenoid into the spec-
ified position.
(A) Lower separator plate
(B) Lower control valve body
AT-00076
(A)
(B)
AT-00077
Bolt length mm (in)
(A) 40 (1.57)
(B) 62 (2.44)
(C) 73 (2.87)
(D) 79 (3.11)
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
AT-02125
B
B
BB D
C
B
D
AA
AA
AT-02124
(E)
(F)(G)
(D)(C)
(B)(A)

4AT-69
AUTOMATIC TRANSMISSION
Control Valve Body
12) Tighten the bolt and nut.
Tightening torque:
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
13) Install the oil strainer to lower control valve
body.
Tightening torque:
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
E: INSPECTION
Make sure that each component is free of harmful
gouges, cuts or dust.
Bolt length mm (in)
(A) 12 (0.47)
(B) 40 (1.57)
(C) 45 (1.77)
(D) 62 (2.44)
(E) 73 (2.87)
Bolt length mm (in)
(A) 12 (0.47)
(B) 62 (2.44)
(C) 81 (3.19)
AT-02126
E
AD
EE
D
D
B
CC
AT-00065
A
ABAA
AC
ACC
AB
AC
CC

4AT-72
AUTOMATIC TRANSMISSION
Shift Solenoids, Duty Solenoids and ATF Temperature Sensor
2) Tighten the bolt and nut.
Tightening torque:
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
3) Connect the harness connectors.
Connect the connectors of same color, and con-
nect the connectors to control valve body using
clips.4) Apply proper amount of liquid gasket to the en-
tire oil pan mating surface.
Liquid gasket:
THREE BOND 1217B (Part No. K0877YA020)
5) Fill liquid gasket to holes except for bolt holes
(three) of transmission case.
Liquid gasket:
THREE BOND 1217B (Part No. K0877YA020)
6) Install the oil pan with equally tighten the bolts.
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
7) Pour ATF from the ATF charge pipe. 4AT-30, Automatic Transmission Fluid.>
8) Check the ATF level. ic Transmission Fluid.>
2. ATF TEMPERATURE SENSOR
For installation procedure of the ATF temperature
sensor, refer to “Front Vehicle Speed Sensor”.
Speed Sensor.>
Bolt length mm (in)
(A) 12 (0.47)
(B) 40 (1.57)
(C) 45 (1.77)
(D) 62 (2.44)
(E) 73 (2.87)
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 2 (Yellow)
(E) Shift solenoid 1 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid (Red)
(H) Transfer duty solenoid (Brown)
AT-02126
E
AD
EE
D
D
B
CC
AT-02122
(A) (B) (C) (D) (E)
(H)
(F)
(G)
AT-00051
AT-02123

4AT-76
AUTOMATIC TRANSMISSION
ATF Filter
21.ATF Filter
A: REMOVAL
NOTE:
The ATF filter is maintenance free.
1) Lift-up the vehicle.
2) Using ST, remove the ATF filter.
ST 498545400 OIL FILTER WRENCH
B: INSTALLATION
1) Apply a thin coat of ATF to the oil seal part of
new ATF filter.
2) Install the ATF filter. Turn it by hand, being care-
ful not to damage oil seal.
3) Tighten the ATF filter using ST.
Calculate the ATF filter tightening torque using fol-
lowing formula.
T2 = L2/ (L1+L2) ×T1
T1: 14 N⋅m (1.4 kgf-m, 10.1 ft-lb)
[Required torque setting]
T2: Tightening torque
L1: ST length 78 mm (3.07 in)
L2: Torque wrench length
Example:
NOTE:
Align the ST with torque wrench while tightening
the ATF filter.
ST 498545400 OIL FILTER WRENCH
4) Fill ATF.
5) Check the level of the ATF. tomatic Transmission Fluid.>
C: INSPECTION
 Replace the part if any defect is found from the
inspection.
 Check for rust, hole, ATF leaks and other dam-
age.
(A) ATF filter
Torque wrench length
mm (in)Tightening torque
N⋅m (kgf-m, ft-lb)
100 (3.94) 7.7 (0.79, 5.7)
150 (5.91) 9.0 (0.92, 6.7)
200 (7.87) 9.8 (1.0, 7.2)
AT-00091
(A)ST

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-113
AUTOMATIC TRANSMISSION
Drive Pinion Shaft Assembly
2) Using a press, press-fit the new roller bearing
into specified position.
NOTE:
If excessive force is applied to roller bearing, the
roller bearing will not turn easily.
3) After fitting a new O-ring to the drive pinion shaft,
attach the drive pinion collar to the drive pinion
shaft.
4) Install the lock washer to drive pinion shaft in
proper direction.
5) Tighten the new lock nuts using ST1, ST2 and
ST3.
Calculate the lock washer and lock nut specifica-
tions using following formula.
T2 = L2/ (L1+L2) ×T1
T1: 116 N⋅m (11.8 kgf-m, 85.3 ft-lb)
[Required torque setting]
T2: Tightening torque
L1: ST2 length 0.072 m (2.83 in)
L2: Torque wrench length
Example:
ST1 498937110 HOLDER
ST2 499787700 WRENCH
ST3 499787500 ADAPTERNOTE:
Install ST2 to torque wrench as straight as possi-
ble.
6) Measure the starting torque of bearing. Make
sure the starting torque is within the specified
range. If the torque is not within specified range, re-
place the roller bearing.
Starting torque:
7.6 — 38.1 N (0.776 — 3.88 kgf, 1.7 — 3.88 kg)
7) Stake the lock nut at two points.
8) Measure the dimension “B” of drive pinion shaft
ST 398643600 GAUGE
9) Calculate the thickness “t” (mm) of drive pinion
shim.
t = 6.5±0.0625− (B−A)
(A) Drive pinion shaft
(B) Roller bearing
Torque wrench length
m (in)Tightening torque
N⋅m (kgf-m, ft-lb)
0.4 (15.75) 98 (10.0, 72.3)
0.45 (17.72) 100 (10.2, 73.5)
0.5 (19.69) 101 (10.3, 74.6)
0.55 (21.65) 102 (10.4, 75.4)
AT-00201
(B)
(A)
ST1
AT-00202
L1 [m (in)]
L2 [m (in)]
ST2
ST3
AT-00203
B
AT-00204

4AT(H4SO)-23
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Clear Memory Mode
9. Clear Memory Mode
A: OPERATION
1. WITHOUT SUBARU SELECT MONITOR
Current DTC shown on display are cleared by turn-
ing the ignition switch to OFF after conducting on-
board diagnostics operation. Previous DTC, how-
ever, cannot be cleared since they are stored in the
TCM memory which is operating on back-up power
supply. These DTC can be cleared by removing the
specified TCM connector for at least two minutes.
CLEAR MEMORY:
Remove the TCM connector (B56) for at least
two minutes.
 TCM connector (B56) is located in the line to
memory back-up power supply of TCM. Removal of
this connector clears the previous DTC stored in
TCM memory.
 Be sure to remove TCM connector (B56) for at
least the specified length of time. Otherwise, the
DTC may not be cleared.
2. WITH SUBARU SELECT MONITOR
Refer to Subaru Select Monitor for information
about how to clear DTC.
MODE, OPERATION, Subaru Select Monitor.>