2004 SUBARU FORESTER transmission

PM-28
PERIODIC MAINTENANCE SERVICE
Front & Rear Differential Oil
17.Front & Rear Differential Oil
A: REPLACEMENT
1. FRONT DIFFERENTIAL (MT MODEL)
For MT model, manual transmission oil works as
differential oil to lubricate differential. Refer to
“Transmission Oil”. Gear Oil.>
2. FRONT DIFFERENTIAL (AT MODEL)
1) Drain the differential gear oil by removing drain
plug using TORX® T70.
CAUTION:
 Before starting work, cool off differential gear
oil well.
 If front differential gear oil adheres to the ex-
haust pipe, wipe it off completely.
2) Replace the gasket with a new one, and then
tighten the drain plug to specified torque.
Tightening torque:
Aluminum gasket:
44 N·m (4.5 kgf-m, 32.5 ft-lb)
Copper gasket:
70 N·m (7.1 kgf-m, 51.6 ft-lb)
3) Fill differential gear oil through the oil level
gauge hole up to the upper point of level gauge.
CAUTION:
Each oil manufacturer has its base oil and addi-
tives. Thus, do not mix two or more brands.Differential gear oil capacity:
1.1 — 1.32 (1.2 — 1.4 US qt, 1.0 — 1.1 Imp qt)
3. REAR DIFFERENTIAL
1) Disconnect the oil temperature switch connector
(For Europe turbo model).
2) Drain the differential gear oil by removing drain
plug.
3) Remove the filler plug or oil temperature switch
for quick draining oil.
NOTE:
Remove the oil temperature switch (For Europe tur-
bo model) and filler plug as a unit.
4) Install the drain plug after draining oil.
NOTE:
 Apply liquid gasket to the drain plug threads ex-
cept for 2.0 L Non-turbo model.
 Use a new aluminum gasket for 2.0 L Non-turbo
model.
Liquid gasket:
Three Bond 1105 (Part No. 004403010)
Tightening torque:
Except for 2.0 L Non-turbo model:
49.0 N·m (5.0 kgf-m, 36.2 ft-lb)
2.0 L Non-turbo model:
34 N·m (3.5 kgf-m, 25.3 ft-lb)
PM-00157
(A) Oil level gauge
(B) Upper level
(C) Lower level
(A) Connector
PM-00035
(B)
(C)(A)
DI-00301
(A)

FU(H4SO)-48
FUEL INJECTION (FUEL SYSTEM)
Fuel Tank
20.Fuel Tank
A: REMOVAL
WARNING:
 Place “NO FIRE” signs near the working area.
 Be careful not to spill fuel.
1) Set the vehicle on a lift.
2) Release the fuel pressure. 47, RELEASING OF FUEL PRESSURE, OPERA-
TION, Fuel.>
3) Drain fuel from the fuel tank. 47, DRAINING FUEL, OPERATION, Fuel.>
4) Remove the rear seat.
5) Disconnect the connector (A) of fuel tank cord to
rear harness.
6) Push the grommet (B) which holds fuel tank cord
on floor panel into under the body.
7) Remove the rear crossmember. REMOVAL, Rear Crossmember.>
8) Disconnect the two-way valve hose (A) from
two-way valve and disconnect the canister hose (B)
from canister.9) Loosen the clamp and disconnect the fuel filler
hose and air vent hose from fuel filler pipe.
10) Move the clips, and disconnect quick connec-
tor. ery, Return and Evaporation Lines.>
11) Disconnect the fuel hoses.
12) Support the fuel tank with transmission jack,
and remove the bolts from bands and dismount fuel
tank from the vehicle.
WARNING:
A helper is required to perform this work.
(B)
(A)
FU-00090
(A)
(B)
FU-00091
FU-00092
FU-00093
FU-00411

FU(H4SO)-49
FUEL INJECTION (FUEL SYSTEM)
Fuel Tank
B: INSTALLATION
1) Support the fuel tank with transmission jack and
push the fuel tank harness into access hole with
grommet.
2) Set the fuel tank and temporarily tighten the
bolts of fuel tank bands.
WARNING:
A helper is required to perform this work.
3) Connect the two-way valve hose (A) to two-way
valve and connect the canister hose (B) to canister.
4) Connect the fuel filler hose and air vent hose.5) Connect the fuel hoses, and secure them with
clips and quick connector. INSTALLATION, Fuel Delivery, Return and Evapo-
ration Lines.>
6) Tighten the band mounting bolts.
Tightening torque:
33 N
⋅m (3.4 kgf-m, 24.3 ft-lb)
7) Install the rear crossmember. INSTALLATION, Rear Crossmember.>
8) Connect the connector (A) to fuel tank cord and
plug the service hole with grommet (B).
9) Set the rear seat and floor mat.
FU-00411
(A)(B)
FU-00091
FU-00092
FU-00093
FU-00411
(B)
(A)
FU-00090

ME(H4SO)-15
MECHANICAL
General Description
C: CAUTION
 Wear working clothing, including a cap, protec-
tive goggles and protective shoes during operation.
 Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
 Keep the disassembled parts in order and pro-
tect them from dust or dirt.
 Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly and replacement.
 Be careful not to burn yourself, because each
part in the vehicle is hot after running.
 Be sure to tighten bolts and nuts to the specified
torque.
 Place shop jacks or rigid racks at the specified
points.
 Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the ground
cable from battery.
 All parts should be thoroughly cleaned, paying
special attention to the engine oil passages, pis-
tons and bearings. Rotating parts and sliding parts such as piston,
bearing and gear should be coated with oil prior to
assembly.
 Be careful not to let oil, grease or coolant contact
the timing belt, clutch disc and flywheel.
 All removed parts, if to be reused, should be re-
installed in the original positions and directions.
 Bolts, nuts and washers should be replaced with
new ones as required.
 Even if necessary inspections have been made
in advance, proceed with assembly work while
making rechecks.
 Remove or install engine in an area where chain
hoists, lifting devices, etc. are available for ready
use.
 Be sure not to damage coated surfaces of body
panels with tools, or not to stain seats and windows
with coolant or oil. Place a cover over fenders, as
required, for protection.
 Prior to starting work, prepare the following:
Service tools, clean cloth, containers to catch cool-
ant and oil, wire ropes, chain hoist, transmission
jacks, etc.
 Lift-up or lower the vehicle when necessary.
Make sure to support the correct positions.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
18231AA010 CAM SPROCKET
WRENCH Used for removing and installing cam
sprocket. (LH side)
 Also the CAM SPROCKET WRENCH
(499207100) can be used.
24082AA230
(Newly adopted tool)CARTRIDGE Troubleshooting for electrical systems.
ST18231AA010
ST24082AA230

ME(H4SO)-16
MECHANICAL
General Description
22771AA030 SUBARU SELECT
MONITOR KITTroubleshooting for electrical systems.
 English: 22771AA030 (Without printer)
 German: 22771AA070 (Without printer)
 French: 22771AA080 (Without printer)
 Spanish: 22771AA090 (Without printer)
498267800 CYLINDER HEAD
TABLE Used for replacing valve guides.
 Used for removing and installing valve springs.
498277200 STOPPER SET Used for installing automatic transmission
assembly to engine.
498457000 ENGINE STAND
ADAPTER RHUsed with ENGINE STAND (499817000). ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
ST22771AA030
ST-498267800
ST-498277200
ST-498457000

ME(H4SO)-36
MECHANICAL
Engine Assembly
(2) Loosen the lock bolt and slider bolt, and
then remove the front side V-belt. ME(H4SO)-43, FRONT SIDE BELT, REMOV-
AL, V-belt.>
(3) Remove the pipe with bracket.
(4) Remove the bolts which install power steer-
ing pump bracket.
(5) Remove the reservoir tank from bracket by
pulling it upward.
(6) Place the power steering pump on right side
wheel apron.14) Remove the front and center exhaust pipe.
Pipe.>
15) Remove the nuts which hold lower side of
transmission to engine.
16) Remove the nuts which install front cushion
rubber onto front crossmember.
17) Separate the torque converter clutch from drive
plate. (AT model)
(1) Lower the vehicle.
(2) Remove the service hole plug.
(3) Remove the bolts which hold torque con-
verter clutch to drive plate.
(4) Remove other bolts while rotating the en-
gine using socket wrench.
ME-00331
FU-00139
FU-00020
FU-00140ME-00210
ME-00211
ME-00212

ME(H4SO)-37
MECHANICAL
Engine Assembly
18) Remove the pitching stopper.
19) Disconnect the fuel delivery hose (A), return
hose (B) and evaporation hose (C).
CAUTION:
 Disconnect the hose with its end wrapped
with cloth to prevent fuel from splashing.
 Catch fuel from the hose into container.
20) Support the engine with a lifting device and
wire ropes.21) Support the transmission with a garage jack.
CAUTION:
Before moving the engine away from transmis-
sion, check to be sure no work has been over-
looked. Doing this is very important in order to
facilitate re-installation and because the trans-
mission lowers under its own weight.
22) Separation of the engine and transmission.
(1) Remove the starter. REMOVAL, Starter.>
(2) Remove the bolts which hold upper side of
transmission to engine.
23) Install the ST to torque converter clutch case.
(AT model)
ST 498277200 STOPPER SET
24) Remove the engine from vehicle.
(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
ME-00213
FU-00149
(A)
(B)
(C)
ME-00214
(A) Transmission
(B) Garage jack
ME-00215
(B)(A)
ME-00216
ST
ME-00217

ME(H4SO)-38
MECHANICAL
Engine Assembly
(3) Move the engine horizontally until main
shaft is withdrawn from clutch cover.
(4) Slowly move the engine away from engine
compartment.
NOTE:
Be careful not to damage the adjacent parts or
body panels with crank pulley, oil level gauge, etc.
25) Remove the front cushion rubbers.
B: INSTALLATION
1) Install the front cushion rubbers.
Tightening torque:
34 N
⋅m (3.5 kgf-m, 25.3 ft-lb)
2) Install the engine onto transmission.
(1) Position the engine in engine compartment
and align it with transmission.
NOTE:
Be careful not to damage the adjacent parts or
body panels with crank pulley, oil level gauge, etc.
(2) Apply a small amount of grease to the spline
of main shaft. (MT model)3) Tighten the bolts which hold upper side of trans-
mission to engine.
Tightening torque:
50 N
⋅m (5.1 kgf-m, 36.9 ft-lb)
4) Remove the lifting device and wire ropes.
5) Remove the garage jack.
6) 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)
7) Remove the ST from torque converter clutch
case. (AT model)
NOTE:
Be careful not to drop the ST into torque converter
clutch case when removing ST.
ST 498277200 STOPPER SET
8) Install the starter. STALLATION, Starter.>
9) Install the torque converter clutch onto drive
plate. (AT model)
ME-00214
ME-00214
ME-00216
ME-00214
ME-00218T2T1