2004 SUBARU FORESTER differential

4AT-118
AUTOMATIC TRANSMISSION
Front Differential
6) Install the new seal pipe to torque converter
clutch case.
7) Install the torque converter clutch case to trans-
mission case. Torque Converter Clutch Case.>
8) Insert the inhibitor switch and transmission con-
nector to the stay.
9) Install the ATF cooler pipe. STALLATION, ATF Cooler Pipe and Hose.>
10) Install the ATF charger pipe with O-ring. to 4AT-88, INSTALLATION, Oil Charger Pipe.>11) Insert the input shaft with rotating it by hand
lightly, and then check the protrusion amount.
Normal protrusion A:
50 — 55 mm (1.97 — 2.17 in)
12) Install the torque converter clutch assembly.
er Clutch Assembly.>
13) Install the transmission assembly into the vehi-
cle. Transmission Assembly.>
C: DISASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
1) Remove taper roller bearing using ST and press.
ST 498077000 REMOVER
(A) Seal pipe
(A) Transmission harness ASSY
(B) Inhibitor switch harness
AT-00176
AT-01351
(B)(A)
AT-00291
A
AT-00216

4AT-119
AUTOMATIC TRANSMISSION
Front Differential
2) Secure the case in a vise and remove the hypoid
driven gear tightening bolts, then separate the hy-
poid driven gear, differential case (RH) and differ-
ential case (LH).
3) Pull out the straight pin and pinion shaft, and
then remove the differential bevel gear, washer and
differential bevel pinion.
2. DIFFERENTIAL SIDE RETAINER
NOTE:
After adjusting the drive pinion backlash and tooth
contact, remove and install the oil seal and O-ring.
1) Remove the O-ring.2) Remove the oil seal.
3) Remove the split pin, and then remove the claw.
ST 398527700 PULLER ASSY
4) Attach two claws to the outer race, and set ST to
differential side retainer.
ST 398527700 PULLER ASSY
5) Restore the removed claws to original position,
and install the pin and split pin.
(A) Hypoid driven gear
(B) Differential case (RH)
(C) Differential case (LH)
(A) Differential case (RH)
(B)
AT-00217
(A)
(C)
AT-00218(A)
AT-00219
(A) Claw
(B) Split pin
(C) Pin
(A) Shaft
(B) Claw
AT-00220
AT-00221
AT-00222

4AT-120
AUTOMATIC TRANSMISSION
Front Differential
6) Hold the shaft of ST to avoid removing from dif-
ferential side retainer, and then remove the bearing
outer race.
ST 398527700 PULLER ASSY
NOTE:
Replace the bearing inner and outer races as a sin-
gle unit.
D: ASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
1) Install the washer, differential bevel gear and dif-
ferential bevel pinion in the differential case (RH).
Insert the pinion shaft.
2) Install the straight pin in reverse direction.
3) Install the washer and differential bevel gear to
differential case (LH). Put the differential case (RH)
on the case, and then combine the both cases.4) Install the hypoid driven gear and secure by
tightening the bolt.
Tightening torque:
62 N
⋅m (6.3 kgf-m, 45.6 ft-lb)
5) Measurement of backlash (Selection of washer)
(1) Measure the gear backlash using ST1 and
ST2, and then insert the ST2 from the access
window of case.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
NOTE:
 Measure the backlash by applying a differential
pinion tooth between two differential bevel gear
teeth.
 Fix the differential bevel pinion gear in place with
a screwdriver or similar tool when measuring.
Standard value:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
(2) If the backlash is not within specifications,
select a washer from the table below.
(A) Shaft
(B) Differential side retainer
(A) Differential case (RH)
AT-00223
AT-00218(A)
(A) Hypoid driven gear
(B) Differential case (RH)
(C) Differential case (LH)
Washer
TOOL NUMBER Thickness mm (in)
803038021 0.95 (0.037)
803038022 1.00 (0.039)
803038023 1.05 (0.041)
(B)
AT-00217
(A)
(C)
AT-00224
ST2
ST1

4AT-121
AUTOMATIC TRANSMISSION
Front Differential
6) Using ST, install the taper roller bearing.
ST 398487700 INSTALLER
2. DIFFERENTIAL SIDE RETAINER
1) Install the bearing outer race to differential side
retainer.
2) Install a new oil seal using ST and plastic ham-
mer.
ST 18675AA000 DIFFERENTIAL OIL SEAL IN-
STALLER
3) Install a new O-ring.
E: INSPECTION
 Check each component for harmful cuts, dam-
age and other faults.
 Measure the backlash, and then adjust it within
specification.
tial.>
F: ADJUSTMENT
1) Using ST, screw-in the differential side retainer
until light contact is felt.
NOTE:
Screw-in the RH side slightly deeper than the LH
side.
ST 499787000 WRENCH ASSY
2) Remove the oil pump housing.
3) Remove the liquid gasket completely.
4) Install the oil pump housing assembly to torque
converter clutch case, and secure them with tight-
ening four bolts evenly.
NOTE:
Use an old gasket or an aluminum washer so as not
to damage the mating surface of housing.
Tightening torque:
41 N
⋅m (4.2 kgf-m, 30.4 ft-lb)
5) Rotate the drive pinion several times using ST1
and ST2.
ST1 498937110 HOLDER
ST2 499787700 WRENCH
(A) Taper roller bearing
AT-00225
AT-00226
ST
AT-00219
AT-00227
ST
AT-00205
AT-00206
ST2
ST1

4AT-122
AUTOMATIC TRANSMISSION
Front Differential
6) Tighten the LH side of differential side retainer
until contact is felt while rotating the shaft. Then
loosen the RH side of differential side retainer.
Keep tightening the LH side of differential side re-
tainer, and loosening the RH side until the pinion
shaft not be able to turned. This is the “zero” state.
7) After the “zero” state is established, back off the
LH side of differential side retainer 3 notches and
secure it with the lock plate. Then back off the RH
side of differential side retainer and retighten until it
stops. Rotate the drive pinion few times. Tighten
the RH side of differential side retainer 1-3/4 notch-
es further. This sets the preload. Finally, secure the
differential side retainer with its lock plate.
NOTE:
Turning the differential side retainer by one tooth
changes the backlash about 0.05 mm (0.0020 in).8) Turn the drive pinion several times with ST1 and
check to see if the backlash is within the specified
value with ST2, ST3, ST4 and ST5.
ST1 499787700 WRENCH
ST2 498247001 MAGNET BASE
ST3 498247100 DIAL GAUGE
ST4 499787500 ADAPTER
ST5 498255400 PLATE
Backlash:
0.13 — 0.18 mm (0.0051 — 0.0071 in)
9) Adjust the tooth contact between front differen-
tial and drive shaft. MENT, Drive Pinion Shaft Assembly.>
(A) Differential side retainer
(A) Lock plate
AT-00229
(A)
AT-00214
(A)
0.05 mm
(0.0020 in)
AT-00230
AT-00231
ST5
ST3
ST2
ST1
ST4

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(H4SO)-5
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
General Description
3. General Description
A: CAUTION
Supplemental Restraint System “Airbag”
The airbag system wiring harness is routed near
the transmission control module (TCM).
CAUTION:
 All airbag system wiring harness and con-
nectors are colored yellow. Do not use an elec-
trical test equipment on these circuit.
 Be careful not to damage the airbag system wir-
ing harness when performing diagnostics and ser-
vicing the TCM.
Measurement
When measuring the voltage and resistance of
ECM, TCM or each sensor, use a tapered pin with
diameter of less than 0.64 mm (0.025 in) in order to
avoid poor contact. Do not insert the pin more than
0.65 mm (0.256 in).
B: INSPECTION
1. BATTERY
Measure the battery voltage and specific gravity of
electrolyte.
Standard voltage: 12 V or more
Specific gravity: Above 1.260
2. TRANSMISSION GROUND
Make sure that the ground terminal bolt is tightened
securely.
Chassis side
Tightening torque:
13 N
⋅m (1.3 kgf-m, 9.4 ft-lb)
3. ATF LEVEL
Make sure that ATF level is in the specification.
mission Fluid.>
4. FRONT DIFFERENTIAL OIL LEVEL
Make sure that the front differential oil level is in speci-
fication. Gear Oil.>
AT-00412
(A) Level gauge
(B) “HOT” side
(C) Upper level
(D) Lower level
(E) “COLD” side
(A) Upper level
(B) Lower level
PI-00105
COLD
LFHOT LF
(A)
(C)
(D)
(C)
(D)
(E)
(B)
AT-00317
(A)
(B)
LF

4AT(H4SO)-110
AUTOMATIC TRANSMISSION (DIAGNOSTIC)
Symptom Related Diagnostic
15.Symptom Related Diagnostic
A: INSPECTION
Symptom Problem parts
Starter does not rotate when select lever is in “P” or “N” range;
starter rotates when select lever is in “R”, “D”, “3” or “2” range. Inhibitor switch
 Select cable
 Select lever
 Starter motor and harness
Abnormal noise when select lever is in “P” or “N” range. Strainer
 Transfer duty solenoid
 Oil pump
Drive plate
 ATF level too high or too low
Hissing noise occurs during standing start. Strainer
 ATF level too high or too low
Noise occurs while driving in “D1”.  Final gear
 Planetary gear
 Reduction gear
 Differential gear oil level too high or too low Noise occurs while driving in “D2”.
Noise occurs while driving in “D3”. Final gear
 Low & reverse brake
 Reduction gear
 Differential gear oil level too high or too low
Noise occurs while driving in “D4”. Final gear
 Low & reverse brake
 Planetary gear
 Reduction gear
 Differential gear oil level too high or too low
Engine stalls while shifting from “1” range to another. Control valve
 Lock-up damper
 Engine performance
 Input shaft
Vehicle moves when select lever is in “N” range.  Low clutch
Shock occurs when select lever is moved from “N” to “D” range.TCM
Harness
 Control valve
 ATF deterioration
Excessive time lag occurs when select lever is moved from “N”
to “D” range. Control valve
 Low clutch
 Line pressure duty solenoid
 Seal ring
 Front gasket transmission case
Shock occurs when select lever is moved from “N” to “R” range.TCM
Harness
 Control valve
 ATF deterioration
Excessive time lag occurs when select lever is moved from “N”
to “R” range. Control valve
 Low & reverse clutch
 Reverse clutch
 Line pressure duty solenoid
 Seal ring
 Front gasket transmission case
Vehicle does not start in any shift range (engine stalls). Parking brake mechanism
 Planetary gear