2004 SUBARU FORESTER sensor
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AUTOMATIC TRANSMISSION
4AT
Page
1. General Description ....................................................................................2
2. Automatic Transmission Fluid ...................................................................30
3. Differential Gear Oil...................................................................................31
4. Road Test..................................................................................................32
5. Stall Test ...................................................................................................33
6. Time Lag Test ...........................................................................................35
7. Line Pressure Test ....................................................................................36
8. Transfer Clutch Pressure Test ..................................................................38
9. Automatic Transmission Assembly ...........................................................39
10. Transmission Mounting System ................................................................47
11. Extension Case Oil Seal ...........................................................................49
12. Differential Side Retainer Oil Seal.............................................................50
13. Inhibitor Switch ..........................................................................................51
14. Front Vehicle Speed Sensor .....................................................................55
15. Rear Vehicle Speed Sensor ......................................................................59
16. Torque Converter Turbine Speed Sensor .................................................60
17. Control Valve Body ...................................................................................61
18. Air Bleeding of Control Valve ....................................................................70
19.
Shift Solenoids, Duty Solenoids and ATF Temperature Sensor.........................71
20. Transfer Duty Solenoid and Valve Body ...................................................73
21. ATF Filter ..................................................................................................76
22. Transmission Control Module (TCM) ........................................................77
23. Dropping Resistor .....................................................................................78
24. ATF Cooler Pipe and Hose .......................................................................79
25. ATF Cooler (With Warmer Function).........................................................84
26. Air Breather Hose......................................................................................87
27. Oil Charger Pipe........................................................................................88
28. Torque Converter Clutch Assembly ..........................................................89
29. Extension Case .........................................................................................90
30. Transfer Clutch..........................................................................................92
31. Reduction Driven Gear..............................................................................97
32. Reduction Drive Gear................................................................................99
33. Parking Pawl ...........................................................................................101
34. Torque Converter Clutch Case ...............................................................102
35. Oil Pump Housing ...................................................................................105
36. Drive Pinion Shaft Assembly ...................................................................111
37. Front Differential......................................................................................117
38. AT Main Case .........................................................................................123
39. Transmission Control Device ..................................................................142
Page 2321 of 2870
4AT-9
AUTOMATIC TRANSMISSION
General Description
4. CONTROL VALVE AND HARNESS ROUTING
A Non-turbo model B Turbo model
(1) Stay (11) Accumulator piston (23) 2-4 brake duty solenoid
(2) Transmission harness ASSY (12) Accumulator spring (24) Line pressure duty solenoid
(3) O-ring (13) Side plate (25) Low clutch timing solenoid
(4) O-ring (14) Upper separate plate (26) Lock-up duty solenoid
(5) Torque converter turbine speed
sensor(15) Middle control valve body (27) Oil strainer
(16) Separate plate (28) Control valve ASSY
(6) O-ring (17) Fluid filter (29) Rear vehicle speed sensor (turbo
model)
(7) Front vehicle speed sensor (18) Fluid filter
(8) O-ring (19) Lower control valve body
(9) Rear vehicle speed sensor (non-
turbo model)(20) Shift solenoid 2Tightening torque: N
⋅m (kgf-m, ft-lb)
(21) Shift solenoid 1T1: 7 (0.7, 5.1)
(10) Upper control valve body (22) 2-4 brake timing solenoidT2: 8 (0.8, 5.8)
AT-01864
T1T2
T2
T2
T2
T2
T2
T2T2
T2
T1
(1)(2)
(3)(4)
(5)
(6)
(7)
(10)
(11)
(12)
(14)
(13)(15)
(16)
(17)
A(24)(19)
(18)
(20)
(21)
(22)
(23) (26) (25)
(27)
(28)
B
T1
(8)
(9)
T1
(8)
(29)
Page 2368 of 2870
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).
4) Remove the intercooler. (Turbo model)
5) Disconnect the transmission connector.
6) Remove the pitching stopper.
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).
12) Remove the center, rear exhaust pipe and muf-
fler. (Turbo model)
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
Page 2369 of 2870
4AT-56
AUTOMATIC TRANSMISSION
Front Vehicle Speed Sensor
17) Lower the transmission jack.
NOTE:
Do not separate the transmission jack and trans-
mission.
18) Remove the ATF cooler inlet and outlet pipes.
CAUTION:
When removing the outlet pipe, be careful not
to lose the ball and spring used with retaining
screw.
19) Remove the front vehicle speed sensor and
torque converter turbine speed sensor.
20) Remove the rear vehicle speed sensor. (Non-
turbo model)21) Disconnect the connector from rear vehicle
speed sensor. (Turbo model)
22) Remove the oil pan.
23) Remove the duty solenoid connector and ATF
temperature sensor. Remove the connectors from
clip and disconnect it.
(A) Front vehicle speed sensor
(B) Torque converter turbine speed sensor
(A) Rear vehicle speed sensor
(B) Front vehicle speed sensor
AT-00044
(A)
(B)
AT-00045
(A) (B)
(A) Rear vehicle speed sensor
(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) ATF temperature sensor
(I) Transfer duty solenoid (Brown)
(J) Transmission ground
AT-01338
(A)
AT-00049
(A) (B) (J) (C) (D) (E)
(I)
(H)
(F) (G)
Page 2370 of 2870
4AT-57
AUTOMATIC TRANSMISSION
Front Vehicle Speed Sensor
24) Disconnect the ground cable from control valve
connector. (Turbo model)
25) Remove the transmission harness assembly.
B: INSTALLATION
1) Pass the transmission harness assembly
through the hole in the transmission case.2) Connect the harness connectors.
Connect the connectors of same color, and secure
the connectors to valve body using clips. (Non-tur-
bo model)
Tightening torque (Transmission ground ca-
ble):
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
3) Connect the control valve connector, and then
connect the ground cable. (Turbo model)
Tightening torque:
8 N
⋅m (0.8 kgf-m, 5.8 ft-lb)
(A) Transmission ground cable
(B) Control valve connector
AT-00050
(B)
(A)
AT-00048
(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) ATF temperature sensor
(I) Transfer duty solenoid (Brown)
(J) Transmission ground
(A) Transmission ground cable
(B) Control valve connector
AT-00049
(A) (B) (J) (C) (D) (E)
(I)
(H)
(F) (G)
AT-00050
(B)
(A)
Page 2371 of 2870
4AT-58
AUTOMATIC TRANSMISSION
Front Vehicle Speed Sensor
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) Install the front vehicle speed sensor, rear vehi-
cle speed sensor and torque converter turbine
speed sensor.
Tightening torque:
7 N
⋅m (0.7 kgf-m, 5.1 ft-lb)8) Install the ATF cooler inlet and outlet pipes.
NOTE:
Use a new copper washer.
Tightening torque:
T1: 25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
T2: 45 N
⋅m (4.6 kgf-m, 33.2 ft-lb)
9) Install the transmission rear crossmember bolt.
Tightening torque:
70 N
⋅m (7.1 kgf-m, 51 ft-lb)
10) Install the propeller shaft.
11) Install the heat shield cover. (If equipped)
12) Install the front, center, rear exhaust pipes and
muffler. (Non-turbo model).
13) Install the center, rear exhaust pipe and muf-
fler. (Turbo model)
14) Lower the vehicle.
15) Install the transmission connector to the stay.
16) Install the pitching stopper.
17) Install the air cleaner case. (Non-turbo model).
18) Install the intercooler. (Turbo model)
AT-00051
AT-00052
AT-00805
T1
T1
T2
Page 2372 of 2870
4AT-59
AUTOMATIC TRANSMISSION
Rear Vehicle Speed Sensor
15.Rear Vehicle Speed Sensor
A: REMOVAL
1. NON-TURBO MODEL
When removing the rear vehicle speed sensor, re-
fer to “Front Vehicle Speed Sensor”.
2. TURBO MODEL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Lift-up the vehicle.
4) Disconnect the connector from rear vehicle
speed sensor.
5) Remove the rear vehicle speed sensor.
B: INSTALLATION
1. NON-TURBO MODEL
When installing the rear vehicle speed sensor, refer
to “Front Vehicle Speed Sensor”.
2. TURBO MODEL
Install in the reverse order of removal.
NOTE:
Replace O-ring with new one.
Tightening torque:
7 N
⋅m (0.7 kgf-m, 5.1 ft-lb)
(A) Rear vehicle speed sensor
AT-01338
(A)
AT-01341
Page 2373 of 2870
4AT-60
AUTOMATIC TRANSMISSION
Torque Converter Turbine Speed Sensor
16.Torque Converter Turbine
Speed Sensor
A: REMOVAL
When removing the torque converter turbine speed
sensor, refer to “Front Vehicle Speed Sensor”.
B: INSTALLATION
When installing the torque converter turbine speed
sensor, refer to “Front Vehicle Speed Sensor”.