2004 SUBARU FORESTER automatic transmission

4AT-45
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
20) Tighten the attachment bolts.
Tightening torque:
49 N
⋅m (5.0 kgf-m, 36 ft-lb)
21) Install the stabilizer link from the transverse
link.
Tightening torque:
45 N
⋅m (4.6 kgf-m, 33.2 ft-lb)
22) Install the shift select cable onto select lever.

23) Connect the ATF cooler hoses to the pipe. (with
ATF cooler (with warmer function))
24) Install the ATF level gauge guide.
25) Install the propeller shaft.

26) Install the heat shield cover. (If equipped)27) Install the rear exhaust pipe and muffler as-
sembly.
(Non-turbo model)
haust Pipe.> TION, Muffler.>
(Turbo model)
Exhaust Pipe.> STALLATION, Muffler.>
28) Install the front and center exhaust pipe. (Non-
turbo model)
haust Pipe.>
29) Install the center exhaust pipe. (Turbo model)
Exhaust Pipe.>
30) Install the under cover.
31) Lower the lift.
32) Install the ATF cooler assembly bracket to
transmission body. (with ATF cooler (with warmer
function))
NOTE:
Insert the end of ATF cooler bracket to the hole of
converter case.
Tightening torque:
T1: 21 N
⋅m (2.1 kgf-m, 15.5 ft-lb)
T2: 23 N
⋅m (2.3 kgf-m, 17.0 ft-lb)
T3: 33 N
⋅m (3.4 kgf-m, 24.3 ft-lb)
AT-00115
AT-00107
AT-00450
AT-01869
T2
T1T3

4AT-46
AUTOMATIC TRANSMISSION
Automatic Transmission Assembly
33) Connect the ATF cooler hoses to pipes on
transmission side, and then install the oil charge
pipe. (with ATF cooler (with warmer function))
34) Install the ATF level gauge guide.
35) Connect the following connectors.
(1) Transmission harness connectors
(2) Transmission ground terminal
36) Install the harness to bracket.
37) Install the air cleaner case stay. (Non-turbo
model)
Tightening torque:
16 N
⋅m (1.6 kgf-m, 11.6 ft-lb)38) Install the air cleaner case and air intake duct.
(Non-turbo model).
Case.> Intake Duct.>
39) Install the intercooler. (Turbo model)
cooler.>
40) Connect the battery ground cable to battery.
41) Pour ATF from the oil charge pipe. 4AT-30, Automatic Transmission Fluid.>
42) Check the ATF level. matic Transmission Fluid.>
43) Take off the vehicle from a lift.
44) Check the select lever operation.

45) Execute the learning control promotion. (Turbo
model) OF LEARNING CONTROL, OPERATION, Subaru
Select Monitor.>
46) Perform the road test.

(A) Inlet hose
(B) Outlet hose
AT-01866(A)(B)
AT-00693
AT-01867

4AT-47
AUTOMATIC TRANSMISSION
Transmission Mounting System
10.Transmission Mounting Sys-
tem
A: REMOVAL
1. PITCHING STOPPER
1) Disconnect the ground cable from battery.
2) Remove the air cleaner case. (Non-turbo mod-
el).
Case.>
3) Remove the intercooler. (Turbo model)
er.>
4) Remove the pitching stopper.
2. TRANSMISSION REAR CROSSMEMBER
& REAR CUSHION RUBBER
1) Disconnect the ground cable from battery.
2) Jack-up the vehicle and support it with study
racks.
3) Remove the front, center, rear exhaust pipes
and muffler. (Non-turbo model).
Pipe.> Exhaust Pipe.> AL, Muffler.>
4) Remove the center, rear exhaust pipe and muf-
fler. (Turbo model)
haust Pipe.> AL, Rear Exhaust Pipe.> 16, REMOVAL, Muffler.>
5) Remove the heat shield cover. (If equipped)
6) Set the transmission jack under the transmis-
sion.
NOTE:
Make sure that the support plate of transmission
jack does not touch the oil pan.7) Remove the transmission rear crossmember.
8) Remove the rear cushion rubber.
B: INSTALLATION
1. PITCHING STOPPER
1) 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)
2) Install the air cleaner case. (Non-turbo model).
Case.>
3) Install the intercooler. (Turbo model)
cooler.>
AT-00023
AT-00024
AT-00025
T1
T2

4AT-48
AUTOMATIC TRANSMISSION
Transmission Mounting System
2. TRANSMISSION REAR CROSSMEMBER
& REAR CUSHION RUBBER
1) Install the rear cushion rubber.
Tightening torque:
39 N
⋅m (4.0 kgf-m, 29 ft-lb)
2) 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)
3) Remove the transmission jack.
4) Install the heat shield cover. (If equipped)
5) Install the front, center, rear exhaust pipes and
muffler. (Non-turbo model).
haust Pipe.> TION, Rear Exhaust Pipe.> INSTALLATION, Muffler.>
6) Install the center, rear exhaust pipe and muffler.
(Turbo model)
Exhaust Pipe.> STALLATION, Rear Exhaust Pipe.> EX(H4DOTC)-16, INSTALLATION, Muffler.>
C: INSPECTION
Perform the following inspection procedures and
repair or replace the parts if defective.
1. PITCHING STOPPER
Make sure that the pitching stopper is not bent or
damaged. Ensure there are no cracks, hardening,
or damage on rubbers.
2. TRANSMISSION REAR CROSSMEMBER
& REAR CUSHION RUBBER
Make sure that the crossmember is not bent or
damaged. Ensure there are no cracks, breakage or
damage on cushion rubbers.
AT-00026
T2T2
T1

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-51
AUTOMATIC TRANSMISSION
Inhibitor Switch
13.Inhibitor Switch
A: INSPECTION
When the driving condition or starter motor opera-
tion is erroneous, first check the shift linkage for im-
proper operation. If the shift linkage is functioning
properly, check the inhibitor switch.
1) Disconnect the inhibitor switch connector.
2) Check continuity in inhibitor switch circuits with
the select lever moved to each position.
NOTE:
 Also check that continuity in ignition circuit does
not exist when the select lever is in “R”, “D”, “3”, “2”
and “1” ranges.
 If the inhibitor switch is inoperative, check for
poor contact of connector on transmission side.3) Check if there is continuity at equal points when
the select lever is turned 1.5° in both directions
from the “N” range to “R” range or “D” range
If there is continuity in one direction and the conti-
nuity in the other or if there is continuity at unequal
points, adjust the inhibitor switch. ADJUSTMENT, Inhibitor Switch.>
4) Repeat the above checks at other ranges. If
there are abnormalities, adjust the select cable.

Signal sent to TCMRange Pin No.
P4 — 3
R4 — 2
N4 — 1
D4 — 8
34 — 7
24 — 6
14 — 5
Ignition circuit P/N 12 — 11
Back-up light circuit R 10 — 9
(A) Inhibitor switch connector
AT-00030
(4)(3)(2) (1)
(5) (6) (7) (8)
(9)
(10) (11) (12)
(A)
(A) Continuity does not exist.
(B) Continuity exists.
(C) 1.5°
(C) (A) (C) (A)
(B)
AT-00452
P
R
N
D
3
2
1