Automatic Transmission 4AT: Removal & Installation Subaru Forester SH

REPLACEMENT

1. Lift up the vehicle.
2. Remove the drain plug (ATF) and completely drain the ATF. CAUTION: Immediately after the vehicle has been running or after idling for a long time, the ATF will be hot. Be careful not to receive burns.
3. Check the condition of ATF. Refer to «CONDITION CHECK»(ref-325309-S25597735782009071800000) , Automatic Transmission Fluid.
4. Perform replacement with a new gasket, and tighten the drain plug (ATF).
5. Lower the vehicle.
6. Pour ATF from the oil charge pipe.
7. Bleed the air of control valve.
8. Check the level and leaks of ATF.

Refer to INSPECTION , Automatic Transmission Fluid.

1. Lift up the vehicle.
2. Remove the differential gear oil drain plug using TORX® bit T70, and drain the differential gear oil completely. CAUTION: Immediately after the vehicle has been running or after idling for a long time, the differential gear oil will be hot. Be careful not to receive burns. Be careful not to spill differential gear oil on the exhaust pipe to prevent it from emitting smoke or causing a fire. If differential gear oil is spilled on the exhaust pipe, wipe it off completely.
3. Replace the gasket with a new part and tighten the differential gear oil drain plug using the TORX® bit T70.
4. Lower the vehicle.
5. Fill the differential with differential gear oil from the level gauge hole. Recommended gear oil: Refer to «RECOMMENDED GEAR OIL»(ref-325309-S24896687752009071800000) , SPECIFICATION, General Description. Gear oil capacity: 1.1 - 1.3 l (1.2 - 1.4 US qt, 1.0 - 1.1 lmp qt)
6. Check the level of differential gear oil.

Refer to INSPECTION , Differential Gear Oil.

INSTALLATION

Install in the reverse order of removal.

Note. Replace the O-ring with a new part.

Tightening torque

7 N.m (0.7 kgf-m, 5.2 ft-lb)

REMOVAL

When removing the torque converter turbine speed sensor, refer to "Front Vehicle Speed Sensor". Refer to REMOVAL , Front Vehicle Speed Sensor.

When installing the torque converter turbine speed sensor, refer to "Front Vehicle Speed Sensor". Refer to INSTALLATION , Front Vehicle Speed Sensor.

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1. Set the vehicle on a lift.
2. Disconnect the ground cable from the battery.
3. Lift up the vehicle.
4. Clean the transmission exterior.
5. Remove the drain plug (ATF) to drain the ATF. CAUTION: Because the AFT will be very hot after driving, be very careful not be receive burns.
6. Perform replacement with a new gasket, and tighten the drain plug (ATF). Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
7. Remove the oil pan. CAUTION: Be careful not to allow foreign matter such as dust or dirt to enter the oil pan.
8. Remove the magnet.
9. Clean the magnet.
10. Completely remove the remaining liquid gasket on the transmission case and oil pan.
11. Remove the control valve strainer attaching bolts, and remove the control valve strainer from the control valve body.

Scheme 277

1. Check the control valve body for dust and other foreign matter.
2. Attach a new control valve strainer to the control valve body. Apply ATF to the periphery of the O-ring on the control valve strainer. CAUTION: When applying ATF, avoid adhesion of dust and foreign matter on the O-ring. Attach the control valve strainer to the control valve body from the O-ring side. CAUTION: If the control valve strainer is inserted diagonally, this may damage the O-ring. Make sure to insert the control valve strainer so that it does not become angled when installing. Tighten the three bolts. Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb)
3. Attach the magnet at the specified position of the oil pan.
4. Apply proper amount of liquid gasket to the entire oil pan mating surface. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) or equivalent
5. Fill the 3 holes aside from the bolt holes in the transmission case, with liquid gasket. Liquid gasket: THREE BOND 1217B (Part No. K0877YA020) or equivalent
6. Install the oil pan by equally tightening the bolts. Tightening torque: 5 N.m (0.5 kgf-m, 3.7 ft-lb)
7. Fill ATF from the oil charger pipe. Recommended fluid: Refer to «HYDRAULIC CONTROL AND LUBRICATION»(ref-325309-S27690140312009071800000) , SPECIFICATION, General Description. Capacity: Fill with the same amount of ATF as drained .
8. Bleed the air of control valve. Refer to «AIR BLEEDING OF CONTROL VALVE»(ref-325309-S23759084052009071800000) .
9. Check the ATF level. Refer to «AUTOMATIC TRANSMISSION FLUID»(ref-325309-S25949610312009071800000) .

1. Install the ATF inlet pipe and outlet pipe along with new washers. Tightening torque: T1: 25 N.m (2.5 kgf-m, 18.4 ft-lb) T2: 40 N.m (4.1 kgf-m, 29.5 ft-lb) T3: 45 N.m (4.6 kgf-m, 33.2 ft-lb)
2. Install the ATF cooler pipe to frame.
3. Connect the ATF cooler hose to the pipe on the transmission side. NOTE: Install so that the hose is not folded over, excessively bent or twisted. Insert the hose to the specified position.
4. Connect the ATF cooler hose to the pipe on the radiator side. NOTE: Install so that the hose is not folded over, excessively bent or twisted. Insert the hose to the specified position.
5. Install the heat shield cover. Tightening torque: 3 N.m (0.3 kgf-m, 2.2 ft-lb)
6. Install the under cover.
7. Install the battery.
8. Fill ATF. Refer to «AUTOMATIC TRANSMISSION FLUID»(ref-325309-S25949610312009071800000) . NOTE: Make sure there are no ATF leaks in joints between the transmission, radiator, pipes, and hoses.

1. Remove the air intake chamber. (Non-turbo model) Refer to «REMOVAL»(ref-325315-S02698974742009071800000) , Air Intake Chamber.
2. Remove the intercooler. (Turbo model) Refer to «REMOVAL»(ref-325300-S41039960822009071800000) , Intercooler.
3. Disconnect the air breather hose.

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1. Non-turbo model
2. Turbo model

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1. Install the air breather hose. Non-turbo model Turbo model
2. Install the air intake chamber. (Non-turbo model) Refer to «INSTALLATION»(ref-325315-S09948998262009071800000) , Air Intake Chamber.
3. Install the intercooler. (Turbo model) Refer to «INSTALLATION»(ref-325300-S37233999532009071800000) , Intercooler.

1. Remove the transmission assembly from vehicle body. Refer to «REMOVAL»(ref-325309-S08422567332009071800000) , Automatic Transmission Assembly.
2. Remove the extension case, and then remove the transfer clutch. Refer to «REMOVAL»(ref-325309-S01042429402009071800000) , Extension Case. Refer to «DISASSEMBLY»(ref-325309-S29310186142009071800000) , Extension Case.

Scheme 282

1. Select the thrust needle bearing. Refer to «ADJUSTMENT»(ref-325309-S25157424622009071800000) , Transfer Clutch.
2. Install the transfer clutch assembly to the case.
3. Tighten the bolts to secure the case. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
4. Install the transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-325309-S08159907062009071800000) , Automatic Transmission Assembly.

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1. Remove the seal ring.
2. Remove the ball bearing using the ST and the press. ST 498077600 REMOVER
3. Using a flat tip screwdriver, etc. remove the snap ring, and take out the retaining plate, drive plate and driven plate.
4. Using the ST1, ST2 and ST3, remove the snap ring, then take out the return spring and transfer clutch piston seal. ST1 399893600 PLIERS ST2 398673600 COMPRESSOR ST3 398623600 SEAT
5. Apply compressed air to the rear drive shaft, to remove the transfer clutch piston.

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1. Install the transfer clutch piston.
2. Install the return spring to transfer clutch piston.
3. Apply ATF to the lip of transfer clutch piston seal, then install.
4. Attach the ST to the rear drive shaft. ST 499257300 SNAP RING OUTER GUIDE
5. Install the snap ring to the ST. ST 499257300 SNAP RING OUTER GUIDE
6. Install the snap ring to the rear drive shaft using ST1 and ST2. ST1 499257300 SNAP RING OUTER GUIDE ST2 499247400 INSTALLER
7. Install the driven plate, drive plate, retaining plate and snap ring.
8. Apply compressed air to see if the assembled parts move smoothly.
9. Check the clearance between the snap ring and retaining plate. Refer to «INSPECTION»(ref-325309-S04757992182009071800000) , Transfer Clutch.
10. Press-fit new ball bearing using ST. ST 899580100 INSTALLER
11. Apply Vaseline to a new seal ring and attach to the seal ring groove of the rear drive shaft. NOTE: While installing the seal ring, not to stretch the seal ring excessively.
12. Install the transfer clutch assembly while taking care not to damage the seal ring.

Scheme 298

1. Remove the transmission assembly from vehicle body. Refer to «REMOVAL»(ref-325309-S08422567332009071800000) , Automatic Transmission Assembly.
2. Remove the rear wheel speed sensor, and separate the extension case from transmission case. Refer to «REMOVAL»(ref-325309-S01042429402009071800000) , Extension Case.
3. Remove the reduction driven gear. Refer to «REMOVAL»(ref-325309-S25554667042009071800000) , Reduction Driven Gear.
4. Using the ST, extract the reduction drive gear assembly.

ST1 499737100 PULLER

ST2 899524100 PULLER SET

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1. Install the reduction drive gear assembly. NOTE: Press-fit it to the bottom of bearing shoulder completely.
2. Install the reduction driven gear. Refer to «INSTALLATION»(ref-325309-S13336896992009071800000) , Reduction Driven Gear.
3. Join the transmission case and the extension case, and then install the rear vehicle speed sensor. Refer to «INSTALLATION»(ref-325309-S29817791412009071800000) , Extension Case.
4. Install the transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-325309-S08159907062009071800000) , Automatic Transmission Assembly.

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1. Take out the seal ring.
2. Remove the ball bearing using ST. ST 498077600 REMOVER
3. Apply vaseline to the outer surface of seal ring and shaft groove.

Scheme 304

1. Press-fit the reduction drive gear to shaft.
2. Press-fit the new ball bearing into reduction drive gear.
3. Apply vaseline onto the seal ring outer surface and shaft grooves.
4. Apply ATF to new seal rings, then install.

1. Assemble the drive pinion shaft assembly to the oil pump housing. NOTE: Be careful not to bend the shim. Be careful not to press-fit the pinion into housing bore. Tightening torque: 40 N.m (4.0 kgf-m, 29.5 ft-lb)
2. Join the converter case with the transmission case. Refer to «INSTALLATION»(ref-325309-S39568497242009071800000) , Converter Case.
3. Install the reduction driven gear. Refer to «INSTALLATION»(ref-325309-S13336896992009071800000) , Reduction Driven Gear.
4. Install the reduction drive gear. Refer to «INSTALLATION»(ref-325309-S38330443782009071800000) , Reduction Drive Gear.
5. Join the transmission case and the extension case, and then install the rear vehicle speed sensor. Refer to «INSTALLATION»(ref-325309-S29817791412009071800000) , Extension Case.
6. Insert the inhibitor switch and transmission harness connector to the stay.
7. Install the air breather hose. Refer to «INSTALLATION»(ref-325309-S10805375142009071800000) , Air Breather Hose.
8. Install the ATF inlet and outlet pipes. Refer to «INSTALLATION»(ref-325309-S06270692962009071800000) , ATF Cooler Pipe and Hose.
9. Install the oil charge pipe with O-ring.
10. Insert the input shaft while rotating it lightly by hand, and then check the amount of protrusion. Normal protrusion A: 50 - 55 mm (1.97 - 2.17 in)
11. Install the torque converter clutch assembly. Refer to «INSTALLATION»(ref-325309-S25725149262009071800000) , Torque Converter Clutch Assembly.
12. Install the transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-325309-S08159907062009071800000) , Automatic Transmission Assembly.

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1. Flatten the lock nut tab, and then remove the lock nut while holding the rear spline part of the drive pinion shaft using ST1 and ST2. Pull out the drive pinion collar. ST1 498937110 HOLDER ST2 499787700 WRENCH ST3 499787500 ADAPTER
2. Remove the O-ring.
3. Separate the rear roller bearing and outer race from the drive pinion shaft using a press.
4. Separate the front roller bearing from the drive pinion shaft using a press and the ST. ST 498517000 REPLACER

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1. Measure the dimension "A" of the drive pinion shaft. ST 398643600 GAUGE
2. Using a press, press-fit the new roller bearing into the specified position. CAUTION: Damage may result if too much force is applied to the roller bearing.
3. After applying ATF to a new O-ring and attaching it 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 the proper direction.
5. Tighten a new lock nut using the ST. Calculate the lock washer and lock nut specifications using following formula. T2 = L2/(L1 + L2) x T1 T1: 116 N.m (11.8 kgf-m, 85.6 ft-lb) [Required torque setting] T2: Tightening torque L1: ST2 length 0.072 m (2.83 in) L2: Torque wrench length Example: TORQUE SPECIFICATION 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, 73.8) 0.5 (19.69) 101 (10.3, 74.5) 0.55 (21.65) 102 (10.4, 75.2) ST1 498937110 HOLDER ST2 499787700 WRENCH ST3 499787500 ADAPTER NOTE: Attach ST2 to torque wrench as straight as possible.
6. Measure the starting torque of the bearing. Make sure the starting torque is within the specified range. If the torque is not within specified range, replace the roller bearing. Starting torque: 7.6 - 38.1 N (0.77 - 3.88 kgf, 1.7 - 8.6 lb)
7. Crimp the locknut in 2 locations.
8. Measure the dimension "B" of the drive pinion shaft. ST 398643600 GAUGE
9. Calculate the thickness "t" (mm) of the drive pinion shim. t = 6.5 ± 0.0625 - (B - A)
10. Select three or less shims from following table. DRIVE PINION SHIM THICKNESS SPECIFICATION Drive pinion shim Part number Thickness mm (in) 31451AA050 0.150 (0.0059) 31451AA060 0.175 (0.0069) 31451AA070 0.200 (0.0079) 31451AA080 0.225 (0.0089) 31451AA090 0.250 (0.0098) 31451AA100 0.275 (0.0108)

1. Remove the transmission assembly from vehicle body. Refer to «REMOVAL»(ref-325309-S08422567332009071800000) , Automatic Transmission Assembly.
2. Pull out the torque converter clutch assembly. Refer to «REMOVAL»(ref-325309-S32869515002009071800000) , Torque Converter Clutch Assembly.
3. Remove the input shaft.
4. Lift up the lever on the rear side of transmission harness connector, and then remove it from the stay.
5. Remove the inhibitor switch from the stay.
6. Remove the oil charge pipe. Refer to «REMOVAL»(ref-325309-S25952766862009071800000) , Oil Charge Pipe.
7. Remove the ATF inlet and outlet pipes. Refer to «REMOVAL»(ref-325309-S36284246302009071800000) , ATF Cooler Pipe and Hose.
8. Separate the converter case from the transmission case. Refer to «REMOVAL»(ref-325309-S10200678432009071800000) , Converter Case.
9. Remove the seal pipe.
10. Remove the differential side retainers using ST. ST 18630AA010 WRENCH COMPL RETAINER NOTE: ST WRENCH ASSEMBLY (499787000) can also be used. Hold the differential case assembly by hand to avoid damaging the retainer mounting hole of the converter case.
11. Remove the front differential assembly while being careful not to damage the attachment part of the retainer.

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1. Install the front differential assembly to the converter case. NOTE: Be careful not to damage the inside of the converter case (especially the mating surface of the differential side retainer).
2. Install the O-ring to left and right side differential retainers.
3. Install the differential side retainers using ST. Refer to «ADJUSTMENT»(ref-325309-S15990482162009071800000) , Front Differential Assembly. ST 18630AA010 WRENCH COMPL RETAINER NOTE: ST WRENCH ASSEMBLY (499787000) can also be used.
4. Adjust the backlash of the front differential. Refer to «ADJUSTMENT»(ref-325309-S15990482162009071800000) , Front Differential Assembly.
5. Install the lock plate. Tightening torque: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
6. Install new seal pipe to converter case.
7. Install the converter case to the transmission case. Refer to «INSTALLATION»(ref-325309-S39568497242009071800000) , Converter Case.
8. Insert the inhibitor switch and transmission harness connector to the stay.
9. Install the ATF cooler pipe. Refer to «INSTALLATION»(ref-325309-S06270692962009071800000) , ATF Cooler Pipe and Hose.
10. Install the oil charge pipe together with an O-ring. Refer to «INSTALLATION»(ref-325309-S16364028422009071800000) , Oil Charge Pipe.
11. Insert the input shaft while rotating it lightly by hand, and then check the amount of protrusion. Normal protrusion A: 50 - 55 mm (1.97 - 2.17 in)
12. Install the torque converter clutch assembly. Refer to «INSTALLATION»(ref-325309-S25725149262009071800000) , Torque Converter Clutch Assembly.
13. Install the transmission assembly to the vehicle. Refer to «INSTALLATION»(ref-325309-S08159907062009071800000) , Automatic Transmission Assembly.

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1. Remove the taper roller bearing using the ST and a press. ST 498077000 REMOVER
2. Secure the case in a vise, remove the hypoid driven gear tightening bolts, and then separate the hypoid driven gear into differential case (RH) and differential case (LH).
3. Pull out the straight pin and pinion shaft, then remove the differential bevel gear, washer and differential bevel pinion.