1999-2004 Forester Service & Repair Manual
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GENERAL DESCRIPTION
Automatic Transmission
1 . General Description 55,0.0,
A : SPECIFICATIONS 5510007E49
1 . DRIVE PLATE AND DRIVEN PLATE S570007E4901
1 .6 L 3
2.0 L 4
Plate number of high clutch 2.0
L
TURBO 5
2
.5
L 4
3.0 L
5
1 .6 L
1
2.0 L
2
Plate number of reverse clutch 2.0 L TURBO
2
2.5 L 2
3.0 L 2
1 .6 L 2
2.0 L 3
Plate number of 2-4 brake 2.0 L TURBO 4
2.5 L 3
3.0 L 4
1
.6
L 4
2.0 L
4
Plate number of low clutch 2.0 L TURBO
7
2.5 L 6
3 .0 L 7
1 .6 L 4
2 .0 L 4
Plate number of low and reverse brake 2.0 L TURBO 7
2.5 L 6
3.0 L 7
2
.0
L 4
2.0 L TURBO (Without
VTD) 6
2.0 L TURBO (With VTD) 3
Plate number of transfer clutch 2.5 L (Without
VTD) 5
2.5 L (With VTD) 3
3.0 L (Without VTD) 6
3.0 L (With VTD) ~ 3
2 . AUTOMATIC TRANSMISSION FLUID
CAPACITY S510007E4902
Dexron III type Automatic transmission fluid
1 .6
L 8 .0-8 .3 L(8.5-8 .8 US qt, 7.0-7 .3Imp qt)
2.0 L 8
.4
- 8
.7
L (8 .9 - 9.2 US qt, 7.4 - 7.7 Imp qt)
2.0
L
TURBO,
2
.5
L,
3.0
L 9 .3 - 9.6 L (9 .8 - 10 .1 US qt, 8.2 - 8.4 Imp qt)
AT- 2
GENERAL
DESCRIPTION
Automatic
Transmission
B : COMPONENT SSfODOtA05
1 . TORQUE CONVERTER CLUTCH
AND
CASE S51000fA0507
l1)
(2)
(4)
cs) _
T2 0
T2
(16) . I /
(7)
o o
o ~(
9
)*
o ~ o i
o T1
T2
J
' T2
*04)~
O
T3 (13) I ~I a
\(10)
o\
(11)*
0
(12)
83M1995A
(1) Pitching stopper bracket
(2) O-ring
(3) Differential oil level gauge
(4) Stay
(5) Seal pipe
(6) Seal ring
(7) Oil pump shaft
(8)
Clip
(9)
Oil drain pipe
(10) Input shaft
(11)
O-ring
(12) Torque
converter clutch ASSY
(13) Drain plug
(14) Gasket
(15) Oil seal
(16) Torque converter clutch
case
Tightening torque: N~m
(kgf-m, nIb)
T1 : 18 (1 .8, 13.0)
T2: 41 (4.2, 30.4)
T3: 44 (4.5, 32.5)
AT- 4
GENERAL DESCRIPTION
Automatic Transmission
2 . OIL PUMP 5510001A0502
(7)
(6)
~,s>*
18) ~
(17)
5)
B3M0876A
(1) Oil
pump rotor (12) O-ring
(2) Oil pump cover
(13) Test plug
(3) Seal ring
(14) Stud bolt
(4) Thrust needle bearing
(15) O-ring
(5) Drive pinion shaft
(16) O-ring
(6) Roller bearing
(17) Oil seal retainer
(7) Shim
(18) Oil seal
(8) Oil pump housing
(19) O-ring
(9) Nipple
(20) Drive pinion collar
(10) Air breather hose
(21) Lock nut
(11) Gasket
(12)
*
T2
,(13)
~~_(12)
w
~`(13)
T2
T3
/
T1
(16)*
(~ .~
4)
1)* T7
Tightening torque : N~m (kgf-m, ft-Ib)
T1 : 7 (0.7, 5 .1)
T2: 13 (1 .3, 9 .4)
T3: 18 (1 .8, 13.0)
T4: 25 (2.5, 18.1)
T5: 39 (4.0, 28.9)
T6: 41 (4.2, 30 .4)
T7: 121 (12.3, 89.0)
AT - 5
GENERAL DESCRIPTION
Automatic Transmission
3 . TRANSMISSION CASE AND CONTROL
DEVICE 5570001A0503
T4
(5)
(4)
°--~ 3
)*\
(41)
(36)*
uU
1 (39A
T10`,\
i
\20)
(17)*
T2
~'
.
(22)* (21)
T9
(as) i
(9)
(10)
83M1996A
AT-6
GENERAL DESCRIPTION
Automatic Transmission
(1)
Oil level gauge
(2) Oil charger pipe
(3) O-ring
(4) Transfer valve plate
(5) Transfer valve ASSY
(6) Transfer clutch
seal
(7) Transfer
duty solenoid
(8) Straight
pin
(9) Return
spring
(10) Shaft
(11) Parking
pawl
(12)
Parking support
(13) Inlet filter
(14) Gasket
(15) Inlet pipe (Except 3 .0 L model)
(16) Union screw
(17) O-ring
(18) Test plug
(19) Oil filter
(Except 3.0 L model)
(20) Oil
filter stud bolt
(21) Drain plug
(22) Gasket
(23) Oil pan
(24)
Magnet
(25) Stud bolt (Short)
(26) Stud bolt (Long)
(27) Parking rod
(28) Manual plate
(29) Spring pin
(30) Detention spring
(31) Ball
(32) Spring
(33) Gasket
(34) Outlet
pipe (Except 3.0 L model)
(35) Union
screw
(36) Oil
seal
(37)
Select lever
(38) Inhibitor switch ASSY
(39) Nipple
(40) Air breather hose
(41) Transmission case
(42) Plate ASSY
(43) Washer
(44)
Outlet pipe (3 .0 L model)
(45)
O-ring
(46)
Cover
(47) Gasket
(48) Union
screw
(49) Inlet pipe (3.0 L model)
(50) Plug
(51) Shim (FWD)
(52) Gasket (FWD)
(53) Transmission cover (FWD)
Tightening torque: N~m (kgf-m, ftIb)
T1: 3 .4 (0 .35, 2 .5)
T2: 4 .9 (0.50, 3 .6)
T3: 5 .9 (0.60, 4 .3)
T4: 7 .8 (0.80, 5 .8)
T5: 12 (1.2, 8 .7)
T6: 12.7 (1.30, 9 .4)
T7: 13.7 (1 .4, 10.1)
T8: 17 .7 (1
.80, 13 .0)
T9: 24.5 (2 .50, 18 .1)
T10: 24.5 (2 .5, 18.1)
T11 : 45 (4 .5, 32.5)
AT -7
GENERAL
DESCRIPTION
Automatic Transmission
4 .
CONTROL VALVE AND
HARNESS
ROUTING
55~~~A~~
(2)
~6)*
\ Ti
~\ (7)
--
l *`
*
~~
8 )
5
)
(9)
( 3 )
0
T2 t/^ (10)
Ti
(11)
(12)
(14)
T2 °
e (15)
(13)
`i (16)
(17)
(18)
(19)
(20)
(25)
(21)
T2
(26)
c2>>
'
"
c~~
T2
T2
(28)
`k~ "
~ -
(24)
T2
T2
B3M1833A
(1) Stay
(2) Transmission
harness
(3) O-ring
(4) O-ring
(5) Torque converter
turbine speed
sensor
(6) O-ring
(7) Front vehicle speed
sensor
(8) O-ring
(9) Rear vehicle speed sensor
(10) Upper valve body
(11) Accumulator piston
(12) Accumulator spring
(13) Side plate
(14) Separate plate
(15) Middle valve body
(16)
Separate plate
(17) Fluid filter
(18)
Fluid filter
(19) Lower
valve body
(20) Shin solenoid
2
(21) Shift solenoid
1
(22) 2-4 brake
timing solenoid
(23) 2-4 brake duty
solenoid
(24)
ATF temperature sensor
(25) Line pressure
duty solenoid
(26) Low clutch
timing solenoid
(27) Lock-up duty
solenoid
(28) Oil strainer
Tightening
torque: N "m (kg/-m,
ft-Ib)
T1:
7 (0.7, 5 .1)
T2: 8 (0
.8, 5 .8)
AT-8
GENERAL DESCRIPTION
Automatic Transmission
5. HIGH CLUTCH AND REVERSE CLUTCH
S510007A0505
(1
(9)
(6)*
I
(5)*
yr yr
D
(3)*
i
(2)* ~ ~
(1)
/
(21)
(20)
\ (18
;
/
~
(16)
(17)
(16)
(15)
(14)
(13)
.
:
/ \2)
(11)
(12}
1)
S3M0221A
(1) High
clutch drum (8)
Spring
retainer (15) Dish plate
(2)
Lip seal (9) Cover (16) Driven plate
(3) Lathe cut seal ring (10) Snap ring (17) Drive plate
(4) Reverse clutch piston (11) Driven plate (18) Retaining plate
(5) Lathe cut seal ring (12) Drive plate (19) Snap ring
(6) Lathe cut seal ring (13) Retaining plate (20) Thrust needle bearing
(7) High clutch piston (14) Snap ring (21) High clutch hub
AT-9
GENERAL
DESCRIPTION
Automatic
Transmission
6 .
PLANETARY
GEAR AND 2-4 BRAKE
S57000fA0506
(5)
(3) °
(2) ~o
(13)
(1) ((\ J/
~J
(12)
(11)
(9)
X10)
(7)
\\ 1\
(19)
(,8)
(16)
(16)(1
\2
(24)
83M1997A
(1) Thrust
needle bearing
(10) Washer
(2) Front sun
gear
(11) Thrust needle
bearing
(3) Thrust
needle bearing
(12) Rear internal
gear
(4) Snap
ring
(13) Washer
(5) Front
planetary carrier
(14) Snap ring
(6) Thrust
needle bearing
(15) Retaining plate
(7) Rear sun
gear
(16) Drive plate
(8) Thrust needle
bearing
(17) Driven plate
(9) Rear planetary
carrier
(18) Pressure rear plate
(19) Snap ring
(20) Spring retainer
(21) 2-4 brake piston
(22) Lathe cut seal ring
(23) Lathe cut seal ring
(24) 2-4 brake piston retainer
(25) 2-4 brake seal
(26)
Leaf spring
AT-1
0
GENERAL DESCRIPTION
Automatic
Transmission
7 .
LOW CLUTCH AND LOW
& REVERSE
BRAKE S57000fA0507
(1
(26)
i 11 \\
/ '~~a~
(27)
(21)
i
(19)
(18)
(29)
(17)*
(16) (28)
D
X20,
(22)
B3M1017A
(1) Retaining
plate
(2) Drive
plate
(3)
Driven plate
(4)
Dish plate
(5) Snap ring
(6) Cover
(7) Spring retainer
(8) Lathe cut seal ring
(9) Low clutch piston
(10) Lathe cut seal
ring
(11) Low clutch
drum
(12)
Needle bearing
(13)
Inner snap ring
(14)
One-way clutch
(15) Outer snap ring
(16) Thrust needle bearing
(17) Seal ring
(18) Needle bearing
(19) One-way
clutch inner race
(20)
Socket bolt
(21) Spring
retainer
(22) Return
spring
(23) Snap ring
(24) Retaining plate
(25) Leaf spring
(26) Drive plate
(27) Driven plate
(28) Dish
plate
(29) Low
and reverse brake piston
Tightening torque : Mm (kgf-m,
ft-Ib)
T 25 (2.5, 18.1)
AT-1
1
GENERAL DESCRIPTION
Automatic
Transmission
8 .
REDUCTION GEAR
WITHOUT VTD
951000,A0 .508
1
AWD
I
1 / ``
(4)
~\~
Vv
(3)
\, I
(2)
(s)
l9)
~~0
i)*F-T
(a)
(7'
(s)
(is)
(s)
(t2)
(2)
FWD
*
(11
*0
(10)
(8)
(7)
(s)
(5)
83M2114A
(1) Seal ring
(2)
Ball bearing
(3)
Reduction drive gear
(4)
Reduction drive shaft
(5)
Drive pinion shaft
(6) Snap
ring
(7) Ball bearing
(8) Reduction driven gear
(9) Snap ring
(10) Washer
(11) Lock nut
(12) Reduction drive shaft
(13) Ball
bearing
Tightening torque: N~m
(kgf-m, n Ib)
T 100 (10.2, 73.8)
AT-1 2
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What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$30.99
This service and workshop manual for the Subaru Forester 1999-2004 covers a wide range of services and repairs, making it perfect for both professional mechanics and DIY enthusiasts. With over 5000 pages, it includes detailed information on engine overhaul, brakes, sunroof, timing belt replacement, trouble codes, wiring diagrams, troubleshooting, diagnostics, engine performance, suspension, transmission, air conditioning service, computer diagnostic codes, firing orders, factory maintenance schedules, serpentine belt routings, driving concerns, torque specifications, U-joint and CV-joint service procedures, repair procedures, and hundreds of illustrations.
The format of the manual allows for easy viewing and printing on all computers, including PC and MAC, without the risk of getting grease on any pages.
