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Camping Out withthe Subaru Forester
18 GEARS July 2004
LETS PLAY BALL
Sometimes everybody needs alittle vacation. Baseball has itsseventh inning stretch, football
has halftime, and even your averagecouch potato takes time to wander overto the refrigerator. Right about now, asyou sit down to read this, most of thecountry is on their annual family trips.Unfortunately, this is one of the busiesttimes of the year for the transmissionindustry, and taking that time off isalmost unheard of. So for you, this willbe a virtual trip as we go camping withthe Subaru Forester.
In 1987, Subaru introduced its firstfour-speed transmission, used in theXT: the 4EAT. It was almost identicalto Nissan’s RE4R01A except it had afront differential to drive the frontwheels. It also came in a 4X4 version.In 1998, Subaru introduced the SubaruForester. It too uses a 4EAT transmis-sion, but it’s far different than the earli-er unit. The main difference is the latertransmission uses clutch-to-clutchapplication. So the 2-4 band is now a 2-4 clutch, and there’s no overrun clutchor low sprag. The differential is in frontof the transmission to allow for frontwheel drive and 4X4 operation,depending on the application.
This unit is fully electronic, witheight solenoids and one sensor (figure1a):
1. Lockup solenoid2. Low clutch timing solenoid3. Line pressure solenoid4. Shift solenoid 15. Shift solenoid 26. 2-4 brake timing solenoid7. 2-4 brake solenoid8. Transfer clutch solenoid (fig-
ure 1b)…plus the ATF temperature sensor.
by Lance Wiggins
Camping Out withthe Subaru Forester
Figure 1A
Figure 1B
GEARS July 2004 19
AXIOM: an established rule or principlea maxim widely accepted on its intrinsic merita statement accepted as truea self-evident truth
AXIOM
AXIOM
AXIOM
AXIOM
AXIOM
AXIOM
AXIOM
AXIO
AXIOM
XIOM
AXIOMAXIOM
AXIOM
AXIOMAXIOM
The valve body is a three-piece design, including the accu-mulator body. The checkballs aresteel, and can appear in manydifferent locations because of thevalve body’s configuration.Make sure you record those loca-tions during disassembly, so youcan be sure you’re putting themback where they belong (figures3, 4, 5).
20 GEARS July 2004
Figure 3 Figure 4
Make sure yourecord those
locations duringdisassembly, soyou can be sureyou’re putting
them backwhere they
belong.
Figure 5
Camping Out with the Subaru Forester
GEARS July 2004 21Automatic Drive • P.O. Box 440 • Bellows Falls, VT 05101-0440 • USA • 802/463-9722 • 800/843-2600 • fax: 802/463-4059 • [email protected] • www.sonnax.com©2004 Sonnax
VISIT OUR WEBSITE FORSONNAX® REAMERS
& OTHER TOOLS.
VISIT OUR WEBSITE FORSONNAX® REAMERS
& OTHER TOOLS.
®
See your nearestTransmission Specialties™
distributor & ask forSonnax® qualityengineered products.
Also availablefrom Sonnax®:
E4OD& 4R100
P/N:36948-18K
PerformanceRated/Heavy Duty
AccumulatorSpring Kit
4L60E& 4L65E1996-UP
P/N:77754-233-2 Control
Valve Spring
AXOD & -EAX4N/AX4S
P/N:96706-01
1-2 Accumulator Pin
Part No.
56947J-S1
4 - 3 P R E - S T R O K E V A LV E S P R I N G
5R55N
NO 4TH OR 5TH GEAR
CORRECTION:The Sonnax spring is madefrom chrome-silicon alloy,which allows higher workingstresses than typical springmaterial, and is designed toreduce operating stresses at thecritical regulating positions ofthe valve.
CAUSE:Breakage of the 4-3 pre-strokevalve spring prevents propervalve function.
COMPLAINT:Also:
• Codes 734 and/or 735• Solenoid C Code
Part Nos.
76948-14KSolenoid Regulator Valve Kit
76948-BST2Bore Sizing Tool
S O L E N O I D R E G U L A T O R V A LV E K I T
AODE4R70W
SHIFT COMPLAINTS, SHIFTS TO NEUTRAL AT HEAVY THROTTLECOMPLAINT:Also:
• No 2nd gear• 2nd & reverse only
Spring
Valve
End Plug
Retaining Clip
Bore Sizing Tool
SolenoidRegulator Valve
Solenoid RegulatorValve Spring
1-2/2-3 End Plugo-ring installed
Retainer
CAUSE:Constant oscillation of sole-noid regulator valve wears thecasting bore, resulting in lossof regulated pressure and/orvalve sticking.
CORRECTION:The solenoid regulator valvekit restores hydraulic integrityto the circuit and prevents oilleakage. The bore sizing tool isrequired to remove bore ridgesand provide optimum fit withthe new valve.
Externally, the transmission has a number ofsensors, including three speed sensors (figure 6):
1. Rear vehicles speed sensor2. Front vehicle speed sensor3. Torque converter turbine speed sensor
All of these speed sensors measure 450-650ohms. During operation, they create an AC signalthat starts at 1 volt and increases gradually asspeed increases.
The inhibitor switch assembly (figure 7) islocated on the passenger side of the vehicle. Ithas seven internal switches: one for each gearrange on the manual lever. As you move the leverthrough the gear ranges, the switch for that rangeshould pull down, from more than 8 volts DC to
less than 1 volt DC (figure 8).Diagnosing this unit is fairly easy; the location of the
components are illustrated in figure 9. The control unit canbe tested for codes manually or you can use the factory tool.When you retrieve codes manually, you’ll have to performa detailed routine:
1) Bring the engine to normal operating temperature.
2) Key off.3) Key on, engine off.4) Start the engine.5) Drive the vehicle above 12 MPH.6) Come to a stop.
22 GEARS July 2004
Banta Place,Pagemaker Ad
Figure 6
Figure 7
Camping Out with the Subaru Forester
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7) Apply the brake pedal, andhold it down through step 15.
8) Move the gear selector leverto Manual 1.
9) Key off.10) Key on, engine off.11) Move the gear selector lever
to Manual 2.12) Move the gear selector lever
to Manual 1.13) Move the gear selector lever
to Manual 2.14) Move the gear selector lever
to Manual 3.15) Move the gear selector lever
to Drive.
GEARS July 2004 23
Figure 9
Figure 8
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The indicator light on the dashshould start to blink. 0.2-second flash-es signify a one; 1.2-second flashes sig-nify a ten (figure 10). Simply count thelight flashes and compare the pattern tothe chart (figure 11) to determine thecode being generated.
To clear the codes manually, turnthe ignition switch off and unplugTCM connectors B54 and B55 fromthe TCM. You should allow about five
24 GEARS July 2004
Figure 11
Figure 10
Camping Out with the Subaru Forester
Simply count thelight flashes and
compare the pattern to the
chart (figure 11) to determine the
code being generated.
GEARS July 2004 25
It’s not just a band. It’s a chain of quality.
Allomatic links high strength steel, OE manufac-
turing expertise,stringent testing and continuous
quality control to supply a variety of bands
that meet or exceed OE specifications.
Allomatic has a lock on consistent quality for
today’s complex transmissions. When new
transmissions are introduced, Allomatic
meets the demand by adding products to its
diverse line of quality filters, friction plates,
bands and steels. Just another reason why
you should choose Allomatic products.
609 E. Chaney Street • P.O. Box 267 • Sullivan, IN 47882 • Toll Free: 1-800-568-0330 • Fax: 516-775-5543 • www. allomatic.com
26 GEARS July 2004
Figure 13
Figure 12
Camping Out with the Subaru Forester
GEARS July 2004 27
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minutes for the codes to clear (figure12).
The codes are fairly self-explana-tory and shouldn’t give you any prob-lems when using the code chart to diag-nose this system.
Before removing and disassem-bling the transmission, always performa pressure test to help isolate the spe-cific failure. There aren’t any secrets orspecial tricks for disassembling andreassembling this unit; don’t be afraidto get into it. You can air test theclutches and lube circuits before andafter teardown (figure 13).
This transmission has two commonproblems. The first is related to the dif-ferential. The differential failure iscaused by lack of lube (figure 14). Thedifferential ring gear, pinion, and carrierare submerged in 80W-90 or equivalentoil. The gasket between the differentialhousing and the transmission tends toleak. In some cases, the seal between theseal pipe and the oil pump housing willleak into the differential from the trans-mission. ATF won’t work in a hypoidapplication, so if this happens, it’ll causea catastrophic failure.
The second common failure is relat-ed to the low clutch assembly, causedwhen the low clutch piston seal shrinks,so it won’t seal properly (figure 15). Thiscauses a slow forward engagement andsometimes no engagement at all.
Well, once again I hope you get thatvacation that’s been eluding you. By thetime this article hits the streets, I’ll be inhigh Sierra Nevada mountain range, oth-erwise known as Shaver Lake, taking myannual vacation. Until next time, remem-ber: the time you missed spending withyour family is lost forever. Spend thattime with them now, while you have thechance… and that’s the game!
Figure 15
Figure 14