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 • info@sonnax.com • 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

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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-

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Allomatic has a lock on consistent quality for

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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