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LETS PLAY BALL
Camping Out with
the Subaru Forester
by Lance Wiggins
S
Figure 1A
Figure 1B
18
ometimes everybody needs a
little vacation. Baseball has its
seventh inning stretch, football
has halftime, and even your average
couch potato takes time to wander over
to the refrigerator. Right about now, as
you sit down to read this, most of the
country is on their annual family trips.
Unfortunately, this is one of the busiest
times of the year for the transmission
industry, and taking that time off is
almost unheard of. So for you, this will
be a virtual trip as we go camping with
the Subaru Forester.
In 1987, Subaru introduced its first
four-speed transmission, used in the
XT: the 4EAT. It was almost identical
to Nissan’s RE4R01A except it had a
front differential to drive the front
wheels. It also came in a 4X4 version.
In 1998, Subaru introduced the Subaru
Forester. It too uses a 4EAT transmission, but it’s far different than the earlier unit. The main difference is the later
transmission uses clutch-to-clutch
application. So the 2-4 band is now a 24 clutch, and there’s no overrun clutch
or low sprag. The differential is in front
of the transmission to allow for front
wheel drive and 4X4 operation,
depending on the application.
This unit is fully electronic, with
eight solenoids and one sensor (figure
1a):
1. Lockup solenoid
2. Low clutch timing solenoid
3. Line pressure solenoid
4. Shift solenoid 1
5. Shift solenoid 2
6. 2-4 brake timing solenoid
7. 2-4 brake solenoid
8. Transfer clutch solenoid (figure 1b)
…plus the ATF temperature sensor.
GEARS July 2004
AXIOM-19.qxd
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AXIOM
AXIOM
AXIOM
AXIOM
AXIOM
AXIOM
AXIOM
AXIOM
AXIOM
AXIOM:
AXIOM
AXIOM
an established rule or principle
a maxim widely accepted on its intrinsic merit
a statement accepted as true
a self-evident truth
AXIOM
GEARS July 2004
AXIOM
AXIOM
AXIOM
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Camping Out with the Subaru Forester
Figure 3
Figure 4
Make sure you
record those
locations during
disassembly, so
you can be sure
you’re putting
them back
where they
belong.
The valve body is a threepiece design, including the accumulator body. The checkballs are
steel, and can appear in many
different locations because of the
valve body’s configuration.
Make sure you record those locations during disassembly, so you
can be sure you’re putting them
back where they belong (figures
3, 4, 5).
Figure 5
20
GEARS July 2004
sonnax placed.qxd
6/9/04
10:41 AM
COMPLAINT:
Also:
• No 2nd gear
• 2nd & reverse only
Page 21
SHIFT COMPLAINTS, SHIFTS TO NEUTRAL AT HEAVY THROTTLE
S O L E N O I D R E G U L AT O R VA LV E K I T
®
AODE
4R70W
CAUSE:
Constant oscillation of solenoid regulator valve wears the
casting bore, resulting in loss
of regulated pressure and/or
valve sticking.
Also available
from Sonnax :
®
Solenoid Regulator
Valve Spring
CORRECTION:
The solenoid regulator valve
kit restores hydraulic integrity
to the circuit and prevents oil
leakage. The bore sizing tool is
required to remove bore ridges
and provide optimum fit with
the new valve.
1-2/2-3 End Plug
o-ring installed
E4OD
& 4R100
P/N:
36948-18K
Performance
Rated/Heavy Duty
Accumulator
Spring Kit
Solenoid
Regulator Valve
Part Nos.
76948-14K
Retainer
Solenoid Regulator Valve Kit
76948-BST2
Bore Sizing Tool
COMPLAINT:
Also:
• Codes 734 and/or 735
• Solenoid C Code
Bore Sizing Tool
AXOD & -E
AX4N/AX4S
NO 4TH OR 5TH GEAR
P/N:
96706-01
4 - 3 P R E - S T R O K E VA LV E S P R I N G
1-2 Accumulator Pin
5R55N
CAUSE:
Breakage of the 4-3 pre-stroke
valve spring prevents proper
valve function.
CORRECTION:
The Sonnax spring is made
from chrome-silicon alloy,
which allows higher working
stresses than typical spring
material, and is designed to
reduce operating stresses at the
critical regulating positions of
the valve.
4L60E
& 4L65E
1996-UP
P/N:
77754-23
Spring
3-2 Control
Valve Spring
Retaining Clip
Valve
Part No.
56947J-S1
End Plug
See your nearest
Transmission Specialties™
distributor & ask for
Sonnax® quality
engineered products.
VISIT OUR
OUR WEBSITE
WEBSITE FOR
FOR
VISIT
REAMERS
SONNAX®® REAMERS
SONNAX
& OTHER
OTHER TOOLS.
TOOLS.
&
Automatic 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
GEARS
July 2004
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Camping Out with the Subaru Forester
Externally, the transmission has a number of
sensors, including three speed sensors (figure 6):
1. Rear vehicles speed sensor
2. Front vehicle speed sensor
3. Torque converter turbine speed sensor
Figure 6
Figure 7
All of these speed sensors measure 450-650
ohms. During operation, they create an AC signal
that starts at 1 volt and increases gradually as
speed increases.
The inhibitor switch assembly (figure 7) is
located on the passenger side of the vehicle. It
has seven internal switches: one for each gear
range on the manual lever. As you move the lever
through the gear ranges, the switch for that range
should 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 can
be tested for codes manually or you can use the factory tool.
When you retrieve codes manually, you’ll have to perform
a 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.
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GEARS July 2004
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Page 23
7) Apply the brake pedal, and
hold it down through step 15.
8) Move the gear selector lever
to 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.
Figure 8
Figure 9
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GEARS July 2004
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23
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Camping Out with the Subaru Forester
Figure 10
Simply count the
light flashes and
compare the
pattern to the
chart (figure 11)
to determine the
code being
generated.
The indicator light on the dash
should start to blink. 0.2-second flashes signify a one; 1.2-second flashes signify a ten (figure 10). Simply count the
light flashes and compare the pattern to
the chart (figure 11) to determine the
code being generated.
To clear the codes manually, turn
the ignition switch off and unplug
TCM connectors B54 and B55 from
the TCM. You should allow about five
Figure 11
24
GEARS July 2004
allomatic placed.qxd
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Allomatic has a lock on consistent quality for
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GEARS July 2004
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Camping Out with the Subaru Forester
Figure 12
Figure 13
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Figure 14
minutes for the codes to clear (figure
12).
The codes are fairly self-explanatory and shouldn’t give you any problems when using the code chart to diagnose this system.
Before removing and disassembling the transmission, always perform
a pressure test to help isolate the specific failure. There aren’t any secrets or
special tricks for disassembling and
reassembling this unit; don’t be afraid
to get into it. You can air test the
clutches and lube circuits before and
after teardown (figure 13).
This transmission has two common
problems. The first is related to the differential. The differential failure is
caused by lack of lube (figure 14). The
differential ring gear, pinion, and carrier
are submerged in 80W-90 or equivalent
oil. The gasket between the differential
housing and the transmission tends to
leak. In some cases, the seal between the
seal pipe and the oil pump housing will
leak into the differential from the transmission. ATF won’t work in a hypoid
application, so if this happens, it’ll cause
a catastrophic failure.
The second common failure is related to the low clutch assembly, caused
when the low clutch piston seal shrinks,
so it won’t seal properly (figure 15). This
causes a slow forward engagement and
sometimes no engagement at all.
Well, once again I hope you get that
vacation that’s been eluding you. By the
time this article hits the streets, I’ll be in
high Sierra Nevada mountain range, otherwise known as Shaver Lake, taking my
annual vacation. Until next time, remember: the time you missed spending with
your family is lost forever. Spend that
time with them now, while you have the
chance… and that’s the game!
GEARS July 2004
Figure 15
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