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Laurel Butler
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LETS PLAY BALL Camping Out with the Subaru Forester by Lance Wiggins Figure 1A Figure 1B Sometimes everybody needs a little vacation.

Right about now, as you sit down to read this, most of the country is on their annual family trips.

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 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.

1 LETS PLAY BALL Camping Out with the Subaru Forester by Lance Wiggins Figure 1A Figure 1B Sometimes 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 2-4 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 brake timing solenoid brake solenoid 8. Transfer clutch solenoid (figure 1b) plus the ATF temperature sensor. 18 GEARS July 2004

2 XIOM : an established rule or principle a maxim widely accepted on its intrinsic merit a statement accepted as true a self-evident truth AXIO GEARS July

Camping Out with the Subaru Forester Figure 3 Figure 4 Make sure you record those

belong. Figure 5 The valve body is a threepiece design, including the accumulator body.

valve body s configuration. Make sure you record those belong (figures 3, 4, 5).

3 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. Figure 5 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). 20 GEARS July 2004

COMPLAINT: Also: No 2nd gear 2nd & reverse only CAUSE: Constant oscillation of solenoid regulator valve wears the casting bore, resulting in loss of regulated pressure and/or valve sticking.

The bore sizing tool is required to remove bore ridges and provide optimum fit with the new valve.

from Sonnax : E4OD & 4R100 P/N: 36948-18K Performance Rated/Heavy Duty Accumulator Spring Kit Part Nos.

AXOD & -E AX4N/AX4S P/N: 96706-01 1-2 Accumulator Pin CAUSE: Breakage of the 4-3 pre-stroke valve spring prevents proper valve function.

4 COMPLAINT: Also: No 2nd gear 2nd & reverse only CAUSE: Constant oscillation of solenoid regulator valve wears the casting bore, resulting in loss of regulated pressure and/or valve sticking. 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. SHIFT COMPLAINTS, SHIFTS TO NEUTRAL AT HEAVY THROTTLE SOLENOID REGULATOR VALVE KIT 1-2/2-3 End Plug o-ring installed Solenoid Regulator Valve AODE 4R70W Solenoid Regulator Valve Spring Also available from Sonnax : E4OD & 4R100 P/N: K Performance Rated/Heavy Duty Accumulator Spring Kit Part Nos K Solenoid Regulator Valve Kit BST2 Bore Sizing Tool Bore Sizing Tool Retainer COMPLAINT: Also: Codes 734 and/or 735 Solenoid C Code NO 4TH OR 5TH GEAR 4-3 PRE-STROKE VALVE SPRING 5R55N AXOD & -E AX4N/AX4S P/N: Accumulator Pin 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. Spring Valve Retaining Clip 4L60E & 4L65E 1996-UP P/N: Control Valve Spring Part No J-S1 End Plug See your nearest Transmission Specialties distributor & ask for Sonnax quality engineered products. VISIT OUR WEBSITE FOR SONNAX REAMERS & OTHER TOOLS. Automatic Drive P.O. Box 440 Bellows Falls, VT USA 802/ / fax: 802/ info@sonnax.com GEARS 2004 Sonnax July

Camping Out with the Subaru Forester Figure 7 Figure 6 Externally, the transmission has a number of sensors, including three speed sensors (figure 6): 1.

During operation, they create an AC signal that starts at 1 volt and increases gradually as speed increases.

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).

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.

5 Camping Out with the Subaru Forester Figure 7 Figure 6 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 All of these speed sensors measure 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. Banta Place, Pagemaker Ad The Key to Reducing Costly Come Backs Is Muscle MT-10 The Original Metal Treatment Muscle Products Corp. "The Strength in Lubrication TM " 112 Fennell Drive Butler, PA Phone: (800) or (724) Fax: (724) GEARS July 2004

12 MONTH UNLIMITED MILE SILVER WARRANTY 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.

15) Move the gear selector lever to Drive.

6 12 MONTH UNLIMITED MILE SILVER WARRANTY 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 INTRODUCING Platinum Torque is a new product line developed by National Drivetrain to usher in a higher standard of quality parts and rebuilt units at affordable prices. QUALITY REBUILT Manual Transmissions & Transfer Cases Member Standard12 MonthUnlimitedMile Warranty. Extended Warranties available HUGE INVENTORY- VOLUME DISCOUNTS Also: Complete Rebuild Kits with OE quality parts Call and request a credit application today TOLL FREE ORDER LINE You can order online and use our complete buyers guide at: Take Note: We beat anyone s published price on Ring and Pinions GEARS July

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.

7 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. Figure 11 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 24 GEARS July 2004

8 It s not just a band. It s a chain of quality. Allomatic links high strength steel, OE manufacturing 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 Toll Free: Fax: www. allomatic.com GEARS July

9 Camping Out with the Subaru Forester Figure 12 Figure GEARS July 2004

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.

There aren t any secrets or special tricks for disassembling and reassembling this unit; don t be afraid to get into it.

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.

In some cases, the seal between the seal pipe and the oil pump housing will leak into the differential from the transmission.

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).

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.

10 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! PATENTED LOW TEMPERATURE VACUUM DISTILLATION TECHNOLOGY T-STILLCLEAN-STD Optional Stand Available Figure 15 StillClean Continuous pure solvent on demand Distills 105 and 140 solvents Portable-can be moved and used on multiple parts washers No service contracts Reduces hazardous waste Monthly costs less than most service contracts Available as stand-alone unit or use T-0177-SOLV Combo Parts Washer T-STILLCLEAN DISTRIBUTION OPPORTUNITIES For Product Information and Specifications Visit sales@atec-trans-tool.com or call T-0177-SOLV AVAILABLE Washers, Tanks, Tables & Tools at Great Prices! GEARS July

What is it that makes that. LET S PLAY BALL Time to Shift Gears. by Lance Wiggins. Typical 4 Speed Mitsubishi

What is it that makes that. LET S PLAY BALL Time to Shift Gears. by Lance Wiggins. Typical 4 Speed Mitsubishi LET S PLAY BALL Time to Shift Gears Typical 4 Speed Mitsubishi by Lance Wiggins What is it that makes that grinding noise in my transmission? I just had it serviced and that noise started shortly after