Technical Service Information

SUBARU 4AT PHASE ll VERSION ll

CONTROL AND VALVE BODY CHANGES
CHANGE: Sometime at the beginning of the 2004 model year, (see Figure 1 for model I.D.), Subaru re-
designed the 4AT Phase ll Control system, while still using the same Clutch and Brake application,
as shown in Figure 2. This required some component changes to accommodate this new design.

REASON: For improved function with fewer electronic components.

PARTS AFFECTED:
1. SOLENOID CONTROL-
The Solenoid firing order changed, as solenoid function has been redesigned. See Figure 3.
2. ALL SOLENOIDS-
Line Pressure control Solenoid: Refer to Figure 4 for a description and operation .
High Clutch, Low/Reverse and TCC Duty Solenoids: Refer to Figure 5 for a description and
operation .
2-4 Brake and Low Clutch Duty Solenoids: Refer to Figure 6 for a description and operation .
Transfer Clutch Duty Solenoid: Refer to Figure 7 for a description and operation .
3. INTERNAL WIRING HARNESS-
The Internal wiring harness changed with the newly designed Solenoids, refer to Figure 8.
4. VALVE BODY ASSEMBLY-
Refer to Figure 9 for Sump Filter and harness location.
Refer to Figures 10 and 11 for Lower Valve Body exploded view, legend and spring specs.
Refer to Figures 12-14 for Upper Valve Body exploded view, legend and spring specs.
Refer to Figure 15 for Upper Valve Body small parts and check ball function and locations.
Refer to Figure 16 for Valve Body Bolt locations.
Note: The Valve names are provided by ATSG and are based on valve function.

5. CASE PASSAGES-
The Case passages changed to accommodate the Valve Body changes. See Figure 17.

INTERCHANGEABILITY:
None of the parts listed above are interchangeable with previous design.

Special Thanks to
Best Transmission 4AT PHASE ll VERSION ll MODEL I.D.
Springfield, MA
2004 and Later Subaru Forester Turbo
2005 and Later Subaru Forester Non-Turbo
2005 and Later Subaru Impreza Non-Turbo
2006 and Later Subaru Impreza Turbo
2005 and Later Subaru Legacy/Outback
Figure 1
12-10
Page 1 of 14
AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

SUBARU 4AT PHASE ll VERSION l AND VERSION ll

COMPONENT APPLICATION CHART

High Clutch Reverse Clutch Low Clutch

2-4 L/R Brake

Brake Low Sprag
Transfer Clutch

SELECTOR REVERSE 2-4 HIGH LOW LOW/REVERSE LOW-ONE WAY TRANSFER

POSITION CLUTCH BRAKE CLUTCH CLUTCH BRAKE CLUTCH CLUTCH

P
R ON ON Mod.
N

D 1 ON ON Mod.
2 ON ON Mod.
3 ON ON Mod.
4 ON ON Mod.
1* ON ON* ON Mod.
Manual
Mode 1 ON ON Mod.
2 ON ON Mod.
3 ON ON Mod.
4 ON ON Mod.

*= Low Reverse Clutch ON at Low speed determined by PCM

Mod. = Transfer Clutch Apply is Modulated which is determined by the PCM/ABS
Copyright © 2012 ATSG

Figure 2

12-10
Page 2 of 14
AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

SUBARU 4AT PHASE ll VERSION ll

SOLENOID APPLICATION CHART

2-4 HIGH LOW LOW/REVERSE TCC TRANSFER

SELECTOR BRAKE CLUTCH CLUTCH BRAKE DUTY % CLUTCH
POSITION DUTY % DUTY % DUTY % DUTY % DUTY %

P H H H H L Mod.
R H H H H to L L Mod.
N H H H H L Mod.

D 1 H H L H L Mod.
2 L H L H L Mod.
3 L** L L H H Mod.
4 L L H H H Mod.
1* H H H to L L L Mod.
Manual
Mode 1 H H L H L Mod.
2 L H L H L Mod.
3 L** L L H H Mod.
4 L L H H H Mod.
*= Low Reverse Clutch ON at Low speed determined by PCM
H to L=Ramps from High to Low during engagement
L** = The 2-4 duty solenoid may be at Low duty cycle in 3rd gear depending on PCM strategy.
2-4 Brake application is prevented by the 2-4 sequence valve.
Copyright © 2012 ATSG

Figure 3

12-10
Page 3 of 14
AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
LINE PRESSURE CONTROL SOLENOID FUNCTIONAL CHECK

Normally
Applied

Output to the
spring side of
Pilot
the Pressure
Pressure
Regulator Valve

Summary: The Pressure Control Solenoid is Normally Applied. When the Solenoid duty cycle is Low,
pressure to the spring side of the Pressure Regulator Valve is high, resulting in Higher Line Pressure.
When the Solenoid duty cycle is High, pressure to the spring side of the Pressure Regulator Valve
is Low, resulting in Lower line pressure. Copyright © 2012 ATSG
Figure 4

HIGH CLUTCH, LOW/REVERSE AND TCC DUTY SOLENOID FUNCTIONAL CHECK

OFF ON
Grey Connector Grey Connector 1.265”

Normally
Applied

Connected to Blocked to
Control Valve Control Valve
Pilot Pilot
Pressure Pressure

Summary: The High, Low/Reverse and TCC Duty Solenoids are Normally Applied. When the Solenoid duty
cycle is Low, Pilot pressure to the Control valve is high, opening the valves for the High Clutch and
Low/Reverse. Note: The TCC Duty solenoid feeds the spring side of the TCC Control Valve preventing TCC
apply. When the Solenoid duty cycle is High, Pilot pressure to the Control valve is blocked, allowing the spring
to close the High and Low/Reverse Control valves. Note: The TCC Duty Solenoid at high duty cycle blocks
the pressure to the spring side of the valve , allowing the TCC Control Valve to open applying the TCC.

Figure 5 12-10
Page 4 of 14
AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
2-4 BRAKE AND LOW CLUTCH DUTY SOLENOID FUNCTIONAL CHECK

OFF ON
Brown Connector Brown Connector 1.365”

Normally
Applied

Connected to Blocked to
Control Valve Control Valve
Pilot Pilot
Pressure Pressure

Summary: The 2-4 Brake and Low Clutch Duty Solenoids are Normally Applied. When the Solenoid duty
cycle is Low, Pilot pressure to the Control valve is high, opening the valves for the 2-4 Brake and
Low Clutch. When the Solenoid duty cycle is High, Pilot pressure to the Control valve is blocked, allowing the spring
to close the 2-4 Brake and Low Clutch Control valves. Copyright © 2012 ATSG
Figure 6

TRANSFER CLUTCH DUTY SOLENOID FUNCTIONAL CHECK

OFF ON
Green Connector Green Connector 1.365”

Normally
vented

Blocked to Connected to
Control Valve Control Valve
Pilot Pilot
Pressure Pressure

Summary: The Transfer Clutch Duty Solenoid is Normally Vented. When the Solenoid duty cycle is Low,
Pilot pressure to the Control valve is blocked, closing the Transfer Clutch Control Valve. When the Solenoid duty cycle is High,
Pilot pressure to the Control valve is High, opening the Transfer Clutch Control valve.
Copyright © 2012 ATSG

Figure 7 12-10
Page 5 of 14
AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

INTERNAL WIRING HARNESS

TFT SENSOR AND INTERNAL
WIRE HARNESS ASSEMBLY

Ground For
Solenoids Transfer & TCC

Ground For
Solenoids L/R & Low

Ground For
Solenoids 2-4 & High

Lower Valve Body

TFT Sensor
Grey
TFT (+) 2
Grey
TFT (-) 4
1 2
Red 5.8 Ohms
Line (+) 1 A Line Across the
Black
3 4 Line (-) 3 B Pressure 2 terminals
View Looking
Into 4-Way 3.9-4.1 Ohms
A TCC
Violet
Connector Across the
Tan Clutch
VB Bolt B (Grey) 2 terminals

Orange 3.9-4.1 Ohms

A High
Across the
Black
B Clutch
(Grey) 2 terminals

TCC (+) Violet Green Transfer 3.9-4.1 Ohms

6 A Clutch
Orange Tan Across the
High (+) 1 VB Bolt B (Green)
2 terminals
Green
1 2 3 Transfer (+) 5
Blue Blue 3.9-4.1 Ohms
4 5 6
2-4 (+) 4 A 2-4 Across the
Low (+) White Black Brake
B (Brown)
2 2 terminals
Yellow
View Looking L/R (+) 3
Into 6-Way
Connector 3.9-4.1 Ohms
White
A Low
Tan Clutch Across the
B (Brown)
VB Bolt 2 terminals

3.9-4.1 Ohms
Yellow
A L/R Across the
Black Brake
B (Grey) 2 terminals

Copyright © 2012 ATSG

Figure 8
12-10
Page 6 of 14
AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
SUMP FILTER AND INTERNAL WIRING HARNESS LOCATION

TFT SENSOR AND INTERNAL

WIRE HARNESS ASSEMBLY

306 00

306
00

306 00

O.E. Filter
part number 303
31728AA130 00

(Plastic)

00 304

00
305

44
0
00

00
2

00

00
T
O
S
O
K

00

M 00
A DE
IN 00
JA
PA 00 00
G

N
4
9
0
7
0
6
6

00
D
E
N

00
S
O

003 Valve Body Assembly

0

303 OIL FILTER RETAINING BOLTS, 10 MM (.393") (3 REQUIRED).

304 OIL FILTER ASSEMBLY.
305 OIL FILTER TO LOWER VALVE BODY "O" RING SEAL.
306 VALVE BODY BOLT, 45 MM (1.771") (13 REQUIRED).
Copyright © 2012 ATSG

Figure 9 12-10
Page 7 of 14
AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
LOWER VALVE BODY EXPLODED VIEW
00

00

306
306

307

310
ENSURE 316 IS
BELOW 332 OR
309 TEMP SENSOR
MAY LEAK
311
308
327 317
00

330
312
306
329
313 318 321
327 316
314
328 315
326 332
325
324
1.41 MM (.055")
317
00

318
300
320
2
T
O
S
O
K

MA
DE 44
IN
JA 0 322
PA
N
G
4
9
0
7
0
6
6

331
D
E
N
S
O

003
0

323

301

319

00

319

00
302

See Legend In Figure 11

Copyright © 2012 ATSG

Figure 10 12-10
Page 8 of 14
AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
FIGURE 10 LEGEND
LOWER VALVE BODY SPRING SPECIFICATIONS
300 LOWER VALVE BODY CASTING. SPRING NUMBER 324 SPRING NUMBER 329
301 VALVE BODY SPACER PLATE. Free Length = 1.150" Free Length = 1.900"
302 UPPER VALVE BODY CASTING. Spring Diameter = .351" Spring Diameter = .359"
303 OIL FILTER RETAINING BOLTS, 10 MM (.393") (3 REQUIRED). Wire Diameter = .046" Wire Diameter = .043"
304 OIL FILTER ASSEMBLY. Approx Coils = 13 (NONE) Approx Coils = 16 (NONE)
305 OIL FILTER TO LOWER VALVE BODY "O" RING SEAL.
306 VALVE BODY BOLT, 45 MM (1.771") (13 REQUIRED).
307 SOLENOID RETAINING BRACKET.
308 LOW CLUTCH DUTY SOLENOID.
309 TRANSFER CLUTCH DUTY SOLENOID.
310 TORQUE CONVERTER CLUTCH DUTY SOLENOID.
311 HIGH CLUTCH DUTY SOLENOID.
312 2-4 BRAKE DUTY SOLENOID.
313 LOW REVERSE BRAKE DUTY SOLENOID.
314 SOLENOID LARGE "O" RING SEAL (6 REQUIRED).
315 SOLENOID SMALL "O" RING SEAL (6 REQUIRED).
316 TRANS TEMP SENSOR RETAINING BRACKET.
317 VALVE BODY BOLT, 40 MM (1.575") (16 REQUIRED).
318 NUT FOR 52 MM VALVE BODY BOLT.
319 VALVE BODY BOLT, 52 MM (2.047") (2 REQUIRED).
320 VALVE BODY BOLT, 60 MM (2.362") (1 REQUIRED). Note: The Valve names are provided by ATSG
321 INTERNAL WIRE HARNESS RETAINER. and are based on valve function.
322 INTERNAL WIRE HARNESS RETAINER.
323 LINE PRESSURE CONTROL SOLENOID.
324 PILOT VALVE.
325 SPRING SHIM, 1.41 MM (.055") THICK.
326 SPRING.
327 RETAINER.
328 SPRING.
329 REVERSE BOOST VALVE.
330 BORE PLUG.
331 MANUAL VALVE.
332 INTERNAL HARNESS CONNECTOR RETAINER BRACKET.

Copyright © 2012 ATSG

Figure 11

12-10
Page 9 of 14
AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
UPPER VALVE BODY EXPLODED VIEW

399
398
397

394
391 396
390 393
389
395 400
392
388 400
385
387
386

385

333
302
334
335

381 339 336

382 340 337
344
378
338
384 383 341
348 345
375 342
379 346
372A
349
376 372
350
380 352
373
356 347 343
377 353 351
360 357 354
374 364
361 358
365 362
368
369 366 355
370 359

363
367

371

See Legend In Figure 13

Copyright © 2012 ATSG

Figure 12

12-10
Page 10 of 14
AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
FIGURE 12 LEGEND
302 UPPER VALVE BODY CASTING. 368 LOW CLUTCH DUTY SOLENOID ACCUMULATOR SPRING.
333 LINE PRESSURE BLOW-OFF BALL, 8.72 MM (.343") DIAMETER. 369 LOW CLUTCH DUTY SOLENOID ACCUMULATOR VALVE.
334 LINE PRESSURE BLOW-OFF BALL SPRING. 370 LOW CLUTCH DUTY SOLENOID ACCUMULATOR.
335 BLOW-OFF BALL SPRING RETAINER. 371 LOW CLUTCH DUTY SOLENOID ACCUMULATOR RETAINER.
336 REAR LUBE CHECK BALL, 8.72 MM (.343") DIAMETER. 372A TRANSFER CLUTCH CONTROL VALVE SPRING
337 REAR LUBE SPRING. 372 TRANSFER CLUTCH CONTROL VALVE.
338 REAR LUBE SPRING RETAINER. 373 TRANSFER CLUTCH CONTROL VALVE BORE PLUG.
339 LOCK-UP CONTROL VALVE SPRING. 374 TRANSFER CLUTCH CONTROL VALVE BORE PLUG RETAINER.
340 LOCK-UP CONTROL VALVE. 375 LOW/REVERSE BRAKE SEQUENCE VALVE.
341 LOCK-UP CONTROL BOOST VALVE. 376 LOW/REVERSE BRAKE SEQUENCE SPRING.
342 LOCK-UP CONTROL BOOST VALVE SLEEVE. 377 LOW/REVERSE BRAKE SEQUENCE SPRING RETAINER.
343 LOCK-UP CONTROL BOOST VALVE SLEEVE RETAINER. 378 LOW/2-4 RELAY VALVE.
344 TCC REGULATOR VALVE 2. (APPLY) 379 LOW/2-4 RELAY VALVE SPRING.
345 TCC REGULATOR VALVE 2 SPRING. 380 LOW/2-4 RELAY VALVE SPRING RETAINER.
346 TCC REGULATOR VALVE 2 BORE PLUG. 381 LOW/REVERSE BRAKE CONTROL VALVE SPRING.
347 TCC REGULATOR VALVE 2 BORE PLUG RETAINER. 382 LOW/REVERSE BRAKE CONTROL VALVE.
348 HIGH CLUTCH DUTY SOLENOID ACCUMULATOR SPRING. 383 LOW/REVERSE BRAKE CONTROL VALVE BORE PLUG.
349 HIGH CLUTCH DUTY SOLENOID ACCUMULATOR VALVE. 384 LOW/REVERSE BRAKE CONTROL VALVE BORE PLUG RETAINER.
350 HIGH CLUTCH DUTY SOLENOID ACCUMULATOR BORE PLUG. 385 STEEL CHECK BALLS, 5.53 MM (.217") DIAMETER (7 REQUIRED).
351 HIGH CLUTCH DUTY SOLENOID ACCUMULATOR RETAINER. 386 2-4 BRAKE SEQUENCE VALVE.
352 HIGH CLUTCH CONTROL VALVE SPRING. 387 2-4 BRAKE SEQUENCE VALVE SPRING.
353 HIGH CLUTCH CONTROL VALVE. 388 2-4 BRAKE SEQUENCE BOOST VALVE.
354 HIGH CLUTCH CONTROL BORE PLUG. 389 2-4 BRAKE SEQUENCE BOOST VALVE SLEEVE.
355 HIGH CLUTCH CONTROL BORE PLUG RETAINER. 390 2-4 BRAKE SEQUENCE BOOST VALE SLEEVE "O" RING SEAL.
356 2-4 BRAKE CONTROL VALVE SPRING. 391 2-4 BRAKE SEQUENCE BOOST VALVE SLEEVE RETAINER.
357 2-4 BRAKE CONTROL VALVE. 392 TORQUE CONVERTER/LUBE REGULATOR VALVE 1.
358 2-4 BRAKE CONTROL BORE PLUG. 393 TORQUE CONVERTER/LUBE REGULATOR VALVE 1 SPRING.
359 2-4 BRAKE CONTROL BORE PLUG RETAINER. 394 TORQUE CONVERTER/LUBE REG. VALVE 1 SPRING RETAINER.
360 2-4 BRAKE DUTY SOLENOID ACCUMULATOR SPRING. 395 LINE PRESSURE REGULATOR INNER VALVE.
361 2-4 BRAKE DUTY SOLENOID ACCUMULATOR VALVE. 396 LINE PRESSURE REGULATOR VALVE.
362 2-4 BRAKE DUTY SOLENOID ACCUMULATOR BORE PLUG. 397 LINE PRESSURE REGULATOR VALVE SPRING.
363 2-4 BRAKE DUTY SOLENOID ACCUMULATOR RETAINER. 398 LINE PRESSURE REGULATOR VALVE BORE PLUG.
364 LOW CLUTCH CONTROL VALVE SPRING. 399 LINE PRESSURE REGULATOR VALVE BORE PLUG RETAINER.
365 LOW CLUTCH CONTROL VALVE. 400 PLASTIC SCREENS (4 REQUIRED).
366 LOW CLUTCH CONTROL VALVE BORE PLUG.
367 LOW CLUTCH CONTROL VALVE RETAINER.

Note: The Valve names are provided by ATSG

and are based on valve function.

Copyright © 2012 ATSG

Figure 13

12-10
Page 11 of 14
AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
UPPER VALVE BODY SPRING SPECIFICATIONS
SPRING NUMBER 334 SPRING NUMBER 348,360 SPRING NUMBER 368 SPRING NUMBER 381
Free Length = 2.700" Free Length = 1.640" Free Length = 1.140" Free Length = 1.425"
Spring Diameter = .375" Spring Diameter = .322" Spring Diameter = .390" Spring Diameter = .328"
Wire Diameter = .062" Wire Diameter = .054" Wire Diameter = .062" Wire Diameter = .020"
Approx Coils = 24 (NONE) Approx Coils = 23 (NONE) Approx Coils = 12 (NONE) Approx Coils = 12 (NONE)

SPRING NUMBER 337 SPRING NUMBER 352 SPRING NUMBER 372A SPRING NUMBER 387
Free Length = 1.500" Free Length = 1.430" Free Length = .600" Free Length = 1.027"
Spring Diameter = .353" Spring Diameter = .331" Spring Diameter = .305" Spring Diameter = .352"
Wire Diameter = .038" Wire Diameter = .021" Wire Diameter = .027” Wire Diameter = .030"
Approx Coils = 12 (NONE) Approx Coils = 11 (NONE) Approx Coils = 12 (NONE) Approx Coils = 9 (NONE)

SPRING NUMBER 339 SPRING NUMBER 356 SPRING NUMBER 376 SPRING NUMBER 393
Free Length = 1.205" Free Length = 1.255” Free Length = 1.272" Free Length = 1.673"
Spring Diameter = .353" Spring Diameter = .331" Spring Diameter = .352" Spring Diameter = .355"
Wire Diameter = .031" Wire Diameter = .021" Wire Diameter = .030" Wire Diameter = .054"
Approx Coils = 10 (NONE) Approx Coils = 11 (NONE) Approx Coils = 10 (NONE) Approx Coils = 17 (NONE)

SPRING NUMBER 345 SPRING NUMBER 364 SPRING NUMBER 379 SPRING NUMBER 397
Free Length = 1.435" Free Length = 1.335” Free Length = 1.448" Free Length = 1.362"
Spring Diameter = .332" Spring Diameter = .331" Spring Diameter = .359" Spring Diameter = .431"
Wire Diameter = .035" Wire Diameter = .021" Wire Diameter = .046" Wire Diameter = .046"
Approx Coils = 14 (NONE) Approx Coils = 11 (NONE) Approx Coils = 18 (NONE) Approx Coils = 10 (NONE)

Figure 14
UPPER VALVE BODY, SMALL PARTS LOCATIONS
Reverse orifice
check ball

Screens
X (4 Required)
Low/Reverse Brake
exhaust check ball

Low/Reverse Brake
shuttle ball

Screens X
(4 Required) Line/Lube
check ball

Low Clutch 2-4 Brake

High Clutch
exhaust check ball exhaust check ball
exhaust check ball

= Steel Check Balls, 5.53 MM (.217") Diameter (7 Required)

X = No Check Ball
= Valve Retainer Locations Copyright © 2012 ATSG

Figure 15
12-10
Page 12 of 14
AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
VALVE BODY, bolt LOCATIONS

1 = 60 MM (2.362") (1 Required)
2 = 45 MM (1.771") (13 Required)
3 = 40 MM (1.575") (16 Required)
4 = 52 MM (2.047"), W/Nut (2 Required)
TEMP SENSOR BRACKET
REFER BACK TO FIGURE 10
FOR ASSEMBLY

3 3 3
3
4

1 2
3 3 3

3 2 2
3

2
2 2
3 3
3

3 2
3 2 2
4
2

0030

3 2
MADE IN JAPAN
DENSO 2 2
TOSOK

G4907066
2

Copyright © 2012 ATSG

Figure 16

12-10
Page 13 of 14
AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information

CASE AIR CHECK/OIL PASSAGE IDENTIFICATION

Pump Reverse Pump TCC TCC High To

Inlet Clutch Outlet Apply Release Clutch Cooler

2-4 Low L/R

Clutch Clutch Clutch Transfer
Clutch
Rear Lube
Press.

Copyright © 2012 ATSG

Figure 17 12-10
Page 14 of 14
AUTOMATIC TRANSMISSION SERVICE GROUP