Transmission Fluid Seepage – 2012-2020 Subaru

NHTSA ID Number: 10202815

Manufacturer Communication Number: 16-103-16R

Summary

This bulletin has been developed in response to a small number of customer concerns regarding fluid seepage found coming from the CVT assembly.

 

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NUMBER: 16-103-16R
DATE: 12/14/16
REVISED: 10/27/21

 

INTRODUCTION:

This bulletin has been developed in response to a small number of customer concerns regarding fluid seepage found coming from the CVT assembly.  Investigation has identified likely sources of the seepage to be the sealant used on the CVT’s oil pump chain cover and the input shaft oil seal.  The repair involves chain cover removal, a thorough cleaning and inspection of the sealing surfaces followed by re-sealing the cover and replacement of the input shaft oil seal with the new, redesigned type.

 

PRODUCTION CHANGE INFORMATION:

Model	Starting VIN
Legacy	L3002280
Outback	L3100230
Ascent	L3407153

 

The available starting VINS for incorporation of the new input shaft oil seal are supplied to the right.  This bulletin will be revised with the VINs for the remaining applicable models as they become available.

 

PART INFORMATION:

Description	Part Number
THREE BOND 1215	SOA868V9600
RING SEAL	31377AA510
RING SEAL	806916060
RING SEAL	31377AA550
OIL SEAL	806747030

 

SERVICE PROCEDURE / INFORMATION:

As a first step, during inspection of the customer’s concern, confirm the fluid found to be seeping is CVT fluid (CVTF) and not engine oil.  The photos below are examples of where CVTF seepage may be evident.

 

• Once the inspection has confirmed the seepage is CVTF, remove the CVT assembly following the procedure outlined in the applicable Service Manual.

• CAREFULLY remove the torque converter from the CVT and inspect the area of the oil pump chain cover as indicated in the photo below for any accumulation of CVTF and road dirt which may also have collected in the area.

 

NOTE:  A small amount of fresh CVT fluid may appear near the 6:00 position of the seal area during removal of the torque converter (GREEN circle).

 

Oil Pump Chain Cover Re-Sealing (TR690) & (TR580):

• Remove the 7- (TR690) or 10- (TR580) 12mm hex bolts securing the oil pump chain cover.

 

TR690 ONLY

Check the mating surface of the converter case cover for CVT fluid seepage.

 

• If CVT fluid is found leaking in this area, remove and re-seal the converter case cover. Refer to the “Converter Case Cover Re-Sealing” section of this bulletin. If NO CVT fluid is found leaking in this area, continue with the procedures for re-sealing the oil pump chain cover.

 

Converter Case Cover Re-Sealing (TR690 ONLY):

• Remove the 5 – 12mm hex bolts securing the converter case in a crossing pattern.

 

• Using a prying tool, CAREFULLY pry the cover loose. Pry ONLY on the specific areas or “tabs” of the converter case cover. Once the cover is loose, continue to pry only on the tabs and not the machined sealing surfaces.

 

• Remove and replace the two one-time use o-rings (806916060).

 

• IMPORTANT: Always confirm the front reduction drive gear shim stays with the converter case cover when removing and prior to re-installation.

 

• CAREFULLY remove all residual sealant completely from the cover and mating surface of the housing. DO NOT use any abrasive or gasket removal / cleaning discs. Use the adhesive side of a piece of duct tape (or equivalent) to pick up any loose pieces of sealant material which may be found in the cavity around the stator support. DO NOT use compressed air.
• Inspect both of the machined sealing surfaces closely for irregularities. If necessary, replace the cover following the applicable Service Manual Procedures.
• Remove and replace the one-time use o-ring (31377AA550).
• CAREFULLY apply the new sealant bead to the converter case cover along the edge of the chamfer as shown

 

NOTE: As shown above, a properly applied, small bead of sealant will fill in the chamfered portion after the cover is installed. Do not use an excessive amount of sealant.

• Install the converter case case cover. Install the 5 – 12mm hex bolts and torque to 24Nm (17.7 ft.lbs) in a crossing pattern.

 

Oil Pump Chain Cover Re-Sealing (TR690) & (TR580) Continued:

• CAREFULLY remove all residual sealant completely from the cover and mating surface of the housing. DO NOT use any abrasive or gasket removal / cleaning discs. Use the adhesive side of a piece of duct tape (or equivalent) to pick up any loose pieces of sealant material which may be found in the cavity around the stator support. DO NOT use compressed air.

 

• Take note of how the sealant on the removed cover forms an additional “seal” when it  becomes displaced into the chamfer around the inside edge of the case’s machined surface  at assembly.

 

• Inspect both of the machined sealing surfaces closely for irregularities. If necessary, replace the cover following the applicable Service Manual procedures.

NOTE:  Should the cover need to be replaced, always confirm the new part has the new-style input shaft seal with the additional side lip as described below before installation.

• IMPORTANT: Before reassembly, always replace the ONE TIME USE plastic sealing ring on the center support and thoroughly lubricate it with CVT fluid.
• Apply CVT fluid to the main seal lip only before installation.
• When installing this new seal, it is STRONGLY recommended to
  use the proper installer tool **OPTIONAL Special Tool 927890000 as shown in the illustration below. Otherwise, If the seal were to be installed too deep into the bore of the chain cover (beyond flush with the chain cover edge as shown below), the oil passage may become restricted or blocked.

 

• Once both surfaces and the area surrounding the cover are completely clean, dry and the new input seal is properly installed, CAREFULLY apply the new sealant bead to the cover along the edge of the chamfer as shown below.

 

NOTE:  As shown above, a properly applied, small bead of sealant will fill in the chamfered portion after the cover is installed.  Do not use an excessive amount of sealant.

• On the TR690, there are 2 different length bolts for the pump cover. Make sure the proper length bolts (A and B) are in their respective holes as shown below.  Torque to  24 Nm (17.7 ft. lbs) in a crossing pattern.

 

• For the TR580 (all 10 cover bolts are the same length), apply the sealer, (EXCEPT for the arrowed hole), reinstall the cover and torque the bolts to 21 Nm (15.5 ft. lbs.) in a crossing pattern.
• CAREFULLY reinstall the torque converter and the CVT assembly in reverse order of removal following the service procedure in the applicable Service Manual.
• Road test to confirm the repair and proper vehicle operation.

 

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48 Affected Products

Vehicles

MAKE	MODEL	YEAR
SUBARU	ASCENT	2019-2020
SUBARU	CROSSTREK	2013-2019
SUBARU	FORESTER	2014-2019
SUBARU	IMPREZA	2012-2019
SUBARU	LEGACY	2010-2019
SUBARU	OUTBACK	2010-2019
SUBARU	WRX	2015-2019

 

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1 Associated Document

Manufacturer Communications

NUMBER: 16-103-16R
DATE: 12/14/16
REVISED: 10/27/21

https://www.nhtsa.gov/recalls?nhtsaId=10202815

MC-10202815-0001.pdf 2325.461KB

 

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NHTSA ID Number: 10185062

Manufacturer Communication Number: 16-103-16R

Summary

This bulletin has been developed in response to a small number of customer concerns regarding fluid seepage found coming from the CVT assembly.

 

1 Associated Document

Manufacturer Communications

NUMBER: 16-103-16R
DATE: 12/14/16
REVISED: 12/01/20

https://www.nhtsa.gov/recalls?nhtsaId=10185062

MC-10185062-0001.pdf 1709.656KB

 

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NHTSA ID Number: 10165497

Manufacturer Communication Number: 16-103-16R

 

Summary

This bulletin has been developed in response to a small number of customer concerns regarding fluid seepage found coming from the CVT assembly. Investigation has identified likely sources of the seepage to be the sealant used on the CVT’s oil pump chain cover and the input shaft oil seal. The repair involves chain cover removal, a thorough cleaning and inspection of the sealing surfaces followed by re-sealing the cover and replacement of the input shaft oil seal with the new, redesigned type.

 

1 Associated Document

Manufacturer Communications

NUMBER: 16-103-16R
DATE: 12/14/16
REVISED: 09/26/19

https://www.nhtsa.gov/recalls?nhtsaId=10165497

MC-10165497-0001.pdf 1712.035KB

 

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NHTSA ID Number: 10164446

Manufacturer Communication Number: 16-103-16R

Summary

“This bulletin has been developed in response to a small number of customer concerns regarding fluid seepage found coming from the CVT assembly. Investigation has identified likely sources of the seepage to be the sealant used on the CVT’s oil pump chain cover and the input shaft oil seal. The repair involves chain cover removal, a thorough cleaning and inspection of the sealing surfaces followed by re-sealing the cover and replacement of the input shaft oil seal with the new, redesigned type”

 

1 Associated Document

Manufacturer Communications

NUMBER: 16-103-16R
DATE: 12/14/16
REVISED: 08/29/19

https://www.nhtsa.gov/recalls?nhtsaId=10164446

MC-10164446-0001.pdf 1711.978KB

 

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NHTSA ID Number: 10154206

Manufacturer Communication Number: 16-103-16R

Summary

This bulletin has been developed in response to a small number of customer concerns regarding fluid seepage found coming from the CVT assembly. Investigation has identified a likely source of the seepage to be the sealant used on the CVT?s oil pump chain cover. The repair involves removal, a thorough cleaning and inspection of the sealing surfaces followed by re-sealing the cover.

 

1 Associated Document

Manufacturer Communications

NUMBER: 16-103-16R
DATE: 12/14/16
REVISED: 01/08/19

https://www.nhtsa.gov/recalls?nhtsaId=10154206

MC-10154206-9999.pdf 1590.457KB

 

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