Diagnosis and Repair of DTCs P172A and P0B0B – 2014-2015 Subaru XV Crosstrek Hybrid Electric Vehicle (HEV)

NHTSA ID Number: 10150950

Manufacturer Communication Number: 16-94-15R

Summary

This bulletin provides a diagnosis and repair procedure for DTC P172A and / or P0B0B. When either of these DTCs is stored, a leaking o-ring which seals the electric oil pump relief valve may allow CVT fluid to enter the pump?s electric motor. Although current Service Manual diagnostic procedures instruct replacement of multiple components, this information will help isolate the actual failed component for a more cost-effective repair. NOTE: The relief valve is now available as an individual part. If there is no damage to the drive motor case assembly, refer to TSB 16-108-17R for the parts needed and Service Procedure for replacing just the relief valve.

 

2 Affected Products

Vehicle

MAKE MODEL YEAR
SUBARU CROSSTREK 2014-2015

INTRODUCTION

This bulletin provides a diagnosis and repair procedure for DTC P172A and / or P0B0B.  When either of these DTCs is stored, a leaking o-ring which seals the electric oil pump relief valve may allow CVT fluid to enter the pump’s electric motor.  Although current Service Manual diagnostic procedures instruct replacement of multiple components, this information will help isolate the actual failed component for a more cost-effective repair.  NOTE: The relief valve is now available as an individual part. If there is no damage to the drive motor case assembly, refer to TSB 16-108-17R for the parts needed and Service Procedure for replacing just the relief valve.

 

PRODUCTION CHANGE INFORMATION

A change to the drive motor relief valve o-ring was incorporated into production on June 16, 2015 starting with VIN F*298545.

 

ADDITIONAL TOOLS REQUIRED:

  • Digital Voltage / Ohm Meter (DVOM) with test leads (1000v, CAT III)
  • ¼” drive T-25 or T-30 TORX bit for battery cover screws
  • Electrical tape to insulate power cable terminal ends (3- 2” long pieces of tape)
  • Personal Protective Equipment (Hybrid Safety Kit J-51311, ALWAYS check  the Expiration Date on Gloves)

 

DIAGNOSIS PROCEDURE / INFORMATION:

VERY IMPORTANT SAFETY WARNING: The HEV system includes a high-voltage circuit. Mishandling of HEV-related components may cause electric shock and serious personal injury. Technicians who have not received Subaru Hybrid training should NOT perform testing or  repairs related to the HEV system. **See Subaru Technician Reference Booklet, Module 702 (MSA5P1702C) for more HEV information.

NOTE:

  • Before starting the diagnosis procedure, use the SSMIII to confirm CVT fluid temperature is below 104 degrees F (40 C).
  • Turn the ignition OFF.

 

IMPORTANT:  The next steps require Personal Protective Equipment be  worn.

  • Remove the rear cargo area floor mat and the sub-trunk (storage tray).
  • Remove the orange HEV Service Disconnect plug and put it in your
  • Remove the TORX screws and necessary trim clips securing the aluminum battery
  • ONE AT A TIME, remove the 3 bolts securing the orange “W”, “V”, and “U” cables to the electric oil pump inverter. As each cable is removed, cover each terminal end with one piece of electrical tape to insulate it. Connect the RED (+) test lead from the DVOM to the “U” cable end and BLACK (-) lead to the “V” cable end as shown.  Confirm the “W”  cable end is wrapped with insulating tape.

cables to the electric oil pump inverter

  • Reinstall the orange HEV Service Disconnect
  • Turn on the DVOM and set it to measure AC
  • Start the engine and with the transmission in PARK, hold the engine at 1800
  • Read the AC voltage on the DVOM display and record your

NOTES:

  • The AT TEMP lamp will stay on because at this point, the power cables to the inverter are
  • Confirm the DVOM is properly set so it can measure and display the correct AC voltage (e.g. select 1000 VAC or “Auto Range” depending on the DVOM being used).

IF THE DVOM SHOWS 0.5V OR MORE: the o-ring and drive motor are damaged. The drive motor / case assembly must be replaced. Remove the CVT assembly following the procedure in the applicable Service Manual.

IF THE DVOM SHOWS LESS THAN 0.5V: the root cause of the DTC is elsewhere. Continue with the DTC diagnostic procedure in the applicable Service Manual.

NOTES:

If the DTC display history shows DTC P0C79: “DRIVE MOTOR “A” INVERTER VOLTAGE TOO HIGH”, check and record the freeze frame data of both the DMCM and TCM.  If P172A or P0B0B are also indicated during the same drive cycle, note that P0C79 is only indicated along with P172A and P0B0B.  Therefore, the Drive Motor Inverter has no problem and is operating normally.

IMPORTANT:  The next steps also require Personal Protective Equipment be worn.

REMINDER: Remove the (orange) Hybrid Service Disconnect plug again and put it in your pocket BEFORE reconnecting the Oil Pump Inverter power cables.

  • Re-connect the inverter power cables ONE AT A TIME and torque the 10mm bolts to 5.5 ft.
  • Replace the battery cover and torque the TORX screws to 5.5 ft.
  • Reinstall the sub-trunk and rear cargo area floor mat.
  • Reinstall the orange HEV Service Disconnect plug.

 

Required Parts List for Drive Motor Case Assembly Replacement:

DESCRIPTION QTY. PART NUMBER
CVTFII Fluid 13 SOA635304*
ThreeBond 1217B (Pink) 1 SOA635068
ThreeBond 1215 (Gray) 1 SOA635019
O Ring 1 806911080
Case Assembly-Motor 1 29019AA001
Bolt Assembly-Seal 2 31325KA151
Clip-Transmission Harness 1 31759AA060
Ring-Seal 2 31377AA600
Gasket 1 33295AA000
O Ring 5 806912200
O Ring 1 806912210
O Ring 2 806917100
O Ring 1 806929070
Hose-ATF 1 99079AA100
Hose-ATF 1 99079AA110
Circlip-CVJ 2 28333AG010
Oil Seal 1 806735300
Oil Seal 1 806735290
Ring Seal 1 31377AA490
Ring Seal 2 31377AA590
O Ring 1 806913250

*Warranty Claim Part Number (Not Orderable)

 

REPAIR PROCEDURE:

  • Remove the CVT assembly following the procedure outlined in the applicable Service Manual.
  • STOP HERE. 
  • If only the Oil Pump Relief Valve is being replaced, order the parts as listed in TSB 16-108-17R. (Always order the most up to date part numbers.) Proceed with the relief valve replacement Service Procedure as outlined in TSB 16-108-17R.
  • If the drive motor case assembly is damaged and requires replacement, order the parts listed above (Always order the most up to date part numbers.) and proceed with the remainder of the Service Procedure outlined in this bulletin, 16-94-15R. • Remove the electric oil pump assembly,

NOTES:

The bulk of this procedure is best performed with the transmission assembly standing vertically. Use the 4- 6M/T stands (S/T# 18632AA000) pictured below for support.

CVT assembly

 

  • The torque converter can also be left in place. Either support it from the underside after standing the unit up with a block of wood or use a retainer strap / bracket included with remanufactured and replacement transmission assemblies to keep the torque converter in place.

retainer strap / bracket

 

  • It is NOT necessary to remove the internal parking pawl control rod or the inhibiter switch assembly to perform this
  • There are 14 bolts securing the drive motor case assembly to the CVT main
  • Use extra caution during removal and installation of the electric oil pump wiring harness to avoid damaging
  • Always utilize a helper when removing and installing the drive motor case
  • The drive motor input shaft and coupling sleeve must be swapped over to the new Drive Motor Case assembly.

IMPORTANT: Before reassembling the cases, the following 3 measurements must be performed to determine the required thicknesses for:

  1. Output clutch roller bearing shim (Note measurement of removed shim(s) here)
  2. Transfer drive gear shim (Note measurement of removed shim(s) here)
  3. Transfer driven gear shim (Note measurement of removed shim(s) here)

1.   Output clutch roller bearing shim:

Steps 1 & 2:

  1. Remove the output clutch assembly. 

output clutch assembly

 

2) Measure the height “A” from the Gauge Block upper face to the ball bearing catch surface.

Gauge Block

Gauge Block

 

Steps 3:

3) Reinstall the output clutch assembly then measure the height “B” from the Gauge Block to the mating surface of the transmission case.

Gauge Block

 

4) Obtain the thickness of reduction driven gear shim using the following formula to select zero to three reduction driven gear shims.

T (mm) = A – B – (0.05 — 0.25)
[T (in) = A – B – (0.002 — 0.01)
T: Shim thickness
A: Height from the Gauge Block upper face to the ball bearing catch surface
B: Height from Gauge Block to transmission case mating surface
0.05 — 0.25 mm (0.002 — 0.01 in): Clearance

Reduction driven gear shim
Part No. Thickness mm (in)
33279AA090 0.3 (0.012)
33279AA100 0.4 (0.016)
33279AA110 0.5 (0.020)
  1. Transfer drive gear shim:

Step 1:

1) Measure the height “A” from the Gauge Block upper face to the ball bearing catch surface.

Gauge Block

 

Steps 2 and 3:

2) Measure the height “B” from the Gauge Block to the mating surface of the transmission case.

Gauge Block

 

3) Obtain the thickness of transfer driven gear shim using the following formula to select zero to three transfer driven gear shims.

T (mm) = A – B – (0.05 — 0.25)
[T (in) = A – B – (0.002 — 0.01)
T: Shim thickness
A: Height from the Gauge Block upper face to the ball bearing catch surface
B: Height from Gauge Block to transmission case mating surface
0.05 — 0.25 mm (0.002 — 0.01 in): Clearance

Reduction driven gear shim
Part No. Thickness mm (in)
33279AA090 0.3 (0.012)
33279AA100 0.4 (0.016)
33279AA110 0.5 (0.020)

 

  1. Transfer driven gear shim:

Step 1:

1) Install the transfer clutch assembly to the extension case with the transfer driven gear shims and thrust bearings removed.

 

transfer clutch assembly

Steps 2, 3, 4, and 5:

2) Install the thrust bearing to the transfer driven gear.

thrust bearing to the transfer driven gear

 

3) Using the Gauge Block, measure the height “A” from the ST end face to the thrust bearing catch surface of the transfer clutch assembly.

 

Gauge Block

 

4) Using the Gauge Block, measure the height “B” from the transmission case mating surface to the end of the Gauge Block

 

Gauge Block

 

5) Obtain the thickness of transfer driven gear shim using the following formula to select zero to three transfer driven gear shims.

T (mm) = A – B – (0.05 — 0.25)
[T (in) = A – B – (0.002 — 0.01)
T: Shim thickness
A: Height from the Gauge Block end face to the transfer clutch assembly thrust bearing catch surface
B: Height from mating surface of the transmission case to the end of the Gauge Block
0.05 — 0.25 mm (0.002 — 0.01 in): Clearance

 

Reduction driven gear shim
Part No. Thickness mm (in)
33279AA090 0.3 (0.012)
33279AA100 0.4 (0.016)
33279AA110 0.5 (0.020)

 

Gauge Block

 

Once all of the proper shim thicknesses have been determined, proceed with reassembly following the procedure outlined in the applicable Service Manual.

REASSEMBLY NOTES:

  • When installing the secondary pressure sensor and inspection plugs, ALWAYS install a new o-ring (with some CVT fluid applied to it) and follow the proper torque specifications as they do
  • Remember to transfer both of the oil baffles shown below over to the new assembly.

oil baffles

 

  • Never expand the output clutch output shaft interlocked split sealing rings any more than necessary to get them onto the shaft. Use caution and patience as they can be tricky to install. NOTE: If these sealing rings become deformed during installation, they MUST be replaced.

split sealing rings

 

IMPORTANT: BEFORE applying any sealer to the cases, always trial fit them together to confirm proper spline alignment between the coupling sleeve, the drive motor input shaft and the primary pulley. The cases are too close together to facilitate turning the primary pulley retaining nut to get the splines aligned properly, especially when there is fresh sealer applied.

confirm proper spline alignment

 

  • Once proper spline alignment is confirmed, use some CVT fluid to hold the 6 o-rings in place between the cases during reassembly.

use some CVT fluid to hold the 6 o-rings in place

 

  • Use the GRAY ThreeBond sealer (004403007) to seal the case assemblies and the PINK (K0877YA020) sealer for the small output clutch control valve body fluid pan.
  • Torque the 14 case bolts to 18.4 ft.
  • Never twist the electric oil pump harness more than 360 degrees to avoid damaging it.


NUMBER: 16-94-15R
DATE: 07/30/15
REVISED: 07/09/18

https://www.nhtsa.gov/recalls?nhtsaId=10150950

https://static.nhtsa.gov/odi/tsbs/2018/MC-10150950-9999.pdf

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NUMBER: 16-94-15R
DATE: 07/30/15
REVISED: 07/09/18

https://www.nhtsa.gov/recalls?nhtsaId=10150925

https://static.nhtsa.gov/odi/tsbs/2018/MC-10150925-9999.pdf

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