“Bump” Feeling from CVT at Idle in Drive – 2015-2017 Subaru

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Bulletin Number: 16-104-17R; Revised 05/30/17 Page 1 of 8 NUMBER: 16-104-17R DATE: 02/23/17 REVISED: 05/30/17 APPLICABILITY: 2015-2017MY Legacy / Outback 2.5 CVT Models 2015-2016MY Crosstrek Hybrid (HEV) SUBJECT: “Bump” Feeling from CVT at Idle in Drive CAUTION: VEHICLE SERVICING PERFORMED BY UNTRAINED PERSONS COULD RESULT IN SERIOUS INJURY TO THOSE PERSONS OR TO OTHERS. Subaru Service Bulletins are intended for use by professional technicians ONLY. They are written to inform those technicians of conditions that may occur in some vehicles, or to provide information that could assist in the proper servicing of the vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do the job correctly and safely. If a condition is described, DO NOT assume that this Service Bulletin applies to your vehicle, or that your vehicle will have that condition. SUBARU OF AMERICA, INC. IS ISO 14001 COMPLIANT ISO 14001 is the international standard for excellence in Environmental Management Systems. Please recycle or dispose of automotive products in a manner that is friendly to our environment and in accordance with all local, state and federal laws and regulations. Continued… SERVICE BULLETIN ATTENTION: GENERAL MANAGER q PARTS MANAGER q CLAIMS PERSONNEL q SERVICE MANAGER q IMPORTANT – All Service Personnel Should Read and Initial in the boxes provided, right. © 2017 Subaru of America, Inc. All rights reserved. INTRODUCTION: This bulletin provides a diagnostic procedure along with Transmission Control Module (TCM) reprogramming files to address isolated customer concerns of a “bump” feeling from the CVT. The bump feeling has been reported to occur after the CVT is fully up to operating temperature, in Drive and with the engine at idle. PRODUCTION CHANGE INFORMATION: The new TCM logic was incorporated into production starting with the following VINs: • 2017MY Legacy: H*046299 • 2017MY Outback: H*324232 PACK FILE APPLICABILITY: Model PAK File Name New TCM Part Number Old TCM Part Numbers Decryption Keyword New CID Number 2015MY Legacy 30919AD323.pak 30919AD323* 30919AD320, 321 &322 C7427FA5 F4F20082 2015MY Outback 30919AD333.pak 30919AD333* 30919AD330, 331 &332 4561EC13 F4F24082 2016MY Legacy 30919AF032.pak 30919AF032* 30919AF030 & 031 74977F60 E5F20081 2016MY Outback 30919AF042.pak 30919AF042* 30919af040 & 041 0082F1E2 E5F24081 2017MY Legacy 30919AF46B.pak 30919AF46B* 30919AF46A 05D465F6 D6F20080 2017MY Outback 30919AF47C.pak 30919AF47C* 30919AF47A & 47B 9D78B154 D6F24081 2015MY Crosstrek HEV 30919AE121.pak 30919AE121* 30919AE120 7A8EF1FD C4FA4081 2016MY Crosstrek HEV 30919AE641.pak 30919AE641* 30919AE640 B17A7137 B5FA4080 *NOTE: These New TCM part numbers are not currently available for order. In the meantime, if a replacement is needed, please use the current part number TCM for the VIN and update it with the corresponding pak file. Bulletin Number: 16-104-17R; Revised 05/30/17 Page 2 of 8 Continued… SERVICE PROCEDURE / INFORMATION: Overview: • After setting up the DST-i and SM4, perform the test procedure following the steps below to determine whether or not the bump condition exists. • If the bump condition is confirmed, variator damage has likely occurred requiring CVT assembly replacement. • Regardless of whether or not the bump condition is confirmed, after testing or repairs are complete, the TCM MUST be reprogrammed before releasing the vehicle to the customer. Preparation of SM4: • Connect the DST-i and start the SM4 application on the SDS PC. • From the Start menu, select “Diagnosis”. • Input (or confirm) the Vehicle information. • Select “Multiple System” from the Main Menu. • From the System List, select “Engine”, “Transmission”, and “Brake Control”. Bulletin Number: 16-104-17R; Revised 05/30/17 Page 3 of 8 Continued… • Select “Multiple active test”. • Select “Idle speed control”. • Select “OK”. • Always confirm the CVTF temperature is 176 degrees f. (80 C) or above. • Set the engine Idle speed to 850 rpm (950 rpm for Crosstrek HEV) using the up/down arrows then select “Start”. • Disconnect the Service Plug on Crosstek HEV following the Service Manual procedure and ALL cautions. Bulletin Number: 16-104-17R; Revised 05/30/17 Page 4 of 8 Continued… • Confirm the idle speed is about 850 rpm (950 for HEV). • Select “Combo Graph” • Select the following list of items: Engine speed Vehicle Speed Turbine Revolution Speed Primary Rev Speed Longitudinal G sensor (BC) • Perform the test following the flow chart and graph supplied below. CAUTION: Perform this drive testing only in a closed area (such as parking lot) away from other vehicle traffic and never on a public roadway due to the need to brake and hold position for 60 seconds during each test cycle. In addition, the use of a co-driver to either drive the vehicle or monitor the SM4 data during this testing is strongly encouraged. Bulletin Number: 16-104-17R; Revised 05/30/17 Page 5 of 8 Continued… START End Replace CVT assembly and reprogram the TCM. Is the “bump” condition confirmed? OR Is there abnormal signal found in the SM4 data? Perform the following test: 1. Accelerate the vehicle to approximately 10mph. 2. Stop the vehicle with approximately -.4g force and KEEP THE BRAKE PEDAL APPLIED FOR 60 SECONDS 3. after the vehicle comes to a stop. 4. Repeat steps 1 and 2 above a total of 5 times. Reprogram the TCM NO YES • While performing the testing above, determine if the “bump” condition can be confirmed and / or if the data graph shows any chain slippage. Examples of “OK” and “NG” graphs are supplied below for reference to help make a proper determination. Bulletin Number: 16-104-17R; Revised 05/30/17 Page 6 of 8 Continued… OK Shows no “bump”, chain slip or damage. NG Shows “bump”, chain slip, and variator damage. Replace CVT. • If the bump condition is confirmed, there is most likely variator damage requiring CVT assembly replacement. Follow the service procedure in the applicable Service Manual when replacing the CVT assembly is required. Shows “bump”, chain slip, and variator damage. Replace CVT. Bulletin Number: 16-104-17R; Revised 05/30/17 Page 7 of 8 Continued… VERY IMPORTANT REMINDERS: The FFD and / or SM4 Project File must be saved to qualify for a replacement CVT when determined necessary. Claims may be charged back for those that do not have these files saved and available to support their testing results when requested. The serial number found on the installed (replacement) unit must be entered in the Miscellaneous Detail field during claim entry for all replacement transmission assemblies. See Section 13.4.4 of the Policy and Procedure manual for more information. Regardless of whether or not the bump condition is confirmed, after testing or repairs are complete, the TCM MUST be reprogrammed following the procedure provided below before releasing the vehicle to the customer. • Reprogram the TCM using the SM4 following the normal FlashWrite procedure. Step 1: SOA now highly recommends connecting the Midtronics GR8 Diagnostic Battery Charger to the vehicle and utilizing the Power Supply Mode feature anytime a vehicle control module is being reprogrammed. Once the GR8 is connected to the vehicle, as long as the battery is fully charged, it takes less than 3 minutes to boot-up the charger, select the Power Supply Mode, and have the battery voltage stabilized and ready for reprogramming. VERY IMPORTANT: This information is applicable to the Midtronics GR8 Diagnostic Battery Charger ONLY. It does not apply to any other brand / type of “generic” battery charger whatsoever. ONLY the GR8 and its Power Supply Mode feature has been tested and approved by Subaru of America, Inc. (SOA). • If the GR8 indicates the vehicle’s battery must be charged, charge the battery using the GR8 before proceeding to reprogram the vehicle while using the Power Supply Mode. • Control module failures as a result of battery discharge during reprogramming are not a matter for warranty. Should any DTCs reset after the reprogramming update is performed, diagnose per the procedure outlined in the applicable Service Manual. Step 2: Using the SSM4, clear the AT Learning Data using the following procedure: • Start > Diagnosis > Vehicle Selection > Each System > Transmission > Work Support > Clear AT Learning Data. • Click “YES” and when “Execute Clear AT Learning” is displayed, click “YES” again. • Turn the ignition OFF, wait at LEAST 30 seconds then turn the ignition back ON. At this point, the AT Temp light will start blinking; 4 times in 2 seconds to signify the Clear AT Learning procedure has completed successfully. If the AT Temp light does not flash as described, repeat Step 2 again from the beginning. Step 3: Using the SSM4, perform the AT Learning Control following the procedure outlined in the applicable Service Manual. Bulletin Number: 16-104-17R; Revised 05/30/17 Page 8 of 8 IMPORTANT: The NEW Calibration Identification number (CID) for any newly-installed programming (as confirmed from the actual control module AFTER installation) MUST be noted on the repair order as this information is required for claim submission. NOTE: The pack file listings provided in this bulletin are the latest available at the time of publishing. Updates are often released thereafter without revision to the original bulletin. For this reason, it is critical to always have the latest version of Select Monitor software installed on your system. You can confirm if a later version is available by entering the CID listed in this bulletin into FlashWrite. If a newer CID is shown as available in FlashWrite, reprogram using that file. WARRANTY / CLAIM INFORMATION: For vehicles within the Basic New Car Limited or Powertrain Limited Warranty period or covered by an active Subaru Added Security Powertrain, Classic or Gold plan, this repair may be submitted using the following claim information: Labor Description Labor Operation # Labor Time / Model Fail Legacy/Outback Crosstrek HEV Code REPROGRAM TCM & AT LEARNING CONTROL FOR BUMP FEEL B860-733 0.7 0.8 MKK-25 CVT (NEW UNIT) REPLACEMENT FOR VERIFIED BUMP FEEL C303-003 4.2 3.9 CVT (REMAN UNIT) REPLACEMENT FOR VERIFIED BUMP FEEL C303-005 0.3 NOTE: C303-003 is complete and includes cooler flush, logging the serial number for claim submission, logging radio presets, and use of the engine hold tool. IMPORTANT REMINDERS: • SOA strongly discourages the printing and/or local storage of service information as previously released information and electronic publications may be updated at any time. • Always check for any open recalls or campaigns anytime a vehicle is in for servicing. • Always refer to STIS for the latest service information before performing any repairs.

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