“This site contains affiliate links for which OEMDTC may be compensated” |
NHTSA ID Number: 10205932
Manufacturer Communication Number: Subaru TechTips
Summary
Special edition, transfer clutch system diagnostics consolidated.
ARTICLES CONTAINED IN THIS ISSUE
Click on a title below to jump to the article.
Click the date located in the footer to return to page 1.
CODE APPENDIXES…………………………… PAGE
(01) Diagnostic Trouble Chart …………………. 3
(02) Appendix A: How to Enter/Exit Front .
Wheel Drive (FWD) mode using
the SSM4…………………………………………..4
(03) Appendix B: Setting up – Transfer Clutch
Pressure test ……………………………………6
(04) Appendix C: Disassembly and .
Identification…………………………………….9
(05) Appendix D: Transfer Clutch, Transfer .
Reduction Gear Shaft, and Rear Drive .
Shaft Inspection………………………………10
(06) Appendix E: Installed Height .
Measurements and Installation
Press Etiquette and Craftsmanship .
Damage…………………………………………..13
1 Affected Product
Vehicle
MAKE | MODEL | YEAR |
SUBARU | SUBARU | 9999 |
1 Associated Document
Manufacturer Communications
TIPS_SE_Dec2021
Transfer Clutch System Diagnostics Consolidated Special Edition Newsletter
https://www.nhtsa.gov/recalls?nhtsaId=10205932
MC-10205932-0001.pdf 5591.789KB
- 【Easy to Use--Work out of box】+【FOXWELL 2024 New Version】 FOXWELL NT604 Elite scan tool is the 2024 new version from FOXWELL, which is designed for those car owners who want to figure out the cause issue before fixing the car problem via scanning the most common systems like abs srs engine and transmission.The NT604 Elite diagnostic tool comes with latest software, which can be used out of box. No need to waste time to download the software first.
- 【Affordable】+【Reliable Car Health Monitor】 Will you be confused what happen when the warning light of abs/srs/transmission/check engine flashes? Instead of taking your cars to dealership, this foxwell scanner will help you do a thorough scanning and detection for your cars and pinpoint the root cause. It will t-urn off the warning light car after the problem is fixed.👉TIPS: Airbag crash/collision data can NOT be cleared even you replace the new airbag.
- 【5 in 1 Diagnostic Scanner】Compared with those auto scanners (50-100), NT604 Elite code scanner not only includes their OBDII diagnosis but also it can be an abs/srs scanner, transmission and check engine code reader. When it’s an odb2 scanner, you can use it to check if your car is ready for annual test through I/M readiness menu. In addition, live data stream, built-in DTC library, data play back and print, all these features are a big plus for it.
- 【Fantastic AUTOVIN】+【No extra software fee】Through the AUTOVIN menu, this NT604 Elite car scanner allows you to get your V-IN and vehicle info rapidly, no need to take time to find your V-IN and input one by one. What's more, the NT604 Elite abs srs scanner supports 60+ car makes from worldwide (America/Asia/Europe). You don’t need to pay extra software fee.
- 【Solid protective case KO plastic carrying bag】+ 【Lifetime update】Almost all same price-level obd scanner diagnostic tool only offers plastic bag to hold on the scanner.However, NT604 Elite automotive scanner is equipped with solid protective case, preventing your obd2 scanner from damage. Then you don’t need to pay extra money to buy a solid toolbox.
- 2024 Top Choice for ABS Bleeding Scan Tool - Is the brake pedal always slowly sinking down or becoming loose? This ABS brake bleeding scan tool will achieve a tight brake pedal to solve the issues you encountered. It's the most affordable obd2 scanner with ABS auto bleed. Coverage check before purchasing via FOXWELL official site: Support- Diagnostic Coverage List. Tip: It won't work on vehicles lacking an auto bleed function.
- More Than a Entry Level OBD2 Scanner - Based on the NT301 FOXWELL Scanner, NT630 Plus takes OBD-II diagnostics to the next level by customizing functions for ABS and SRS system. This SRS and ABS scanner provides in-depth insights on error code diagnosis, wheel speed sensor, airbag circuits, cable connectors monitor, etc... Note: This scanner DOES NOT work on Airbag crash data/programming issues.
- No More Higher End Service than You Need - One NT630 Plus is enough! This obd2 scanner with ABS and SRS takes in-depth diagnosis on Anti-Lock Brake System & SRS/Airbag, and also performs Airbag light reset/ SAS(Steering Angle Sensor) adjustment/ Oil light reset daily reset services. These issues will be restored after the car faults repaired. Note: Reset service will be vary on different car makes and models, please confirm the coverage before purchasing.
- Also can Work like NT301 - The NT630 Plus ABS code reader can connect to the OBD-II port directly. It will diagnose all OBD-II modules instantly, displays the live data, locates bad sensors and indicate I/M readiness status before the annual inspection. Reducing the potential driving risk and keep a peak performance on the road.
- Higher-level Services wih Lower Cost - Cost less to own a ABS SRS Bidirectional Scan Tool that is not found on similar code readers & scan tools. This car diagnostic scanner allows you to test all potential car faults in the ABS/Airbag system, with functions returning to normal once you exit the program. Please note, that only ABS/SRS modules are supported.
- [Transform Your Car Care Experience] - With BLCKTEC, instantly become your own professional mechanic. Effortlessly read and clear your car’s trouble codes and check engine light, ensuring your vehicle stays in top condition.
- [Empower Yourself with Comprehensive Diagnostics] - Unlock the full potential of your vehicle with the BLCKTEC 430. Access detailed diagnostics previously exclusive to professional mechanics’ OBD2 scan tools, including ABS, Airbag, SRS, TPMS codes, and beyond, right at your fingertips.
- [Drive with Confidence] - The BLCKTEC 430 is more than just a car code reader; it's your personal vehicle health advisor. Receive tailored repair reports with potential causes and verified solutions for your specific make and model, guiding you to the right fix every time.
- [Seamless Connectivity, Ultimate Convenience] - Experience the freedom of wireless diagnostics with this portable car scanner. Easily connect via Bluetooth to our intuitive sensor, and enjoy all the functionalities of high-end scan tools without the clutter of wires, directly from your smartphone or tablet.
- [DIY Repairs Made Easy] - Navigate car maintenance with ease using our premium app. Access a vast library of easy-to-follow repair videos, guiding you through each step of the repair process, compatible with both iOS & Android devices.
- 🎉【2024 Upgraded Ver. of AL519/ ML519/ ML619】Autel develops the brand-new AutoLink AL619 as the advanced ver. of Autel ML519, AL519, AL319, MS309. This AL619 OBD2 scanner can scan ABS & SRS systems, and support 10 Modes of OBD II Diagnostics Function on Worldwide Vehicles to read, erase codes and turn off the MIL, ABS, SRS warning lights so that you can better maintain your car when related malfunctions occur and make your vehicle ready for the annual test.🚦📢Kindly note: AL619 only supports 2015 or pre-2015 cars. And services are not universal, please send us your car VIN# to check the compatibility before ordering.📩Autelonline @ outlook . com📩.
- 🎉【Accurate ABS/ SRS Diagnostics Functions】The ABS/ SRS diagnostic function is used to retrieve and clear codes from the ABS/ SRS systems. It can read and clear DTCs, show definitions of each code, display live data of multiple sensors in the graph to locate fault causes, and assist home mechanics to do the proper repair and clear ABS & Airbag warning lights. Diagnoses ABS/ SRS system codes on most 1996 and newer major vehicle models. Please email 📩 immoautel @ outlook. com 📩 for help.
- 🎉【All 10 Modes of OBD II Diagnostics Function】The OBD II Diagnostics function is a fast-access option that allows you to carry out a quick test on the engine system of OBD II vehicles. Read Codes, Erase Codes, Live Data, Freeze Frame, Retrieving I/M Readiness Status, O2 Monitor Test, On-Board Monitor Test, DTC Lookup, Component Test, Viewing Vehicle Information, Modules Present.
- 🎉【Live Data and Freeze Frame Data】With Live Data functions, Autel AL619 OBD2 diagnostic code reader allows you to view the live PID (Parameter Identification Data) of the vehicle's computer module(s) in text, graph to check the status of various sensors. And Freeze Frame Data enables you to view the vehicle's operating parameters at the moment a DTC is detected. These information will aid the technician by allowing the parameters to be duplicated for diagnostic and repair purposes.
- 🎉【DTC Lookup Feature】Besides showing you the code’s definition while you are reading the diagnostic trouble codes, AL619 features comparably user-friendly DTC Lookup Function which enables you to retrieve the definitions of any error codes from the large database of AL619, saving you from the hassle of wasting time searching definition of every code via Google.
- [ABS & SRS Scanner with Active Test] The ABS/ SRS diagnostic tool Read & clear DTCs, displays live data in a graph to locate the cause of faults and assists the home mechanic with repairs and clearing ABS and airbag warning lights. Active test sensors, valves or solenoids etc. and tracks any threats in real time. It is invaluable to have a diagnostic tool with Active Test feature that you will never find on similar ABS/ SRS scanners.
- 【3 HOP Reset Services 】Easy to set up 3 regular reset services for Oil Light, Battery Management System, and Steering Angle Position. With this obd2 scanner, you can reset the oil service light and reset pre-programmed mileage intervals for energy efficiency; adjust or reset the steering angle position to keep steering aligned; and clear the original low battery fault information. No need to leave home for shop-quality car maintenance.
- 【All OBD2 Test Modes 】 This ABS & SRS scan tool is also a full featured obd2 code reader, allowing a quick test of the engine system of OBD II vehicles, can Read/Clear engine light codes, Live Data, Freeze Frame, Retrieving I/M Readiness Status, O2 Monitor Test, On-Board Monitor Test, Evap Test, Read Vehicle Information, and help pass smog test for most post-1996 OBD2/CAN vehicles.
- [DTC LookUp Library] Can't read the code? Go to the DTC LookUp Library. The Topdon AL600 OBD2 scanner offers a wealth of code definitions so you don't have to look them up in a list or database, and the HELP function takes you to diagnostic tips for possible fixes, saving time searching for repair materials online. No other scan tool or code reader under $100 offers this level of assistance.
- [User-Oriented] You'll love the feel of this automotive scanner, with black rubber grips all around the outer edges for durability and to withstand accidental drops. With its easy access menu, you can operate all functions in minutes with just a few button presses. The 3-color LEDs give you a intuitive indication of the OBD2 test results in a second. 3 shortcut keys, one key to read/clear DTCs and a one-touch smoke status check make it easy to use even for beginners.
- The VD500 OBD2 scanner is specifically designed to diagnose Volkswagen Group (Fits for VW/Audi/Skoda/ SEAT) 12-volt 16-pin vehicles, but can also be used with other 12-volt (non-Volkswagen) and light trucks (non-electric) vehicles manufactured in 1996 or later that are OBD II -compliant with standard 16-pin OBD II protocols (J1850 VPM, J1850PWM, ISO9141, KWP 2000 and CAN).
- For Volkswagen (VAG) vehicles diagnostics, the device can not only read and clear codes on engine, ABS, transmission, SAS (not all cars), ESP, TPMS and other systems, but also reset the oil, brake pad and throttle position adaption.
- For other OBD II vehicles (non-Volkswagen), the VD500 can read and clear fault codes, display fault code definitions, turn off the CEL (check engine light) and retrieve VIN information ONLY.
- The VD500 diagnostic offering for Volkswagen vehicles covers the following vehicles: fits for VW (CC, EOS, Golf, GTI, Jetta, Passat, Phaeton, Polo, Rabbit, Sharan, Tiguan, Touran, Touareg); fits for Audi (A3, A4, A6, A7, A8, A5, Q3, Q5, Q7, R8, RS3, TT, RS, RS5, S4, S6); fits for Skoda (Octavia, Rapid, Yeti, Kodiaq, Fabio, Superb); fits for SEAT (Leon, Ateca, Ibiza, Altea, Cushion, Cord, Alhambra) Diagnostics.
- With English and German as display languages, this diagnostic scan tool support costs nothing to lifetime software updates to fix the latest bugs or add new parameters. Simply download the software from the official website, then follow on-screen instructions to install it.
- [Pro OBD2 Scanner] - BlueDriver is the easiest way to scan and understand your vehicle like a professional mechanic. Read and clear your car’s trouble codes and check engine light.
- [Read & Clear All The Codes] - BlueDriver's enhanced vehicle diagnostics gives you access to information normally available only to mechanics on their OBD2 scan tools. Now you can read and clear ABS, Airbag, SRS, TPMS codes, and many more.
- [Get The Right Fix] - Much more than a car code reader, BlueDriver is a diagnostic tool. Get unlimited specific repair reports containing possible causes, reported fixes, and more for virtually every vehicle make and model.
- [Wireless & Bluetooth Enabled] - Say goodbye to wires. BlueDriver connects with Bluetooth via your phone/tablet to a sensor that plugs into your car's OBDII port. Get all of the capabilities of an expensive code reader & scan tool without any annoying wires.
- [User-Friendly App and Repair Videos] - BlueDriver gives you more ways to scan and fix your vehicle. Our iOS & Android app connects you to a large database of repair videos with step-by-step directions of repairs.
- 【Great Ideal For Every Car Owner】Prefect choice for your father, husband, brother or boyfriend. EVERY CAR OWNER WILL NEED IT! Also, the lifetime f-ree update is provided for more vehicle coverage, bug fixes. SAVE AT LEAST $1000+ PER YEAR!Get LAUNCH CRP123 Elite car diagnostic scanner and give your lover a surprise!🎁Get the Extra Gifts :Protective Case Storage Bag,please reach us at: cardiag-aftersales @ hotmail.com.
- 【 Read & Clear/Reset Engine/ABS/SRS/Transmission Diagnostic Scan Tool 】LAUNCH CRP123 OBD2 Scanner can test Engine, Transmission, ABS and Airbag four systems, also reads and resets code, displays data stream graphic, stores and playbacks dynamic data stream,helps to quick analysis and diagnosis.
- 【 Error Fault Code Reader】Except the full 10 modes OBD2 diagnostic functions like, retrieving I/M readiness, Freeze Frame Data, Read Dynamic Data stream and V-ehicle Information, O2 Sensor Test, EVAP Test of F-uel Tank System (Mode 8) and Advanced On-board Monitoring (Mode 6), launch crp123 obd2 scanner can not only reveal what error codes your car is producing, but also erase your v-ehicle’s check engine light after problem fixed, the DTC help and explanation also tell you the exact problem.
- 【 Live Data Graphing + Read/Record/Playback Data stream + Print diagnostic data 】Live Data Graphing,more intuitive to know your vehicle’s problem.Large size Color Screen ;Print Function:Print the diagnose result easily; with user manual and register & update tutorial video uploaded in the link by us,you can Look up it anytime by ONE-CLICK.
- 【 Find Your Vehicles Here】Launch CRP123 obd2 scanner Supports mainstream vehicles on the world,fit for ACURA VW AUDI AUST FORD BENZ BMW CHRYSLER FIAT GM HOLDEN HONDA HYUNDAI INFINITI JAGUAR ISUZU KIA LANDROVER LEXUS MAZDA MITSUBISHI NISSAN OPEL PORSCHE SAAB SEAT SKODA SMART MERCEDES SPRINTER SUBARU SUZUKI SCION TOYOTA USA FORD VOLVO PEUGEOT CITROEN RENAULT EUROFORD.Etc.
- ABS/SRS OBD2 Scanner > Enjoy this ABS SRS OBD2 code reader to reveal exact issues underlying in your brake, airbag, and engine systems, test individual ABS/SRS sensors, valves, or solenoids to quickly locate malfunctions (compatible with GM, Nissan, Fiat, Benz, Volvo, Land Rover, BMW, USA Ford, please reach us for details.), making sure critical safety systems work in perfect harmony together against accidents to be safe than sorry. NOTE: Only support upgrade on windows.
- 3 Most Needed Service Functions > This TOPDON OBD2 scanner guides you through step by step procedures to reset oil service light and programmed mileage intervals for engine efficiency (Oil Reset); to calibrate steering wheel position for vehicle’s traveling in a straight line (SAS Reset); to clear the original low battery fault information against coming battery failures or damage (BMS Reset); saving your needless visits to mechanics. NOTE: Not suitable for all models, please reach us for compatibility.
- Full OBD2 Diagnostics > Say goodbye to the hassle of manual check-ups via this srs bi-directional code reader. Quickly correct Check Engine Light warning on most OBD2/CAN compatible vehicles. Easily access to your smog status with one simple click I/M Readiness; and being filled with features for live data readings, freeze frame data, plus EVAP system, onboard monitor test means this scan tool checks all daily car care boxes.
- Work Easier > Red-Yellow-Green LEDs in this OBD2 diagnostic scanner TOPDON Arilink600 quickly show the overall DTC status without toggling through menu selections. HELP hotkey takes you directly to detailed descriptions/tips. Read/Erase DTC, I/M readiness shortcuts are added for optimized operation, along with DTC Lookup library for interpreting codes, designing the SRS OBD2 reader diagnostic tool a pleasure to use right out of the package even for beginners.
- Helpful Service > Get instant, free lifetime access to the most recent updates to add new car models and troubleshooting bugs making the OBD2 scanner TOPDON AL600 a long-term investment for any home mechanics. The extended 1 years of quality assurance sweetens the worry-free deal even further. Multilingual Menu: EN, FR, ES, DE, IT, RU, PT, and JP. NOTE: Only support upgrade on windows.
- [OBD2 Scanner] The TOPDON OBD2 scanner performs all ENG/AT/SRS/ABS diagnostics with 4-in-1 graphic live data. 🚩It covers all OBD2 tests for 67 manufacturers and 10000+ model. It also features 5-second one-touch AutoVIN, 🚩a free one-touch lifetime upgrade through WiFi, library DTC, 12 languages, 🚩printable auto-generated report with email sharing, 🚩smooth Android 11.0, 32GB ROM, 🚩vivid 5-inch touchscreen, and up to 10 hours of battery life.
- [4 Car System Code Reader] The TOPDON OBD2 scanner accesses 4 systems: 🚩Engine/ABS/SRS/Transmission. It identifies the ECU version, pull DTCs with 4-in-1 graphic live data and DTC explanation to identify issues, erase DTCs to turn off the warning lights after repair (For cars made in 2005 and newer). In order to help you extend the lifespan of your vehicle while improving performance, this code reader also includes all obd2 test modes to solve the major concerns for all vehicles.
- [User-Oriented TOPDON OBD2 Scanner] With this scan tool's touchscreen and rubberized buttons, you may easily navigate through menus or process while following a logical path. With 32GB on-board memory, the scanner enables for the recording of several diagnostic reports, which can be shared via email and printed for review. Along with this, you can 🚩upgrade your software for free for lifetime with one-touch over Wi-Fi for that help update the features and expanding car coverage.
- [Multiple Functions] The Smart AutoVIN of this TOPDON OBD2 scanner keeps track of your manual selections for vehicle make, model, and year and directs you to the suitable diagnostics. 🚩Max 4 Live Data streams integrated for much easier data processing. Diagnostic feedback online with this diagnostic tool to help you get tough repair operations well-completed. Real-time car battery voltage monitoring identifies probable vehicle defects.
- [Wide Coverage] With its multilingual menu and 🚩coverage of 67 car brands and 10,000+ models spanning North America, Europe, and Asia (including Malaysia, India, and Iran), this car scanner is compatible with the majority of 1996 and newer OBDII compliant automobiles (EN, FR, ES, DE, IT, RU, PT, JP, KR). Before buying, make sure the OBD2 scanner is compatible with your vehicle. The package contains only a charging cable and not a power adapter.
Last update on 2024-06-30 / Affiliate links / Images from Amazon Product Advertising API
This product presentation was made with AAWP plugin.
SEOCONTENT-START
Subaru Service and Technical Support Line Newsletter The Subaru TechTIPS newsletter is intended for use by professional Technicians ONLY. Articles 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 your vehicle has or will have that condition. Impreza, Legacy, Justy, Loyale, Outback, Forester, Subaru SVX, WRX, WRX STI, Baja, Tribeca, BRZ, XV Crosstrek and “Quality Driven” are Registered Trademarks. 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. CAUTION: VEHICLE SERVICING PERFORMED BY UNTRAINED PERSONS COULD RESULT IN SERIOUS INJURY TO THOSE PERSONS OR TO OTHERS. SUBARU OF AMERICA, INC. IS ISO 14001 COMPLIANT The Subaru AWD system is a staple of our brand. Identifying a concern and addressing it correctly the first time is critical to servicing the vehicle right the first time. There have been many TechTIPs and service bulletins on this system in the past. This Special edition TechTIP will focus on the CVT transfer clutch system; both the TR690 and TR580. The document will help you determine if the concern is transfer clutch related or not. The transfer clutch unit is located at the rear of the CVT assembly in the extension housing. This system is considered serviceable on all CVT assemblies as per SOA Claims Policies and Procedures as well as shown in TSB 16-107-17R (multi-plate clutch system). Technicians repairing this area should have completed the CVT Web Based Training and Instructor Led Training to make this repair and have a strong understanding of transmission theory. Always duplicate the customer’s concern before making any repairs. The tires are a major component in the transfer clutch system. The transfer clutch applies power to the rear wheels to maintain traction. Originally posted in the December 2010 TechTIPs, the tire circumference difference should be no more than 6mm or ¼” of each other. This measurement is different than tread depth. This measurement should be made with all the tires at an equal pressure as found in the door jamb safety plate. If a tire is deformed or severely worn, it can be smaller than the opposing tire. This could result in transfer clutch damage. Tires that are mixed brands, size or even mismatched models can also potentially cause this concern. It is recommended to use a cloth tape measure to make this ©2021 Subaru of America, Inc. All rights reserved. CONTINUED ON THE NEXT PAGE home Click on a title below to jump to the article. Click the date located in the footer to return to page 1. SPECIAL EDITION Transfer Clutch System Diagnostics Consolidated Home Special Edition TechTIPS Page 1 of 16 measurement; typically, 120” in total length. A string can be substituted for the cloth tape measure and then marked and measured on the ground in a straight line if the string has no deflection (stretch). Be sure all tires match in terms of brand and type as even tires from the same brand listed as the same size can have some variation in circumference. A tread pattern difference can interfere with the system as well. All tires should have the same pattern. As an example, an Ascent with factory Falken Ziex tires and one or two Falken WildPeak replacement tires of the same size could experience a binding condition. Moving into the dianostic flow chart, the Technician will need the Subaru Select Monitor as well as the proper transmission pressure gauge. Avoid using aftermarket scanners and incorrect tools for the job. The secondary pressure gauge ST18801AA000 is not appropriate to measure transfer clutch pressure. This gauge will not provide enough detail to see a concern with the system. The proper gauge is displayed in Transmission/Transfer clutch pressure test and is typically ST498575400; the adapters required will vary per vehicle. Always follow the diagnostic steps outlined in STIS. It is good practice to document results on the repair order. There will be no confusion or repeat testing if the Technician needs to contact Techline. Please review Appendix B for Transfer clutch pressure testing. The transfer clutch pressure solenoid control is measured in two ways on Subaru vehicles. The older method is displayed on the SSM as Transfer Duty Ratio in a percentage. These vehicles will have the Technician raise the accelerator pedal opening angle until the Transfer Duty Ratio displays 60% and then read the gauge attached to the transmission. The newer method is displayed as AWD Sol Set Current in milliamps. It requires depressing the accelerator pedal until the current displayed is 600ma, then observing the gauge attached to the transmission. Special care should be taken when performing the test so it is done correctly. These tests are similar and can be easily mistaken or inaccurate. In addition, these tests should be performed at the CVT fluid temperatures specified on STIS, 60 – 80ºC (140 – 176ºF). Failure to perform testing correctly could lead to misdiagnosis. CONTINUED ON THE NEXT PAGE Special Edition TechTIPS Page 2 of 16 01 DIAGNOSTIC TROUBLE CHART CONTINUED ON THE NEXT PAGE Special Edition TechTIPS Page 3 of 16 02 APPENDIX A: HOW TO ENTER/EXIT FRONT WHEEL DRIVE (FWD) MODE USING THE SSM4 Following the example outlined below will help guide Technicians on the proper way to turn off the All Wheel Drive (AWD) system and enter FWD mode for diagnostic purposes. The example shown here is a TR690 CVT, and is the same for a TR580 CVT. The Subaru Select Monitor 3 will look similar and operate the same for 2014 and older CVT models. This mode will need to be activated in the vehicle while stationary, Key On Engine Off (KOEO). Once the SSM is connected to the vehicle, select Diagnosis -> Each System -> Transmission. CONTINUED ON THE NEXT PAGE Special Edition TechTIPS Page 4 of 16 APPENDIX A: HOW TO ENTER/EXIT FRONT WHEEL DRIVE (FWD) MODE USING THE SSM4 (CONTINUED) 02 The SSM will prompt the Technician to confirm the vehicle is stationary, and the ignition switch is on. Select OK. The SSM will now prompt the change in drive mode. Select Yes. The vehicle will now “ding”, and warn the operator on the combination meter of the change to the drive mode as shown below. The yellow warnings indicate the AWD system is disabled. Now start the vehicle and continue through the diagnostic trouble chart. When diagnostics are complete, the vehicle must re-enter AWD mode. Complete the same mode selection in Work Support to complete this. CONTINUED ON THE NEXT PAGE Special Edition TechTIPS Page 5 of 16 CONTINUED ON THE NEXT PAGE 03 APPENDIX B: SETTING UP TRANSFER CLUTCH PRESSURE TEST This Appendix will cover the testing of the transfer clutch pressure. Transfer clutch pressure is controlled by the transfer clutch solenoid inside the valve body. It is important to make this measurement during testing because if the solenoid has failed; the pressure could be zero or extremely high depending on the failure. First set the vehicle up safely on the lift. Prepare the scan tool for use by extending the cords and connecting to the vehicle’s OBD port. This measurement will require the vehicle to be warmed up. Be extremely careful working around the exhaust and hot transmission fluid. Some transmissions will require a special adapter tool to gain access to the transfer clutch pressure testing port. These are essential tools. If the retailer does not have them, they are available from the Special Tool and Equipment site on Subarunet. Next, prepare the Transfer clutch pressure gauge. Do not drop the glass-faced gauge, as this will cause damage. Do not use too small of a gauge, as doing so will ruin it’s calibration. Each retailer was provided a pressure gauge that goes to 300 or 600 PSI. Transfer clutch pressure is significantly less pressure than secondary line pressure. The correctly scaled gauge will need to be used to perform this test and provide an accurate reading. Here are some pictures of acceptable gauges. The gauge on the LEFT is the correct gauge. The gauge on the RIGHT is for secondary pressure and must NOT be used for this test. Special Edition TechTIPS Page 6 of 16 CONTINUED ON THE NEXT PAGE 03 APPENDIX B: SETTING UP TRANSFER CLUTCH PRESSURE TEST (CONTINUED) Here are pictures of the transfer clutch pressure gauge set up with the required adapters to achieve installation on a TR690. Insert the hex bit into the correct CVT access plug. Using the extension, remove the plug. Be careful of hot CVT fluid. The TR580 is similar depending on what vehicle it is installed in. Always refer to STIS->Transmission->Transfer clutch pressure test, for the required vehicle tools. Remember, the copper sealing washers are one time use and cannot be reused. Depending on the gauge being used, there may be an additional hydraulic adapter. Once the gauge is properly installed, start the engine, and check for leaks. Next, warm the CVT fluid up to 60-80C (140-176F). Connect the SSM scan tool and begin to document pressures on the repair order. The air conditioning system should be turned off. X-mode should be turned off. Pre-collision braking should be turned off. Always chock the wheels for safety. Special Edition TechTIPS Page 7 of 16 CONTINUED ON THE NEXT PAGE 03 APPENDIX B: SETTING UP TRANSFER CLUTCH PRESSURE TEST (CONTINUED) On the SSM4, enter Each System ->Transmission ->Data monitor. Select ALL the available PIDs to the right side of the screen. Activate Data Monitor. The transmission fluid should be between 140F and 176F. Accelerator Pedal Position will need to be displayed and the vehicle specific transfer clutch PID Transfer Duty Ratio OR AWD Sol Set Current (covered on page 1 of this document). The transfer clutch pressure idling in park should be zero. Move the selector to Drive with the foot brake firmly applied. Be sure all other personnel are safely away from the vehicle. The parking brake cannot be set for this test. The the wheel chocks are for safety. The test can be done in the air if needed, but it is important to keep brake pedal pressure applied during the whole test. Watch the Transfer Clutch Solenoid PID. With the brake pedal applied, in Drive, slowly press on the accelerator pedal until the duty cycle is at 60% or 600mA. At the desired point, observe the pressure gauge and document the result. Example A: 600mA is reached on a 2020 outback XT and the transfer clutch pressure is 75psi; this passes the test as per specifications according to STIS. Example B: select Drive on a 2020 outback XT and the transfer clutch pressure instantly reaches 200 psi and will not go down until Park is selected. This is a failed test. Lastly, perform the same test in Drive, at WOT (wide open throttle). Keep pressure on the brake and apply the throttle quickly and hold it just long enough to get a stable reading on the gauge. Be careful not to overheat the CVT fluid. Document the result and review the vehicle specifications on STIS. If the results are within specification, seek authorization to inspect the transfer clutch assembly. Example of the gauge display at 60% duty cycle or 600mA=50-80psi Example of the gauge display at WOT =150-180PSI Special Edition TechTIPS Page 8 of 16 CONTINUED ON THE NEXT PAGE 04 APPENDIX C: DISASSEMBLY AND IDENTIFICATION The transfer clutch system is made of multiple components that look very similar to one another. This section will help identify the components and their relationship to each other. Once the extension housing assembly (22) has been CAREFULLY removed; the rear drive shaft (16) splined into the transfer clutch assembly will now be visible. The clutch pack turns the rear drive shaft drum and shaft to apply power to the rear wheels. The transfer reduction drive gear can be seen, which will typically be stuck into the extension housing. This is normal. It will need to be inspected and clean to be sure no excess sealant gets into the bearing. Next, remove the reduction drive gear shaft (6). This houses the transfer clutch assembly. Set this component to the aside for inspection. Be sure to inspect all roller bearings for debris or physical damage. They should be clean and rotate smoothly. If they are not pressed off the transfer reduction driven gear, the assembly can be reused. The transfer clutches are identified as item number (14). The first component is the snap ring (15). This will be removed to gain access to the selective thickness pressure plate. Beneath that is a series of alternating steels and fictions for a total of twelve plates (six of each), and finally another pressure plate (13). The friction discs should be inspected for heat marks, burnt spots, and missing or patchy areas. These components should be ordered as a selectable set which will be covered in Appendix D. Special Edition TechTIPS Page 9 of 16 04 APPENDIX C: PARTS REMOVAL AND IDENTIFICATION (CONTINUED) Beneath the transfer clutches is the piston assembly. This piston receives the transfer clutch pressure and applies the clutch when power transfer is needed. This assembly should never be coated in any chemical other than CVTF. No transmission grease should be applied. The piston assembly has a special tool to lightly compress it. Only compress the spring (10) enough to remove the snap ring. Full compression will damage the spring and it will need to be replaced. The clutch piston seal (11) should be inspected for wear. The direction of these components should be noted. Be aware that any component marked with a black star ( ) is a one-time use component. If removed or pressed off another component, this is considered used. This includes 1,2,17,18,20, and 23. If the transfer reduction drive gear is replaced, the bearing (2) will need to be replaced along with the three sealing rings (1). Any component with the black circled is a selectable component and STIS will need be consulted on what measurements to make (7,13, and 21). APPENDIX D: TRANSFER CLUTCH, TRANSFER REDUCTION GEAR SHAFT, AND REAR DRIVE SHAFT INSPECTION 05 Inspection of the transfer clutch assembly after tear down is critical for fixed right the first time. These are held inside the larger drum like component, (6) on the component image shown in Appendix C. First, measure the transfer clutch clearance. This will require a feeler gauge. This check should be done with an offset gauge for best results. Insert the feeler gauge just under the snap ring starting with the smallest clearance. Pull up on the opposite side of the feeler gauge to help it insert smoothly and parallel to the disc. Always refer to STIS for the proper specifications. This example is from a 2020 Ascent, TR690. Start with the smallest measurement to determine if the end gap is too tight or too small. Ideally it should be near the middle of the specification, in this case 0.7mm – 1.2mm, the ideal measurement is 0.9mm – 1.0mm. The picture shown below on the left is using a 45° feeler gauge and the picture on the right is using a 90° gauge. Both are acceptable and will provide the desired result. If the transfer reduction gear shaft is replaced, this measurement should be made with all new components installed. Then, the desired selectable plate at the top should be ordered. Measure the original selectable plate as a reference when ordering selectable parts. When the reduction gear shaft is new, it is necessary to measure the transfer clutch end gap. This will be done by installing the original bottom selectable plate. Then, install the new transfer clutch pack set in alternating fashion. Finally, install the new selectable pressure plate. Install the snap ring and perform the gap measurement. If the measurement is too tight or too loose, the Technician will need to order a different selectable transfer clutch set. The bottom selectable pressure plate can be replaced if a significant change is needed. Special Edition TechTIPS Page 10 of 16 APPENDIX D: TRANSFER CLUTCH, TRANSFER REDUCTION GEAR SHAFT, AND REAR DRIVE SHAFT INSPECTION (CONTINUED) 05 Next, remove the snap ring. Be sure to use the appropriate tools as this is reusable. The snap ring has storing energy under tension, always have safety glass on and the proper PPE. After the snap ring is removed, start to remove the transfer clutches. Remove the top selectable pressure plate. This plate will need to be measured with a caliper to determine the stack set size. Next, inspect the alternating friction and steel plates until the bottom pressure plate is reached. Remove it and clean the drum. Using a flashlight and fingernail, inspect the inside of the “drum” looking for very tiny teeth marks. This is where the transfer clutches can damage the drum. The red arrows show the first major scoring found. This component is now considered damaged and should be replaced. Special Edition TechTIPS Page 11 of 16 APPENDIX D: TRANSFER CLUTCH, TRANSFER REDUCTION GEAR SHAFT, AND REAR DRIVE SHAFT INSPECTION (CONTINUED) 05 Next, inspect the rear drive shaft hub. This component slides inside the transfer clutches and is turned by the assembly. The transfer clutches can mark the rear drive shaft hub. This component is also considered damaged and should be replaced. Special Edition TechTIPS Page 12 of 16 APPENDIX D: TRANSFER CLUTCH, TRANSFER REDUCTION GEAR SHAFT, AND REAR DRIVE SHAFT INSPECTION (CONTINUED) 05 If the reduction gear shaft or the rear drive shaft are replaced, there are measurements that will need to be done to correct the installed heights of the components. This will ensure the components do not fail prematurely. This will be covered in Appendix E. If the transfer gear reduction shaft is being replaced, it will need to have the bearing pressed off to remove the gear and parking pawl gear. Technicians have called into Techline to report finding rust under the parking pawl and gear assembly. This condition is normal and not detrimental to the operation of the gearset unless there is shaft or spline damage. The rust can be cleared off with a simple brush. Do not use air or pneumatic tools to clean the component. The gear set will need to be transferred to the new components. The gear set should fit smoothly, with a minimal amount of movement. The new bearing is then pressed on until it touches the ledge on the shaft. There may be a minimal amount of slack to allow the parking pawl to mesh. 06 APPENDIX D: INSTALLED HEIGHT MEASUREMENTS AND INSTALLATION When replacing the rear drive shaft or bearing, it is necessary to make the installed height measurements. First, measure down the rear drive shaft center lip. NOTE: it is extremely important to only measure to the center of the drum where there is a machined lip. Below are pictures demonstrating this measurement compared to STIS (A) compared to the measurement made in the shop. Special Edition TechTIPS Page 13 of 16 06 APPENDIX D: INSTALLED HEIGHT MEASUREMENTS AND INSTALLATION (CONTINUED) Shown here is the installed height of the reduction gear shaft measurement. This measurement should be made with the transmission in the upright position and could require multiple special tools. Be extremely careful with the bridge, it should never be dropped. Set the bridge up as shown below for the measurement. The reduction gear shaft should be fully assembled for this measurement. Measure the depth of the case from the bridge. If the caliper is not tall enough to make this measurement, you can use special tool block from the previous step to assist. Remember you will need to add the tool block thickness to the measurement for a total value (B). Special Edition TechTIPS Page 14 of 16 06 APPENDIX D: INSTALLED HEIGHT MEASUREMENTS AND INSTALLATION (CONTINUED) Finally, measure the center height of the reduction gear shaft drum from the bridge tool. Measure down to ONLY the specified landing on the shaft. This machined area is shown below. Once all the measurements have been gathered, complete the provided formula in STIS and select the rear drive shaft shim needed to complete the repair. IMPORTANT REMINDER: all the components should be clean of sealant. There is also an O-ring to seal the extension housing to the rear cover. This O-ring is a one time use component and must always be replaced. Press Etiquette and Craftsmanship Damage: Special Edition TechTIPS Page 15 of 16 06 APPENDIX D: INSTALLED HEIGHT MEASUREMENTS AND INSTALLATION (CONTINUED) Techline has received calls with a common concern of the transfer clutch pack set not fitting under the snap ring in the reduction drive gear shaft (the transfer clutch basket). This concern has been traced back to workmanship error when installing the reduction drive gear shaft bearing. When pressing the bearing on, if excessive force is applied to the component, the drum backing will start to bend in on itself decreasing the amount of space available for clutch packs. When installing the bearing onto the shaft, STIS shows the shaft sitting on the drum surface against the press blocks (right). This can be done by an experienced Technician with strong hydraulic press experience. When the bearing touches the seating surface on the shaft and is fully seated, the hydraulic pressure gauge needle on the press will start to rise. This means the bearing is seated. Applying more pressure to the component will start to cause damage. (Note the gap between the parking pawl gear and the drum shell, if this gap is gone, the component has been damaged.) If the shop press does not have a hydraulic pressure gauge, use a generic press tool to support the shaft as pictured (left). This will protect the drum assembly. Pay close attention to the feel of the press, once the bearing is seated and tension starts to build in the handle, STOP pressing. Special Edition TechTIPS Page 16 of 16
**************************************************************************************************************
SEOCONTENT-END