4EAT ATSG-Subaru--Transfer-Premature-Failure-Replacement.pdf

"2014” SEMINAR INFORMATION  SUBARU 4AT PHASE ll VERSION ll AWD BINDING ON TURNS AND/OR PREMATURE TRANSFER CLUTCH FAILURE COMPLAINT:

2004 -2009 All Wheel Drive Subaru vehicles equipped with the 4AT Phase 2 Version 2 transmission, may exhibit a binding condition when maneuvering into a tight corner, which may be as a result from a malfunctioning Transfer Clutch Solenoid or premature Transfer Clutch failure. Refer to Figure 1 for model identification, that use this type of transmission.

CAUSE:

The cause may be, that the Transfer Clutch solenoid is faulty, not allowing the Transfer Clutches, which drive the rear drive shaft, to slip enough when whe n a tight corner, or the Transfer Clutch Control Valve Valve is stuck in the valve body. See Figure 2 for the location of the Phase 2 Version 2 Transfer Clutch Solenoid. Testing:  The easiest way to verify that the solenoid is mechanically good is to simply disconnect disconne ct the wiring harness for the transmission with the wheels free on a lift. This will cause a third gear start and there should be no power transmitted to the rear wheels, if the solenoid is mechanically good and the Transfer Clutch Valve is free, as the Transfer Clutch Solenoid is Normally Vented. See Figure 3 for a functional description of the Transfer Clutch Solenoid. If when the h arness is disconnected, the rear wheels are a re being driven, this would indicate that the Transfer Clutch Control Valve Valve is stuck or the Transfer Clutch solenoid is faulty. faulty. See Figure 2 for location. This problem can also be intermittent and may require testing with a pressure gage and a volt meter. Refer to Figure 4 for a voltage to pressure chart from a working vehicle. If a pressure gage shows that there is no pressure on the gage but yet the rear wheels are still driving on the lift with the harness unplugged, the Transfer Clutch pack is probably welded together. A common cause to the Transfer Clutch pack welding together is because of rear CV joint spline failure where the axle is connected to the rear differential as shown in Figure 5. Spline failure can cause the Transfer Clutch to fail as it is not always connected to the front differential, and can even cause a complaint related to falling out of gear at highway speeds.

CORRECTION: To

correct a condition of a Transfer Clutch Solenoid mechanical problem after testing  pressure and comparing the voltage listed listed in Figure 4, to find that Transfer Clutch pressure is higher than what is listed in the chart, it will be necessary to replace the Transfer Clutch solenoid and verify that the Transfer Clutch Control valve is free and not binding in the bore. Refer to Figures 5-8 for the location of the Transfer Clutch Solenoid and valve train. Refer to Service Information for the new Transfer Clutch Solenoid available from Rostra. To correct a condition of the Transfer Clutch pack welded together, dis-assemble the clutch and piston to verify sealing components. If the clutch is sealed up properly replace the clutch  pack and refer to Figure 5 to verify the integrity of the splined area where the CV joint connects to the Rear Differential and repair as necessary. Note: If the CV joints are good where they connect to the splined area it may be necessary to verify that the Transfer Clutch  pressure is functioning correctly as shown in the chart in Figure 4.

SERVICE INFORMATION:

ROSTRA TRANSFER CLUTCH SOLENOID (Rostra part no.)...............................52-0527 Contact your local transmission transmissio n parts distributor.  Special thanks to:  Paul and Shannon  from Fairview Trans  Dwayne and David   from Walkers Walkers Trans Trans

4AT PHASE ll VERSION ll MODEL I.D.

2004 - 2009 Subaru Forester Turbo 2005 - 2009 Subaru Forester Non-Turbo 2005 - 2009 Subaru Impreza Non-Turbo 2006 - 2009 Subaru Impreza Turbo 2005 - 2009 Subaru Legacy/Outback 

"2014” SEMINAR INFORMATION   solenoid LOCATIONS 

 Line Pressure Control Solenoid 

Torque Converter Clutch  Duty Solenoid  Transfer Clutch  Duty Solenoid 

 High Clutch  Duty Solenoid  2-4 Brake  Duty Solenoid 

 L/R Brake  Duty Solenoid  G4907066

 Low Clutch  Duty Solenoid 

Figure 2 TRANSFER CLUTCH DUTY SOLENOID FUNCTIONAL CHECK 

Green Connector 

Green Connector 

OFF 

Normally  

ON 

vented 

 Blocked to Control Valve

Connected to Control Valve

 Pilot  Pressure

 Pilot  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.

Figure 3

"2014” SEMINAR INFORMATION  TRANSFER CLUTCH VOLTAGE AND PRESSURE SPECS

TCM CONNECTORS  B55

B54

Back-probe Yellow/Green wire at terminal 5 to ground with Multimeter  TCM located next to pedal bracket near steering column Terminal I.D. from 2008 Subaru Outback models may vary. OBSERVED TRANSFER CLUTCH SPECS 

RANGE

MPH

THROTTLE

TRANSFER VOLTAGE

Psi.

Park

0

0

.68V

0

Reverse

0

0

2.2V

40-42

Drive Drive

0

0

2.2V

40-42

Cornering

2-5

10%

1.7V

20-25

Drive

35

25%

1.8V

32-35

Drive

50

25%

1.8V

32-35

Drive

2-5

90%

3.2V

100

Observed voltage and pressure specifications at various driving conditions off of a working vehicle 2008 Outback. Transfer Clutch pressure port located on the tailhousing.

Figure 4

"2014” SEMINAR INFORMATION  REAR DIFFERENTIAL ASSEMBLY

CV JOINT/AXLE SHAFT 

 Inspect the CV joint connection to the  Rear Differential. The splined area where the CV Joint connects wears causing the axle to dis-connect from the Rear Differential.

Figure 5

"2014” SEMINAR INFORMATION  TRANSFER CLUTCH SOLENOID REPLACEMENT

 New Connector   Included   New Design Solenoid  from Rostra

 Previous Design Transfer Clutch  Solenoid 

4       4       0      00

00

00

00

G     4      9     0     7      0     6     6    

 New Design Solenoid from Rostra is a two piece adapter that houses a 01M  Pressure Control solenoid. Also included in the kit is a harness connector that splices into the OE harness. NOTE: The OE solenoid can only be purchased  with a complete valve body from Subaru.

Figure 6

"2014” SEMINAR INFORMATION  UPPER VALVE BODY EXPLODED VIEW 

399 398 397 394 391

396 393

390 389

395

400

392

388

400 385

387 386 385

333

302

334 335

339

381 382

336 337

340

344 378

384 383

375

379

380

338 342

346

372A  376

341

345

348

349

372

350

352

373

347

356

377 360 374

357

364

354

362 366

369

355 359

370 363 367 371

Figure 7

351

358

361 365

368

353

343

"2014” SEMINAR INFORMATION   LEGEND 302  333  334  335  336  337 338  339  340  341  342  343  344  345  346  347  348  349  350  351 352 353  354  355  356  357  358  359  360  361  362  363  364 365  366  367

UPPER VALVE BODY CASTING. LINE PRESSURE BLOW-OFF BALL, 8.72 MM (.343") DIAMETER. LINE PRESSURE BLOW-OFF BALL SPRING. BLOW-OFF BALL SPRING RETAINER. REAR LUBE CHECK BALL, 8.72 MM (.343") DIAMETER. REAR LUBE SPRING. REAR LUBE SPRING RETAINER. LOCK-UP CONTROL VALVE SPRING. LOCK-UP CONTROL VALVE. LOCK-UP CONTROL BOOST VALVE. LOCK-UP CONTROL BOOST VALVE SLEEVE. LOCK-UP CONTROL BOOST VALVE SLEEVE RETAINER. TCC REGULATOR VALVE 2. (APPLY) TCC REGULATOR VALVE 2 SPRING. TCC REGULATOR VALVE 2 BORE PLUG. TCC REGULATOR VALVE 2 BORE PLUG RETAINER. HIGH CLUTCH DUTY SOLENOID ACCUMULATOR SPRING. HIGH CLUTCH DUTY SOLENOID ACCUMULATOR VALVE. HIGH CLUTCH DUTY SOLENOID ACCUMULATOR BORE PLUG. HIGH CLUTCH DUTY SOLENOID ACCUMULATOR RETAINER. HIGH CLUTCH CONTROL VALVE SPRING. HIGH CLUTCH CONTROL VALVE. HIGH CLUTCH CONTROL BORE PLUG. HIGH CLUTCH CONTROL BORE PLUG RETAINER. 2-4 BRAKE CONTROL VALVE SPRING. 2-4 BRAKE CONTROL VALVE. 2-4 BRAKE CONTROL BORE PLUG. 2-4 BRAKE CONTROL BORE PLUG RETAINER. 2-4 BRAKE DUTY SOLENOID ACCUMULATOR SPRING. 2-4 BRAKE DUTY SOLENOID ACCUMULATOR VALVE. 2-4 BRAKE DUTY SOLENOID ACCUMULATOR BORE PLUG. 2-4 BRAKE DUTY SOLENOID ACCUMULATOR RETAINER. LOW CLUTCH CONTROL VALVE SPRING. LOW CLUTCH CONTROL VALVE. LOW CLUTCH CONTROL VALVE BORE PLUG. LOW CLUTCH CONTROL VALVE RETAINER.

368 LOW CLUTCH DUTY SOLENOID ACCUMULATOR SPRING.  369 LOW CLUTCH DUTY SOLENOID ACCUMULATOR VALVE.  370 LOW CLUTCH DUTY SOLENOID ACCUMULATOR.  371 LOW CLUTCH DUTY SOLENOID ACCUMULATOR RETAINER. 372A TRANSFER CLUTCH CONTROL VALVE SPRING 372 TRANSFER CLUTCH CONTROL VALVE.  373 TRANSFER CLUTCH CONTROL VALVE BORE PLUG. 374 TRANSFER CLUTCH CONTROL VALVE BORE PLUG RETAINER.  375 LOW/REVERSE BRAKE SEQUENCE VALVE.  376 LOW/REVERSE BRAKE SEQUENCE SPRING.  377 LOW/REVERSE BRAKE SEQUENCE SPRING RETAINER. 378 LOW/2-4 RELAY VALVE. 379 LOW/2-4 RELAY VALVE SPRING. 380 LOW/2-4 RELAY VALVE SPRING RETAINER.  381 LOW/REVERSE BRAKE CONTROL VALVE SPRING.  382 LOW/REVERSE BRAKE CONTROL VALVE.  383 LOW/REVERSE BRAKE CONTROL VALVE BORE PLUG.  384 LOW/REVERSE BRAKE CONTROL VALVE BORE PLUG RETAINER.  385 STEEL CHECK BALLS, 5.53 MM (.217") DIAMETER (7 REQUIRED).  386 2-4 BRAKE SEQUENCE VALVE.  387 2-4 BRAKE SEQUENCE VALVE SPRING.  388 2-4 BRAKE SEQUENCE BOOST VALVE.  389 2-4 BRAKE SEQUENCE BOOST VALVE SLEEVE.  390 2-4 BRAKE SEQUENCE BOOST VALE SLEEVE "O" RING SEAL.  391 2-4 BRAKE SEQUENCE BOOST VALVE SLEEVE RETAINER.  392 TORQUE CONVERTER/LUBE REGULATOR VALVE 1.  393 TORQUE CONVERTER/LUBE REGULATOR VALVE 1 SPRING.  394 TORQUE CONVERTER/LUBE REG. VALVE 1 SPRING RETAINER.  395 LINE PRESSURE REGULATOR INNER VALVE. 396 LINE PRESSURE REGULATOR VALVE.  397 LINE PRESSURE REGULATOR VALVE SPRING.  398 LINE PRESSURE REGULATOR VALVE BORE PLUG.  399 LINE PRESSURE REGULATOR VALVE BORE PLUG RETAINER. 400 PLASTIC SCREENS (4 REQUIRED).

 Note: The Valve names are provided by ATSG and are based on valve function.

Figure 8