16-94-15R

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SERVICE MANAGER
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SERVICE BULLETIN
APPLICABILITY: 2014-15MY XV Crosstrek Hybrid Electric Vehicle (HEV) NUMBER: 16-94-15R
DATE: 07/30/15
SUBJECT:	Diagnosis and Repair of DTCs P172A and P0B0B
REVISED: 10/22/15
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.
PRODUCTION CHANGE INFORMATION
A change to the drive motor relief valve o-ring was incorporated into production per the following:
• Transmission # 1722831, dated June 6, 2015
• VIN EH298545 dated June 16, 2015.
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).
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 pocket.
• Remove the TORX screws and necessary trim clips securing the aluminum battery cover.
• 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.
Continued...
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.
Bulletin Number: 16-94-15R; Revise: 10/22/15
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.
Page 1
•
•
•
•
Reinstall the orange HEV Service Disconnect plug.
Turn on the DVOM and set it to measure AC Voltage.
Start the engine and with the transmission in PARK, hold the engine at 1800 RPM.
Read the AC voltage on the DVOM display and record your result.
NOTE: The AT TEMP lamp will stay on because the power cables to the inverter are removed.
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.
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. lbs.
Replace the battery cover and torque the TORX screws to 5.5 ft. lbs.
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:
PART NUMBER
DESCRIPTION
QTY.
SOA635304*
K0877YA020
004403007
806911080
29019AA001
31325KA151
31759AA060
31377AA600
33295AA000
806912200
CVTF II Fluid
ThreeBond 1217B (Pink)
ThreeBond 1215 (Gray)
O Ring
Case Assembly-Motor
Bolt Assembly-Seal
Clip-Transmission Harness
Ring-Seal
Gasket
O Ring
13
1
1
1
1
2
1
2
1
5
*Warranty Claim Part Number (Not Orderable)
Bulletin Number: 16-94-15R; Revise: 10/22/15
Continued...
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PART NUMBER
DESCRIPTION
QTY.
806912210
806917100
806929070
99079AA100
99079AA110
28333AG010
806735300
806735290
31377AA490
31377AA590
806913250
O Ring
O Ring
O Ring
Hose-ATF
Hose-ATF
Circlip-CVJ
Oil Seal
Oil Seal
Ring Seal
Ring Seal
O Ring
1
2
1
1
1
2
1
1
1
1
1
REPAIR PROCEDURE:
•
Remove the CVT assembly following the procedure outlined in the applicable Service
Manual.
•
CAREFULLY remove the sensor cover, disconnect the wiring harness connectors and
remove the transmission harness as necessary to facilitate removal of the extension
housing and drive motor case assembly from the CVT main case. See: “38. Drive Motor
Assembly” in the applicable Service Manual on STIS.
•
Remove the electric oil pump assembly, output clutch control valve body, power connect
cover and the secondary pressure sensor from the old drive motor case 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.
•
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.
Continued...
Bulletin Number: 16-94-15R; Revise: 10/22/15
Page 3
•
It is NOT necessary to remove the internal parking pawl control rod or the inhibiter switch
assembly to perform this repair.
•
There are 14 bolts securing the drive motor case assembly to the CVT main case.
•
Use extra caution during removal and installation of the electric oil pump wiring harness to
avoid damaging it.
•
Always utilize a helper when removing and installing the drive motor case assembly.
•
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:
Remove
2) Measure the height “A” from the Gauge Block upper face to the ball bearing catch surface.
Gauge
Block
Gauge
Block
Continued...
Bulletin Number: 16-94-15R; Revise: 10/22/15
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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
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
Continued...
Bulletin Number: 16-94-15R; Revise: 10/22/15
Page 5
2. 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
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
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
Continued...
Bulletin Number: 16-94-15R; Revise: 10/22/15
Page 6
3. Transfer driven gear shim:
Step 1:
Steps 2, 3, 4, and 5:
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
Gauge
Block
Continued...
Bulletin Number: 16-94-15R; Revise: 10/22/15
Page 7
4) Using the Gauge Block, measure the height “B” from the transmission case mating surface to the end of
the Gauge Block
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
Once all of the proper shim thicknesses have been determined, proceed with reassembly following
the procedure outlined in the applicable Service Manual.
Continued...
Bulletin Number: 16-94-15R; Revise: 10/22/15
Page 8
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 vary.
Remember to transfer both of the oil baffles shown below over to the new assembly.
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.
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.
Coupling Sleeve
Drive Motor
Input Shaft
Primary
Pulley
Spline
Primary Pulley Retaining Nut
Continued...
Bulletin Number: 16-94-15R; Revise: 10/22/15
Page 9
•
Once proper spline alignment is confirmed, use some CVT fluid to hold the 6 o-rings in place
between the cases during reassembly.
•
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. lbs.
Never twist the electric oil pump harness more than 360 degrees to avoid damaging it.
•
•
WARRANTY / CLAIM INFORMATION:
For vehicles within the Basic New Car Limited or Powertrain Warranty period or vehicles with
an active Added Security Classic, Gold or Powertrain plan, this repair may be claimed using the
following information:
LABOR DESCRIPTION
LABOR
OPERATION #
HEV DRIVE MOTOR ASSY. R&R
B302001
REPLACE DRIVE MOTOR ASSY.
C302003
HEV TESTING & DIAGNOSIS
C800201
FAIL
CODE
LABOR
TIME
4.8
MTO-42
1.2
.5
REMINDER: 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 refer to STIS for the latest service information before performing any repairs.
Bulletin Number: 16-94-15R; Revise: 10/22/15
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