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: 07/09/18
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) and test leads (1000v, CAT III) w/ alligator clips
• 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.
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: 07/09/18
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 of 11
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.
•
•
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.
NOTES:
• The AT TEMP lamp will stay on because at this point, the power cables to the inverter are
		 removed.
• 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 (DVOM will usually display 10V): the o-ring and
possibly the drive motor are damaged. If 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.
Continued...
Bulletin Number: 16-94-15R; Revise: 07/09/18
Page 2 of 11
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*
CVTFII Fluid
13
K0877YA020
ThreeBond 1217B (Pink)
1
004403007
ThreeBond 1215 (Gray)
1
806911080
O Ring
1
29019AA001
Case Assembly-Motor
1
31325KA151
Bolt Assembly-Seal
2
31759AA060
Clip-Transmission Harness
1
31377AA600
Ring-Seal
2
33295AA000
Gasket
1
806912200
O Ring
5
806912210
O Ring
1
806917100
O Ring
2
806929070
O Ring
1
99079AA100
Hose-ATF
1
99079AA110
Hose-ATF
1
28333AG010
Circlip-CVJ
2
806735300
Oil Seal
1
806735290
Oil Seal
1
31377AA490
Ring Seal
1
31377AA590
Ring Seal
2
806913250
O Ring
1
*Warranty Claim Part Number (Not Orderable)
REPAIR PROCEDURE:
•
Remove the CVT assembly following the procedure outlined in the applicable Service
Manual.
•
STOP HERE.
1) 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.
Continued...
Bulletin Number: 16-94-15R; Revise: 07/09/18
Page 3 of 11
2) 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,
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 to the right 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.
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)
Continued...
Bulletin Number: 16-94-15R; Revise: 07/09/18
Page 4 of 11
1. Output clutch roller bearing shim:
Steps 1 & 2:
1) Remove the
Removeoutput clutch assembly
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: 07/09/18
Page 5 of 11
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
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
Continued...
Bulletin Number: 16-94-15R; Revise: 07/09/18
Page 6 of 11
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
3. Transfer driven gear shim:
Step 1:
Continued...
Bulletin Number: 16-94-15R; Revise: 07/09/18
Page 7 of 11
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
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
Continued...
Bulletin Number: 16-94-15R; Revise: 07/09/18
Page 8 of 11
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.
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.
Continued...
Bulletin Number: 16-94-15R; Revise: 07/09/18
Page 9 of 11
•
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
•
Once proper spline alignment is confirmed, use some CVT fluid to hold the 6 o-rings in place
between the cases during reassembly.
Bulletin Number: 16-94-15R; Revise: 07/09/18
Page 10 of 11
•
•
•
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, Powertrain Limited an applicable Emission 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 #
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: 07/09/18
Page 11 of 11