Sie sind auf Seite 1von 7

"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 a tight corner, or the Transfer
Clutch Control 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 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 harness is disconnected,
the rear wheels are being driven, this would indicate that the Transfer Clutch Control Valve is
stuck or the Transfer Clutch solenoid is 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 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 parts distributor.
Special thanks to:
Paul and Shannon
from Fairview Trans
Dwayne and David
from Walkers 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
Figure 1

Automatic Transmission Service Group

"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

0030

L/R Brake
Duty Solenoid

MADE IN JAPAN
TOSOK

DENSO
G4907066

Low Clutch
Duty Solenoid

Figure 2
TRANSFER CLUTCH DUTY SOLENOID
FUNCTIONAL CHECK
Green Connector

Green Connector

OFF

Normally
vented

ON

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

Automatic Transmission Service Group

"2014 SEMINAR INFORMATION


TRANSFER CLUTCH VOLTAGE AND PRESSURE SPECS
TCM CONNECTORS
B55

B54

7
6 5
4
3
2 1
19 18 17 16 15 14 13 12 11 10 9 8
27 26
25 24
23 22 21 20
35 34
33 32
31 30 29 28

4
3
2
1
6 5
16 15 14 13 12 11 10 9 8 7
27 26 25 24 23 22 21 20 19 18 17
35 34 33 32 31
30 29 28

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
Park

MPH
0

THROTTLE TRANSFER VOLTAGE


0
.68V

Psi.
0

Reverse

2.2V

40-42

Drive
Drive

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

Automatic Transmission Service Group

"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

Automatic Transmission Service Group

"2014 SEMINAR INFORMATION


TRANSFER CLUTCH SOLENOID REPLACEMENT

New Connector
Included
New Design Solenoid
from Rostra

Previous Design
Transfer Clutch
Solenoid
44

0
00

00

2
T
O
S
O
K
00

MA

DE
IN
JA

00

G
4
9

PA
N

0
7
0
6
6

O
S
N
E
D

3
00

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

Automatic Transmission Service Group

"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

346

372A
376

380

341

345

348

338
342

349

372

350

352

373
356

377
360

374

357

364

354
358

361
365

368

347
351

353

362
366

369

355
359

370
363
367
371

Figure 7

Automatic Transmission Service Group

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

Automatic Transmission Service Group