another "awd not working" thread

[TomK]

Hello

I know this topic has been beaten to death but I've run into a problem that nobody seems to have. I had my AT rebuilt in my 94 turbo wagon and my awd hasn't worked properly since. After going back to the shop 4 times, they told me that it's the clutch packs in the transfer case and that wasn't part of the rebuild. After many searches on this site I figured I would replace the clutch pack and the duty solenoid c myself. The problem I ran into was that my local subaru dealer told me that the clutch pack for my tranny is no longer available. I could only replace it with a newer pack that comes with a different "hypiod" gear which requires the tranny to be removed and disassembled. Has anyone heard of this??
Thanks

[sandals]

i'd just change the duty c solenoid and see what happens.

my 91 tranny (which i beat tremedously) is still good, but the duty c solenoid has been shot for a long time. in march i swapped and rebuilt the engine and had the tranny checked out in the process.

last winter i couldn't make it up my driveway until i turned the car off and then back on.

[All_talk]

I found a place online that sells Subaru AT rebuild parts

http://www.bulkpart.com/Merchant2/merch ... de=R4AX-EL

At the time I was considering rebuilding my 4EAT myself, in the end a replaced it with a good used unit so I never ordered anything from them. They seem to have every thing tho.

Gary

[All_talk]

After a little pokin around...


p/n 23118A - Friction, R4AX-EL TRANSFER clutch
1/90-UP, .071, 24 teeth …… Common brand - Raybestos

$3.03 each (not sure how many you need)


p/n 23006 - Master kit, R4AX-EL 1990-94 LEGACY with TURBO & 1992-97 SVX
For 1/95-97 SVX, order (6) 73108A & (6) 73128 seperately.. Includes: overhaul kit, friction clutch plates & standard steel plates

$317.39


And...

p/n 23400 - Technical manual, R4AX-EL, EC8 4 speed SUBARU
ATSG manual, Disassembly, inspection and assembly sections. Diagnosis, testing and lot of pictures

$16.50


I'm sure its not a job for a novice machanic and may require some special tools but if you're brave enough it could save a lot money. An auto trans is about the only part of a car I haven't rebuild myself, but I may give it a try someday.

Gary

[TomK]

Thanks for the info. I ordered the manual to get started. The local mountains just got a dusting, I hope I can sort this out before ski season.

Tom

[damonmlime]

My awd went out in my car last year, I took it to my local sube mechanic and he said that the clutch packs in the rear of the tranny develop "burrs" that keep them from coming all the way together and you only need to file off the burrs. He also said that it's not very often that he sees one that needs the packs replaced. If you do change the clutch packs would you mind doing a writeup on it, I'm looking at doing it myself this time.

[TomK]

That makes sense considering I couldn't find a single thread about changing the clutch packs. I have a feeling that a new duty C solenoid would fix my problem but I would just rather pull the transfer case once and replace anything that can wear out.
Unless someone has the manual scans for removing it, I'm stuck until I get the manual from the place All_talk suggested.

[bean]

I have my AWD Legacy L in the garage as I write this with everything undone and the housing refuses to come off. So far it was pretty simple -

dropped the drive shaft out
supported the tranny and dropped the rear brace
removed the tranny mount
removed the mounting bolts and rpm sensor

I have it loose at the bottom - but the thing just doesn't want to come off. I don't want to force it - so if anyone knows of something I've missed it would be appreciated...

Rabin

[bean]

Success!

I got the case off and will re-assemble tomorrow. The upper dowel was the culprit and it just took some work to get it free. Soak with penetrating fluid before you start and it should hopefully work better for you.

Only other thing I had to do was drop the exhaust and that was pretty much it.

I have all the subie part numbers so let me know if you want them and I'll post them up.

If your still hesitant I can do a quick step by step.

Later...

Rabin

[TomK]

If you have part # for the clutch pack then please post. It would be nice to have the parts before I take the case off. Did you have to drain the tranny fluid?

[bean]

Sorry - I'm just doing the solenoid, so I have part numbers for doing just that.

My AWD works erratically, sometimes it works fine and engages properly, but it often starts up with the power light flashing followed by the torque bind symptoms. It rarely just works in FWD after the power light flashes - so I'm replacing the solenoid.

I know that the AWD works great when it's working - so I have no worries of my clutch pack being fubar.

As for draining the fluid - I didn't. I cracked the case and let it drain. I'm going to drain the fluid after I'm done though - fluid was OK looking, but with all the binding I'm guessing there's going to be some clutch pack particles in the fluid.

I may even see if they have a pan and gasket for the tranny and do that too while I'm at it - hopefully they have it in stock at the dealer...

Rabin

[monk]

Hey bean, im just trying to find out if the solenoid, fixed you problems. Mine doesnt have the power light probs, it just runs in 4wd. I was previously thinking of replacing the solenoid but now am erring towards the clutch plates.

Let me know what your outcome was.

thanks