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06 OBW 2.5, 05 Forester, had 03 H6 OBW
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Discussion Starter · #1 ·
Ongoing saga of a 2004 4EAT in a 2003.

2004 has max lockup with the transfer solenoid driven at +12V, min at 0V.

2003 is the opposite- no juice and it locks, +12V to disengage.

I successfully used an inverting solenoid driver to invert the signal, that is, turn the 2003 signal of little blips to 0v for a little lockup and longer blips to 0v for more lockup into little blips to +12V for a little lockup and longer blips to +12V for more lockup.

(In reality it is a 50Hz pulse-width-modulated signal).

The outcome is about what I thought- it is driveable, doesn't seem to bind on tight circles, and it is sufficiently locked when I need it to be (still some snow about for testing), but it isn't quite right.

In D from a standing start in snow it will spin for a moment then engage with a bang, and if I drive through snow slowly it will bang on and bang off. Fortunately it engages nice and smooth in 2 and 1, so I can live with it.

On wet pavement, planting the gas from a standing start works OK with no bang.

So, it's not 100%, and I need to drive it a bit to make sure nothing weird happens, but for my 200,000 mile subie I can live with it.

Of course some of the symptoms might be from a trans that has seen some torque bind, or perhaps the clutch baskets are grooved a bit. Not in the mood for further teardowns this season, though.
 

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2009 Tribeca Now - 2004 Outback EJ259 - Sold
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Nice work, glad you got it sorted out.

There is a parameter in FreeSSM TCU adjustments that might allow you to eliminate some of that harsh engagement.
Or like you said, it could be just a worn out transfer clutch.

:29:
 

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06 OBW 2.5, 05 Forester, had 03 H6 OBW
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5,966 Posts
Discussion Starter · #4 ·
I might feel like working on the car again in a few months.

Diagnosing the trans, doing the trans swap, figuring out what-the-heck was wrong, then putting in a temp 'normal/disconnected/full-AWD switch', then swapping in a boneyard rear wheel bearing, doing the inverter, and soon rebuild-boneyard-calipers do-all-4-brakes e-brakes-literally-fell-apart, I'd like to do something else for a few weekends!
 

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06 OBW 2.5, 05 Forester, had 03 H6 OBW
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Discussion Starter · #6 ·
But yeah, if the duty signal can be modified via software, even if it's just pushing the mapping up or down a bit, it's probably worth a shot.
 

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2009 Tribeca Now - 2004 Outback EJ259 - Sold
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Yep you can push it + - ~10% from its base. (have to check on the specific range)
It will remember the settings you put in until either TCU codes are cleared or power is lost due to batt disconnect, ect...
 

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06 OBW 2.5, 05 Forester, had 03 H6 OBW
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Discussion Starter · #8 ·
Worst behavior so far is the AWD thumping in-and-out during full-throttle good-traction acceleration (3/4 to full), and it seemed to be bound a bit on one very tight parking-lot turn (but only one).

Intermittent 'parking-lot' binding would more be a sign of a grooved clutch basket, I think.
 

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2009 Tribeca Now - 2004 Outback EJ259 - Sold
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Engaging in and out is probably not a good sign.
Can you tap into the post inverted signal and see whats going on during normal driving?
 

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06 OBW 2.5, 05 Forester, had 03 H6 OBW
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Discussion Starter · #10 ·
At the moment I don't have access to a meter with %duty cycle or a portable scope.

I checked it with my voltmeter, I can't get an AC reading, the DC reading is roughly the reverse of what I previously measured, 'low' when it needs little lockup, 'high' when it needs more lockup. I get almost 0 volts when I put in the FWD fuse, as is proper (for the 2004 trans).

It could just be that the signal for '04 is radically different from just an inverted '03 signal, that's why I was hoping to get actual scope traces of each.

If the solenoid was different in '04 and they just changed the way the solenoid worked I'd plan on swapping the solenoid this summer, but I think that was ruled out in the other thread.

That is, if the '03 was at rest in the 'build pressure' state and the signal caused it to release pressure, and the '04 was at rest in the 'release pressure' state and the signal caused it to build pressure, and everything else was the same, I could just swap the solenoids.
 

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2009 Tribeca Now - 2004 Outback EJ259 - Sold
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Yeah hard to say.
If you take enough measurements of how your 03' works and compare the inverse to the measurements I have taken on the 04' it should give you some good info.
Would give you some better informed decisions on what should or could be done next.
 

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06 OBW 2.5, 05 Forester, had 03 H6 OBW
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Discussion Starter · #12 ·
Yeah, i just have to figure out who I can borrow some test gear from.

Where I used to work we had a scopemeter, not sure there's one here.
 

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03 Outback H6 base
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Congrats on a successful adventure into the ?unknown.... !:29:
 

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06 OBW 2.5, 05 Forester, had 03 H6 OBW
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5,966 Posts
Discussion Starter · #14 ·
Just putting in the right trans would have been preferable, but even if one for the same price were available and it was an even-steven swap, that's a few days of hard labor I really couldn't do again at this time.

Working on the floor is at least 5x as hard as working with a lift- I've done both.
 

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06 OBW 2.5, 05 Forester, had 03 H6 OBW
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Discussion Starter · #15 ·
ntippet, on the pre-build thread you posted

plain OM I looked up the part #'s for the transfer solenoid, 03' and 04' are definitely different.

03' - 31942AA103 (spec'ed for 99-03')
04' - 31942AA130 (a bulletin 16-67-04 was released to replace 31942AA120 with 31942AA130...)

New style solenoid started production in October of 2003 with transmission number 012485.
Glennda5id then posted

Anyways, regarding the revised transfer clutch solenoid. The '04 Part, 31942AA130, is marked as the superseded part for the 03 transmission. So this is not where the changes are occurring.

opposedforces.com/parts/legacy/us_b12/type_28/automatic_transmission/at_transfer_and_extension/illustration_3/
The link won't load, so I can't follow up right now.

But, you mentioned the valve controlled by the transfer solenoid was also a bolt-on item?
Do you know where this valve physically resides?

OK, some digging done, the valve bolts to the rear of the interior case, and the solenoid bolts to the valve.

I'm not sure- are those part numbers for the valve/solenoid combination, or just the solenoid? Pics on those part numbers show the solenoid mounted in the valve as the part.
 

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2009 Tribeca Now - 2004 Outback EJ259 - Sold
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The part #'s I posted are for the small transfer solenoid valve body which includes the solenoid.

Glennda5id is misreading what model received the superseded part #.
103 is for models 99-03'
120 was the original part # for 04' which was superseded by 130.

Here are the views of where it is located and what is included with the solenoid assembly.
http://opposedforces.com/parts/legacy/us_b12/type_23/automatic_transmission/at_transfer_and_extension/illustration_2/
http://opposedforces.com/parts/legacy/us_b12/type_23/automatic_transmission/at_transfer_and_extension/illustration_3/

I have only seen the separate solenoids available used on ebay, minus the small valve assembly.
 

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06 OBW 2.5, 05 Forester, had 03 H6 OBW
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Discussion Starter · #17 ·
I haven't been able to view an opposedforces page for a long time.

The key to what Glennda5id posted is the bulletin, that there's mention of the reason for the change but not the reason that I think I'm looking for.

Of note is the trans case gasket is different, too.

99-03 = 31337AA191
04 = 31952AA060

but both use the transfer valve body gasket 31954AA071.

I wonder if the trans case is the same?

I think I need to beg for pics of the solenoid and valve from the collective, and scour ebay for good pics, but the one I can remove and examine is the one perhaps most people have sitting around.
 

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06 OBW 2.5, 05 Forester, had 03 H6 OBW
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Discussion Starter · #18 ·
103 comes with case gasket 31337AA191-
130 comes with 31952AA060

31954AA071- GASKET TRANSFER VALVE is common to all

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31942AA103 &31337AA191 & 31954AA071(x2) Baja 2003
TRANSFER DUTY SOLENOID FOR 2003 BAJA ALL

31942AA130 & 31952AA060 & 31954AA071(x2) Baja 2004-2006
TRANSFER DUTY SOLENOID FOR 2004-2006 BAJA ALL

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31942AA103 &31337AA191 & 31954AA071(x2) Forester 1999-2003
TRANSFER DUTY SOLENOID FOR 1999-2003 FORESTERS ALL

31942AA130 & 31952AA060 & 31954AA071(x2) Forester 2004
TRANSFER DUTY SOLENOID FOR 2004 FORESTERS ALL

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31942AA103 &31337AA191 & 31954AA071(x2) Impreza 1999-2004
TRANSFER DUTY FOR 1999-2004 IMPREZA ALL

31942AA130 & 31952AA060 & 31954AA071(x2) Impreza 2005
TRANSFER DUTY SOLENOID FOR 2005 IMPREZA WRX 2.05 Automatic

--------------------------------------

31942AA103 &31337AA191 & 31954AA071(x2) Legacy 1999-2003
TRANSFER DUTY SOLENOID FOR 1999-2003 LEGACY ALL

31942AA130 & 31952AA060 & 31954AA071(x2) Legacy 2004
TRANSFER DUTY SOLENOID FOR 2004 LEGACY ALL

--------------------------------------

31942AA103 &31337AA191 & 31954AA071(x2) Outback 1999-2003
TRANSFER DUTY SOLENOID FOR 1999-2003 LEGACY OUTBACK ALL

31942AA130 & 31952AA060 & 31954AA071(x2) Outback 2004
TRANSFER DUTY SOLENOID FOR 2004 LEGACY OUTBACK ALL

--------------------------------------
 

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2009 Tribeca Now - 2004 Outback EJ259 - Sold
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Yeah I tried looking up as many photos as I could find, hence the reason for the russian sites.

You should really find a browser to pull up oppposed forces, a wealth of info in there.
 

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Discussion Starter · #20 ·
Come to think of it, I have a 2003 manual, I need to locate an '04 manual, maybe the trans fluid flow diagram will show some discernible change.
 
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