1993 Legacy Wgn -

Started as an intermittent torque bind that upon next start up would trigger the POWER light flashing - happened only once in awhile.

From what I read it sounded like a failing solenoid (a bit more history: the issue started immediately after having a front/inner CV boot replaced and the gear oils changed) So I removed the transfer case housing to inspect - intended to replace clutch pack and solenoid assembly - inspected the housing and it looked fantastic so I replaced the two seals at the output shaft. I also found some deep grooves worn both at the drum on the output shaft and the mating drive gear - the gear drive gear was hammered so I replaced it - the part the clutch pack sits in was not bad and I filed the grooves away. Everything went together great and I filled the gearbox with Redline synth for Dexron II apps.

Everything worked flawless for a few days - the problem had been intermittent before so I was sceptical anyway - but reappeared a few days after the repair work was done. It always sets a DUTY C fault code when it happens. I feel I have ruled out the inards of the trans. (unless I put in a bad solenoid) and am now turning to other possibilites, but don't know where to go.

*What feeds the Duty C solenoid its signal (bad TCU)?

*Possible issues from a wheel bearing, CV joint, or axle? (Is this possible with the limited slips?)

*Fluid levels?

*Everything seems okay as far as I can tell at this point, and the problem is so sporadic I don't really know where to go at this point. My wife typically drives the car and hates the randomness of the issue, but I am at a loss.

Any help would be greatly appreciated.

 

P.S. - I have checked tires psi and tire circumference - fluid level, etc... - I feel all the bases have been covered and now I need to hear of someone who experienced a similar issue and resolved it.

Have you inserted a fuse in the FWD fuse holder? If so, does the problem not occur?

 

Due to the sporadic nature of the issues, I would wonder if your electrical harness has a short or area where the wire is breaking down.

1993 Legacy Wgn -

Started as an intermittent torque bind that upon next start up would trigger the POWER light flashing - happened only once in awhile.

From what I read it sounded like a failing solenoid (a bit more history: the issue started immediately after having a front/inner CV boot replaced and the gear oils changed) So I removed the transfer case housing to inspect - intended to replace clutch pack and solenoid assembly - inspected the housing and it looked fantastic so I replaced the two seals at the output shaft. I also found some deep grooves worn both at the drum on the output shaft and the mating drive gear - the gear drive gear was hammered so I replaced it - the part the clutch pack sits in was not bad and I filed the grooves away. Everything went together great and I filled the gearbox with Redline synth for Dexron II apps.

Everything worked flawless for a few days - the problem had been intermittent before so I was sceptical anyway - but reappeared a few days after the repair work was done. It always sets a DUTY C fault code when it happens. I feel I have ruled out the inards of the trans. (unless I put in a bad solenoid) and am now turning to other possibilites, but don't know where to go.

*What feeds the Duty C solenoid its signal (bad TCU)?

*Possible issues from a wheel bearing, CV joint, or axle? (Is this possible with the limited slips?)

*Fluid levels?

*Everything seems okay as far as I can tell at this point, and the problem is so sporadic I don't really know where to go at this point. My wife typically drives the car and hates the randomness of the issue, but I am at a loss.

Any help would be greatly appreciated.

 

P.S. - I have checked tires psi and tire circumference - fluid level, etc... - I feel all the bases have been covered and now I need to hear of someone who experienced a similar issue and resolved it.

 

Do a search here, there has been lots and lots and lots of disccusion this topic

 

nipper

Do a search here, there has been lots and lots and lots of disccusion this topic

 

Not on this specifically. He's already covered virtually all that I've ever read here on the topic.

 

bridorf

 

I'm not completely clear - you DID replace duty solenoid C?

Yes. I replaced the solenoid and clutch pack.

I am leaning towards either another bad solenoid or a bad wire somewhere or a bad TCU. It is odd to me that it started almose right after I changed gear oils - I assumed I had dislodged some crap and caused the solenoid to die - which I suppose could still be an issue, but everything is fresh inside the transfer case and the fluid is new.

 

also, the problem goes away when the FWD fuse is inserted.

It is odd to me that it started almose right after I changed gear oils - I assumed I had dislodged some crap and caused the solenoid to die

 

 

 

Flush or don't Flush?

also, the problem goes away when the FWD fuse is inserted.

 

Definitely not the Solenoid then, as it's working fine. Probably not associated connections than either.

 

I dunno...

It is odd to me that it started almose right after I changed gear oils - I assumed I had dislodged some crap and caused the solenoid to die

 

 

 

Flush or don't Flush?

 

Did you flush the tranny flluid? That usually will fix the problem if it is still fixable. i would have done that first. Have the tranny flushed, drive in a tight circle about eight times. That will usually make it go away.

Also there is a long thread here on manually operating the AWD unit, and it goes into great detail on how to test the solenoid and how the system works.

also you can dislodge crap that can cause the solenoid to be stuck, or gum up the plates in the clutch pack.

 

 

nipper