1999 Subaru Outback - transfer clutch fix or swap ?

[lowrentride]

Longtime lurker, first time poster.  I have a 1999 Subaru Outback 2.5 130K miles. For about 2 months, I have had the AT temp light flashing constantly at random times and not in any pattern (not on startup! maybe about an 20 min to hour into the drive).  My wife, when I was out of town and trying to make less work for me, took it to the dealer and they did a $750 trans flush (!!!) where they 'removed the pan to check for shavings'. This didn't help the issue, btw. After I gathered myself and calmed down, I found the handshake procedure for reading the TCM codes.  I got a 76.  This told my I had a incomplete circuit in the Transfer clutch solenoid.  I put the FWD fuse in there and no light on dash and we're still stuck in AWD.  I hadn't really noticed binding in turns, but now that I am trying to get it to bind, I do feel some and it's definitely still got lots of grip.  Sorry for the long post, here comes the questions... because I have a 76 code, this is a Phase II 4EAT trans (also have external filter).  The Phase II 4EAT version2 (that is the only info  I can find online) has this solenoid accessible in the trans pan but looks like it starts being used in 2002.  

• I can only assume I have Phase II 4EAT verson#1? and the Solenoid is in the tail end of the trans?  
• So I need to take off the tail end of the trans and access it there?  
• Is 2500 miles driving locked up enough to damage the transfer clutch and should I plan on servicing that while I have it out?

OR

 

Is it an opportunity to 'upgrade' and find a newer and better trans (like from an 03 or 04) and if so, which best, coolest option should I look for that will work easily in my 1999?  

 

Thanks for any opinion you folks can provide and thanks for all the past help.

 

T

Edited November 4, 2016 by lowrentride

[Fairtax4me]

Transfer solenoid should be in the tail housing on that one.

I would pull the housing and replace the solenoid and inspect the clutches while its apart. More than likely they're ok, but you may find that the drum they sit in is grooved. Mild grooving can simply be filed down. If it's excessive you will be better off replacing the drum and clutches.

 

Actually I wouldn't pull the tail yet. If the light is intermittent, that could just mean you have a wire issue such as a poor connection in the main harness connector, or a chafed wire in the harness where it runs down the side of the trans.

Could also be a pinched or chafed wire inside the pan where it runs along the bottom of the valve body to the back of the trans.

Edited November 4, 2016 by Fairtax4me

[lowrentride]

Thanks for that. I'll get under there today and scour around for harness/connector issues. The light is flashing all the time now, it must have heard me post

[idosubaru]

what he said.

 

what do you mean a $750 trans flush, that's like impossible, do you just walk around oozing dollar signs?  can i do your next brake job?

 

could also cut power to the Duty C - thereby rendering it indefinitely "locked" in 4WD and then disconnect the rear driveshaft/axles, making it a FWD outback.