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Post by kwahom203 on Apr 2, 2012 19:53:00 GMT -5
I have had my 91 justy 4x4 with ecvt tranny for about a year now and just this morning I went in to have the tranny serviced and the shop I took it to looked it up and the computer called for dex 2 fluid so that is what they put. I drove it across town and it slipped a few times and the clutch temp light was on and blinking and beeping at me. I let it sit for a few hours then went to drive it home and made it a little ways then it started slipping a lot worse and eventually would not go. I have read on here that you should use cvt fluid, I am wondering if putting dex2 ruined it or if putting the cvt in it would possibly fix it? Any advice would be GREATLY appreciated thanks
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Post by Justy4x4 on Apr 2, 2012 20:57:32 GMT -5
The clutch temp light coming on has nothing to do with the transmission itself. It's for problems related to the electromagnetic clutch. The most likely cause is worn out clutch brushes. I've seen this many times and new brushes have always fixed the problem, so far anyway.
The brushes are accessible by first removing the starter (two bolts) then removing the brush holder, another two small bolts. New brushes can be purchased from Subaru as a complete assembly for around $100. I take the low cost approach and purchase Nippondenso alternator brushes from a local starter/alternator rebuilder. $2 for the pair out the door! I then solder them in the original brush holder and it's good as new once again. Pull those brushes and have a look.
The Dextron shouldn't cause any immediate harm but it's not good to leave in their for the long haul.
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Post by kwahom203 on Apr 2, 2012 23:58:09 GMT -5
Ok thanks I will check out those brushes. The brushes being bad can make it not go when its in drive or reverse? Or is that an issue with the transmission itself?
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Post by Justy4x4 on Apr 3, 2012 6:44:03 GMT -5
Ok thanks I will check out those brushes. The brushes being bad can make it not go when its in drive or reverse? Or is that an issue with the transmission itself? When the clutch brushes get worn down and loose contact with the slip rings, the clutch will no longer energize and drive the input shaft of the trans. The light will come on, the warning beeper will sound and the car won't move regardless of the gear position. Most of the ECVT equipped Justy's I've bought have had this problem. None of the tranny shops or dealerships would touch the cars so the previous owners would sell them cheap just to get rid of them. $2 later and I end up with a good reliable car
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Post by kwahom203 on Apr 4, 2012 12:59:02 GMT -5
I have little time to put into doing this so I was wondering if you might know the size of the 4 bolts that need to be removed? Also where the the starter located. I don't work on cars too often and want to go in prepared and get it done fast. Thank you for all your help!
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Post by Justy4x4 on Apr 4, 2012 13:53:49 GMT -5
I have little time to put into doing this so I was wondering if you might know the size of the 4 bolts that need to be removed? Also where the the starter located. I don't work on cars too often and want to go in prepared and get it done fast. Thank you for all your help! Just open the hood and look down. The starter is right on top of the tranny towards the front of the car. Easy to access! I'm just going off of memory but I believe the 2 starter bolts are 14mm and the 2 brush holder bolts are 8mm.
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Post by kwahom203 on Apr 4, 2012 18:38:31 GMT -5
This is what I got. Gonna look around for the brushes tomorrow. Attachments:
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Post by Justy4x4 on Apr 4, 2012 20:13:18 GMT -5
It looks like removed the starter and then the back cover off of the starter itself. These aren't the brushes you need to replace. The clutch brushes are under a cover that's bolted to the transmission. The starter only needs to be removed to access the brush holder assembly beneath it. It'll have some wires coming out of it. Have another look, you'll find it.
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dogoman
A Boxer engine will fit in a Justy, its called a WRX
Posts: 445
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Post by dogoman on Apr 5, 2012 0:11:35 GMT -5
yep, thats a starter back end, except yours actually has brushes that look ok and aren't all broken and burnt like my ones were.
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Post by kwahom203 on Apr 5, 2012 9:26:35 GMT -5
Ok I am going to put that back on and look for the right thing. But I have a small metal ring almost looks like a washer that came off of the part the brushes go around. I don't know how to put it back or if I need to? I can take a picture if necessary. also side note, since those brushes in the starter look kinda worn down and two are shorter than the others is that what makes it hard to start? It has a special trick to starting it, I am the only one that can get it going most of the time. Thanks for all the help so far.
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dogoman
A Boxer engine will fit in a Justy, its called a WRX
Posts: 445
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Post by dogoman on Apr 6, 2012 22:35:12 GMT -5
ok, the ring is a thrust washer and goes between the brush plate and the commutator, or the end plate and the commutator depending on the setup, yes, it is required, stick it in place with a little bit of grease.
The brushed are a bit warn, won't affect starting per se, just the cranking of the starter motor. if the motors spins every time you turn the key, then the brushes are probably ok. Check the commutator for obvious burnt segments, if there are any that are really burnt (heres a hint, there will be pairs burnt at either 90 or 180 degrees to each other) then the commutators toast.
Assuming nothings badly cooked, clean it with a bit of 400 or 600 grit sandpaper to remove the rubbish and get you back to some nice clean copper before reassembling it, brake cleaner is a good idea on a rag to remove traces of sanding and any grease residue on the commutator. Lightly grease the shaft where it runs in the bearing and i use an old playing card rolled up into a semi conical tube placed over the commutator and shaft to guide the brushes into the correcgt location, otherwise you need 5 pairs of hands and a good selection of swear words.
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Post by kwahom203 on Apr 7, 2012 11:38:43 GMT -5
OK Thank you. I got the Clutch brushes off and one is almost gone, the other is only 1/2 an inch. I couldnt see the brush holder and bolts because there was oil and sand gunk all over right there so I couldnt even see that there was something there. I had to scrape off tons of the gunk to get to it. I may end up replacing two of the starter brushes and cleaning it up to see if that helps that starting. Sometimes when you turn it over it makes no sound, and sometimes it makes a click sound, and then after a few turns of the key the engine actually turns over and starts. Thank you for all of the great input!
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Post by Justy4x4 on Apr 7, 2012 12:16:08 GMT -5
Good to hear you found the brushes!
The starter issue you're having is quite common. Generally it's the starter solenoid that need to be replaced. I've have three different Justy's that had that problem all at the same time. My local starter rebuilder fixed them for under $25 each. Good as new again!
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dogoman
A Boxer engine will fit in a Justy, its called a WRX
Posts: 445
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Post by dogoman on Apr 7, 2012 17:04:13 GMT -5
it could just be the solenoid thats gunked up too, give it a good spray and wash out with brake cleaner where the plunger goes into the solenoid, quite common for them to get gunked up with dust.
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Post by kwahom203 on Apr 7, 2012 17:41:35 GMT -5
I went to a parts store to get those brushes and they had all different sizes but none exactly the same. I am going to go to an alternator shop on monday but if they can't find the exact size is it better to get one that is bigger on one side and file it down to the same size as the old ones or get one that is just a little bit smaller so that it fits in the holder. Or do either of you know a part number? or where I can get the actual dimensions that the brushes should be?
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Post by Justy4x4 on Apr 7, 2012 19:09:32 GMT -5
The shop I get my brushes from said they are for a Nippondenso alternator. They are slightly shorter then the original Subaru brushes but otherwise the dimensions are the same. Just cut off your old brushes and reuse the springs from them. When soldering in the new ones be careful not to use too much solder as it tends to wick up the braided wire and stiffen it.
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dogoman
A Boxer engine will fit in a Justy, its called a WRX
Posts: 445
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Post by dogoman on Apr 7, 2012 21:53:31 GMT -5
as long as they are an alternator brush, not a starter one (the carbon compound is harder in the starter ones and will wear the slip rings rather than the brush) then filing to a nice sliding fit is fine, don't go too small otherwise they can bind up and try to turn in the holders. Good rule of thumb is to set length to about 1/16" to 1/8" below the top of the holder to give the brush enough tension, without the tension spring popping off the top of the brush and out of the holder
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Post by kwahom203 on Apr 9, 2012 19:18:02 GMT -5
Now I have the brushes that fit perfectly in the holder but my next problem is that I didnt take a picture before I snipped the old brushes off and now I don't know which way to put the new brushes in the holder. I took a picture of the holder so that someone may be able to explain better, basically with reference to the picture I need to know if the higher end of the brushes goes to the left or to the right? Attachments:
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Post by Justy4x4 on Apr 9, 2012 21:50:32 GMT -5
This pic is probably from the wrong angle but maybe you can figure it out. It's the only brush pic I have at the moment. I might be able to take a better one tomorrow if I can find my spare brush holder set.
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dogoman
A Boxer engine will fit in a Justy, its called a WRX
Posts: 445
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Post by dogoman on Apr 10, 2012 0:22:15 GMT -5
both brushes should be the same length, and it doesn't matter if they are square on the ends, just sand a small chamfer on them so they don't chip, and they will bed in pretty quickly with use.
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