Subaru Forester: TR580/TR690 CVT belt wear and cooling line crack

The Jatco-sourced TR580 (SH) and TR690 (SJ) continuously variable transmissions are susceptible to two distinct failure modes. Primary steel push-belt wear accelerates when fluid service intervals are missed beyond 40,000 km, causing ratio hunt, belt slippage under load, and eventual primary pulley scoring. Separately, the external transmission oil cooler lines — steel-to-rubber crimped joints — develop stress cracks from vibration and thermal cycling, resulting in ATF weeping that reduces fluid level and accelerates belt wear. Both failures are progressive and linked: low fluid from a leaking cooler line accelerates belt degradation. Rebuilds and factory-exchange units are the only remedy once belt wear causes pulley damage.

• Shudder or vibration at light throttle between 40-80 km/h
• Ratio hunting — engine revs rising and falling without throttle input
• Delayed engagement from Park or Neutral
• CVT warning light or flashing D indicator
• ATF puddle under centre of vehicle (cooler line leak)
• Burnt or dark transmission fluid on dipstick

1. 1

   Inspect the transmission cooler lines at the crimped rubber-to-steel joints for ATF weeping or staining.

2. 2

   Check ATF level and condition — healthy fluid is translucent red; degraded fluid is dark brown with burnt odour.

3. 3

   During test drive, note any shudder at cruise or under load uphill.

4. 4

   Confirm CVT fluid change history — every 40,000 km is mandatory.

5. 5

   If a workshop inspection is possible: Check for any stored CVT fault codes with OBD scanner.

Parts involved: CVT belt and pulleys.

$3,500 to $9,000 at New Zealand independent workshop rates. That is for this job on its own, not for the car.

An estimate, in NZD, for the repair as normally carried out. What a specific car costs depends on which part has failed and what it damaged on the way — treat this as the floor for a negotiation, not a quote.

• “Has the CVT fluid been changed, and when and how many times?”
• “Has the CVT ever shown warning lights or been serviced under warranty?”
• “Have the transmission cooler lines been replaced or inspected?”
• “Any shudder, vibration, or hesitation from the gearbox?”

The failure described above is documented in published sources — owner forums, technical service bulletins, recall notices and workshop write-ups — held in our fault database. The inspection instructions and the cost estimate are KickTyres’ own interpretation of them, and it is a starting point for an inspection rather than a manufacturer statement.