Body - Noise on Right Hand Turns

86subaru2

NUMBER 12-36-86


APPLICABILITY DATE 10-02-86
ALL 1985 AND 1986 4DR, STATION WAGON, 1986 3DR AND XT COUPE MODELS WITH FWD or 4WD MANUAL TRANSMISSIONS

SUBJECT: FLOOR PAN CROSSMEMBER BOLT TORQUE

THIS BULLETIN IS A REVISION FOR SERVICE BULLETIN NUMBER 12-33-86 RELEASED 01-17-86


If you have an owner complaint regarding body noise on 1985-1986 4 Door sedan, Station Wagon, 3 Door, and XT Coupe models while making a right hand turn or accelerating, improperly torqued crossmember bolts may be the cause. Follow the instructions below to repair the condition.

NOTE: THIS APPLIES ONLY TO VEHICLES UP TO THE FOLLOWING VIN's.

Vehicle Type VIN:

4 DOOR SEDAN 236 043
STATION WAGON 445 621 To February 9, 1986
3-DOOR 804 046 PRODUCTION DATE
XT COUPE 314 241

Materials Required:

8 mm Flange Bolt Part Number 010108200
10 mm Flange Bolt Part Number 010110200

NOTE: 10 mm FLANGE BOLTS ARE USED ON VEHICLES WITH A PRODUCTION DATE BEFORE JANUARY 31, 1986, AND 8 mm FLANGE BOLTS ARE USED ON VEHICLES PRODUCED ON FEBRUARY 1, 1985 THROUGH FEBRUARY 9, 1986.

Rust Inhibiting Paint Examples: Spray or Brush-on Enamel, Rustoleum, Krylon, etc.

Tools Required:

12 mm and 14 mm Sockets and Ratchet Torque Wrench (ft.lbs) Scraper or Screwdriver (For removing undercoating)

FIGURE 1:

Step 1) Locate the crossmember by looking at the back of the transmission and below the hand brake. Remove the undercoating around the bolts and on the bolt heads. See Figure 1.
Step 2) Remove the flange bolts and replace them with new bolts one at a time, this will prevent the floor pan from flexing and will keep the crossmember bolt holes not aligning with the crossmember and floor pan bolt holes.

NOTE: REPLACE ALL CROSSMEMBER BOLTS WITH NEW ONES.

NOTE: EXAMINE THE THREADS OF THE BOLTS BEING REMOVED FOR RUST, FOREIGN MATERIAL OR CROSS THREAD. IF THIS CONDITION OCCURS, CLEAN THE RUST, REMOVE FOREIGN MATERIAL OR RETAP THE FLOOR PAN ACCORDINGLY BEFORE INSTALLING THE NEW BOLT.

STEP 3) Tighten each bolt to the specified torque shown in the chart below.

BOLT TIGHTENING TORQUE

8 mm 37.5 ft.lbs. (5.2 kg-m)
10 mm 63.5 ft.lbs. (8.8 kg-m)

STEP 4) Coat any bare metal areas on the crossmember or floor pan where the crossmember is bolted with rust inhibiting paint.

NOTE: IT IS POSSIBLE TO USE CROSSMEMBER PART NUMBER 59081GA011 WITH 12 mm HOLES IN PLACE OF PART NUMBER 59081GA010 WITH 10 mm HOLES, BUT YOU MUST USE A WASHER FOR EACH BOLT, PART NUMBER 031108000.

This procedure can be claimed for vehicles within the terms of the Subaru Limited Warranty using:

Operation Number: A122621 Time 0.3
Failure Code : XAV-20