Recall - A/T 4EAT Parking Pawl
NUMBER: WZP-46DATE: August 9, 1991
APPLICABILITY:
1989-1990MY Loyale 4D, SW, 3D 1989-1991 MY XT, XT6 1990-1991 MY Legacy 4D, SW
SUBJECT:
(4EAT) 4SPD Electronically Controlled Automatic Transmission, Parking Pawl
Subaru of America has determined that a defect exists in certain Loyale, XT and Legacy models that are equipped with a 4EAT. Specifically the transmission parking gear disengagement mechanism, when subject to loads resulting from certain parking situations, may not release immediately into Reverse gear when selected. This condition if not corrected could result in delayed and possibly abrupt movement of the vehicle. To prevent this potential condition from occurring, it is necessary to replace the parking pawl with a improved part.
VEHICLES INVOLVED
The affected vehicles are all 1989-1991 MY vehicles equipped with a 4EAT which fall within the following VIN ranges (last 8 digits only):
Involved vehicles have been identified by the Vehicle Identification Number (VIN). Computer listings contain the VIN. owner name and address data, and are furnished to the dealers with this bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign.
These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles originally allocated.
OWNER NOTIFICATION
SOA will prepare and mail an Owner Notification Letter and a two-part Recall Certification/Repair Order Form to the owners of all potentially affected vehicles. The Owner Notification mailing is scheduled for mid-August. A copy of the Owner Notification Letter and a sample two-part Recall Certification/Repair Order Form are included in this bulletin.
Owners are being advised that the parts necessary to perform the repair will not be available until September 13,1991.
As a temporary measure, the following procedure should be used if their vehicle does not engage into (R) Reverse at the time of selection.
With your foot firmly on the brake pedal and the hand brake applied, move the shift selector into the (D) Drive position and then back into the (R) Reverse position, release the brakes and then continue normal driving. This procedure may be necessary on each start-up of the vehicle when moving the selector from (P) Park to (R) Reverse. Following this procedure will allow you to operate your vehicle safely until the actual repair is performed. Remember to wear your lap and shoulder restraints at all times when operating your vehicle. Your lap belt must be fastened manually.
DEALER CAMPAIGN RESPONSIBILITY
Dealers are to promptly service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward. When you are presented a two-part Recall Certification/Repair Order Form by a Subaru owner, follow the instructions presented in the Service Procedure section of this bulletin.
Whenever a vehicle subject to this campaign or any open campaign is taken into new or used vehicle inventory, or it is in your dealership for service in the future, you should take the steps necessary to be sure that all campaign corrections have been made before reselling or releasing the vehicle.
Owners of vehicles recently sold from your new vehicle inventory within the VIN range listed are to be contacted by the dealer, and arrangements should be made to make the required correction according to instructions contained in this bulletin.
PARTS INFORMATION
Quantities of the modified parking pawl kits will be available through your normal parts supply after September 13, 1991.
PARTS PRICING
SERVICE PROCEDURE
Note:
The steps below can also be found in the 1990-91 MY service manual section 3-2.
(1) Shift into "N" range.
(2) Disconnect ground wire terminal of BATTERY.
(3) Raise the vehicle.
(4) Remove EPF or Turbo Outlet Pipe. (Note: Be sure to disconnect the connector for OXYGEN SENSOR.)
(5) Remove PROPELLER SHAFT (4WD).
(6) Support the transmission by using a transmission jack and raise slightly. Remove BOLTS and NUTS on REAR CROSSMEMBER and remove REAR CROSSMEMBER.
4WD: 6 BOLTS and 4 NUTS
FWD: 6 BOLTS and 2 NUTS
After the above operation.. remove the transmission jack carefully.
Note:
Removal of the select cable assembly is not necessary.)
(7) Remove REVOLUTION SENSOR (4WD).
(8) Remove 11 BOLTS on EXTENSION CASE.
Note:
Use a clean container that will hold approximately 4 quarts to catch used ATF flowing from the extension case.
(9) While pulling the EXTENSION CASE section slightly, disconnect the connector for DUTY SOLENOID C (4WD).
(10) Separate the EXTENSION CASE section from transmission case.
(11) Remove the PARKING PAWL, RETURN SPRING and SHAFT.
(12) Reinstall the SHAFT and RETURN SPRING with the modified PARKING PAWL contained in the kit.
(13) Attach THRUST NEEDLE BEARING to the end surface of REDUCTION DRIVE GEAR with vaseline.
(14) Set PARKING RETURN SPRING as shown in figure 1.
(15) Remove TRANSFER CLUTCH from EXTENSION CASE with a plastic mallet (4WD). Fig. 2
(16) Set NEEDLE BEARING on REDUCTION DRIVE SHAFT, and then install TRANSFER CLUTCH to TRANSFER CLUTCH HUB (4WD). (Note: Be sure to engage the spline teeth correctly.)
(17) Install the EXTENSION CASE to TRANSMISSION CASE after attaching a new GASKET to TRANSMISSION CASE with vaseline. (Note: A new GASKET is included in kit.)
After inserting the EXTENSION CASE about halfway, connect the connector for DUTY SOLENOID C (4WD). (Note: To prevent damage to the wiring harness, the connector should be set at the hollowed portion as shown in figure 3.)
(18) Fit EXTENSION CASE to TRANSMISSION CASE while aligning PARKING SHAFT and ROLLER BEARING for REDUCTION DRIVE GEAR in correct position. (Note: Be careful not to damage REAR DRIVE SHAFT SEAL RING.)
(19) TIGHTEN 11 BOLTS ON EXTENSION CASE TIGHTENING TORQUE: 17-20 ft.lb. (2.3-2.7 kg-m).
(20) Install REVOLUTION SENSOR (4WD). Tightening torque: 4.3-5.8 ft.lb. (0.6-0.8 kg-m).
(21) Slightly raise the transmission by using transmission jack and reinstall REAR CROSSMEMBER to the body with BOLTS and NUTS.
4WD: 6 BOLTS and 4 NUTS
FWD: 6 BOLTS and 2 NUTS
Tightening torque (CROSSMEMBER-BODY): 40-61 ft.lb. (5.5-8.5 kg-m)
(CROSSMEMBER-CUSHION): 9-17 ft.lb. (1.3-2.3 kg-m)
(22) Install PROPELLER SHAFT. (4WD)
(23) Install EPF or Turbo Outlet Pipe using new GASKETS included in kit. (Be sure to connect the connector for OXYGEN SENSOR.)
(24) Lower vehicle and fill transmission with new Dexron II or equivalent to the specified level at operating temperature and on a level surface.
(25) Raise vehicle and check for any leakage of ATF.
(26) Lower the vehicle.
(27) Reconnect ground wire terminal of BATTERY.
(28) Apply a "Campaign Completion Label" properly filled out to the Radiator Core Support.
CAMPAIGN IDENTIFICATION LABEL
Each vehicle corrected in accordance with the instructions outlined in this bulletin will require a "Campaign Identification label." Each label provides a space to include the five digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or ballpoint pen.
Each "Campaign Identification Label" is to be affixed to the radiator core support which will be visible when the vehicle is brought in for periodic servicing by the owner. Apply "Campaign Identification Label" only on a clean dry surface.
A quantity of 50 blank labels are being provided to each dealer with this bulletin.
CLAIM PROCESSING INFORMATION - DEALER REIMBURSEMENT
Credit for the performance of the modified Parking Pawl kit installation per the Service Procedure will be provided from the two-part Recall Certification/Repair Order Form. Therefore, it is very important that all information on the form be complete and correct.
All claims for reimbursement should follow the procedures outlined below.
You must complete the repairing dealer section of the two-part Recall Certification/Repair Order Form and remove and retain the first copy for your records.
Star System dealers may enter the applicable information using the Campaign Claim (RY) routine.
Non Star System dealers will be reimbursed upon submission of the remaining copy of the Recall Certification/Repair Order Form to your Distributor/Region in an envelope with postage prepaid.
Dealers will be credited with either 1.4 labor hours (2WD) or 1.6 labor hours (4WD) for a total of $24.35 for Parts & Fluid, based on the two-part Recall Certification/Repair Order Form. Parts & Fluid cover the Parking Pawl kit and 4 quarts of ATF ($2.73/qt.). Retail states will receive reimbursement at suggested retail cost.
OWNER NOTIFICATION MATERIALS
OWNER LETTER
SUBARU OF AMERICA
Subaru Plaza
P.O. Box 6000
Cherry Hill, NJ 08034-6000
August, 1991
Dear Subaru Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Subaru of America has determined that a defect which relates to motor vehicle safety exists in certain 1989-1991 Model Year Legacy, Loyale, and XT models equipped with a 4 speed electronically controlled automatic transmission (4EAT). The defect is due to the transmission parking gear disengagement mechanism. When subject to loads resulting from certain parking situations, this mechanism may not release immediately into reverse gear when selected. This condition if not corrected could result in delayed and possibly abrupt movement of the vehicle.
As a temporary measure, if your vehicle does not engage into (R) Reverse at the time of selection please follow this procedure. With your foot firmly on the brake pedal and the hand brake applied, move the shift selector into the (D) Drive position and then back into the (R) Reverse position, release the brakes and then continue normal driving. This procedure may be necessary on each start-up of the vehicle when moving the selector from (P) Park to (R) Reverse. Following this procedure will allow you to operate your vehicle safely until the actual repair is performed. Remember to wear your lap and shoulder restraints at all times when operating your vehicle. Your lap belt must be fastened manually.
In order to remedy this condition the Parking Pawl will be replaced by your Subaru dealer at no cost to you. The replacement parts will be available at your Subaru dealer September 13, 1991. You should make an appointment with your Subaru dealer to have the repair procedure performed after this date. The actual labor time to perform this repair procedure is just over one (1) hour. However, please plan to leave your vehicle at your Subaru dealer for the full day of your scheduled appointment to allow the dealer some flexibility in scheduling other customers.
You must present the enclosed two-part Recall Certification/Repair Order Form to your dealer at the time this repair procedure is performed. If you lose the Recall Certification/Repair Order Form provided with this notification. or if the dealer doesn't make the repair promptly and without charge, you may contact the Owner Service Department of the Subaru Distributor/Region responsible for your area shown on the map on the back of this letter. You will then be sent a new form. If you are no longer in possession of this vehicle, please complete the enclosed prepaid postcard and mail it to us so that we may update our records.
If your dealer fails or is unable to remedy this condition without charge and within a reasonable period of time, you should contact the Subaru Distributor/Region responsible for your area. If your complaint is not resolved, you may contact Subaru of America Recall Headquarters at the above address or you may wish to notify the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, Washington, D.C. 20590, or call the toll free Auto Safety Hotline at 800-424-9393 (Washington, D.C. area residents may call 366-0123).
We regret any inconvenience this may cause you. However, we have taken this action in the interest of your safety and your continued satisfaction with our products.
WE URGE YOU TO SCHEDULE AN APPOINTMENT TO HAVE THESE REPAIR PROCEDURES PERFORMED AS OUTLINED IN THIS LETTER.