Campaign - Axle Shaft Grease Leakage
NUMBER: WXN-71DATE: 05/05/99
APPLICABILITY:
All 1997-1999 MY Subaru Vehicles as applicable in chart 1
SUBJECT:
Axle Shaft Grease Leakage
The following describes the repair procedure for resealing the front axle Shudderless Free Ring Tripod Joint (SFJ) (or Double Offset Joint (DOJ)). The instructions cover the proper disassembly, resealing, and reassembly procedures for both left and right axle SFJ (DOJ).
PLEASE NOTE:
Resealing procedures are to be performed on BOTH sides.
VEHICLES INVOLVED
The potentially involved vehicles are 1997-1999 Model Year Legacy, Forester and Impreza models as indicated on Chart 1.
Affected vehicles are listed in Chart 1. However, only some of those vehicles within the affected range require inspection and repair. Some vehicles may have already been repaired; check the vehicle for a campaign completion sticker in addition to the Dealer Communication System (DCS). All vehicles must be confirmed as applicable using the Vehicle Coverage Inquiry in the DCS.
Dealers will be forwarded a listing of affected vehicles as indicated from the retail sale records. Customer letters will be sent only for vehicles shown as sold on the date indicated on the listings. If you sold an affected vehicle since that date, you need to contact the owner and have the customer return for the inspection/repair. Be certain to check the DCS system before contacting the owner to confirm it is an affected vehicle.
PARTS INFORMATION
One kit is required for each vehicle repaired. Each kit includes two (2) seal rings, two (2) spring pins, and two (2) gaskets.
KIT PART NUMBER APPLICABILITY DEALER COST SUGG. LIST PRICE
28097AC000 2.5L A/T $6.45 $9.03
28097AC010 2.5L M/T $6.45 $9.03
28097AC020 2.2L A/T $6.75 $9.45
28097AC030 2.2L M/T $6.75 $9.45
Dealers will be sent free of charge the following items for this repair procedure:
PART NUMBER DESCRIPTION DEALER COST
S0A635062 LOCTITE GEL N/C
S0A635063 NOX RUST N/C
S0A635064 LOCTITE PLUNGER N/C
The Loctite Gel and Nox Rust spray sent free of charge will repair approximately 250 vehicles. Be sure to follow instructions on the products for proper use and storage. If additional quantities are required you should contact your Parts Information Coordinators or Parts Expeditors as required.
SERVICE PROCEDURE
1. Set the vehicle on a lift for repair.
2. Open the hood and disconnect the front 02 sensor connector.
3. Raise the vehicle and disconnect the rear 02 sensor connector.
Note:
Do not start engine with the 02 sensors disconnected, otherwise a DTC will be set.
4. Remove the engine undercover (if applicable).
5. Remove and lower the front exhaust "Y" pipe from the engine and center pipe from the center exhaust hanger bracket, as an assembly.
6. Support the exhaust system from the left side engine mount using a generic hanger.
Caution:
Maintain clearance between the exhaust pipe flanges. This is to prevent distortion to the flanges and damage to the exhaust donut gasket.
7. Remove both stabilizer clamp to crossmember mounting brackets.
8. Remove the balljoint from the knuckle housing.
9. Remove the SFJ (DOJ) roll pin. (Do not reuse the removed roll pin.)
1O. Push the knuckle housing outward and remove the axle shaft from the transaxle.
RESEALING PROCEDURE:
1. Wipe excess grease from exterior parts of the SFJ (DOJ) prior to using brake cleaner.
NOTE:
Do not clean the grease from inside the SFJ (DOJ). Even if some leakage has already occurred, it is not necessary to remove and/or replace the existing grease inside the SFJ (DOJ).
2. Use brake cleaner or equivalent and clean the SFJ (DOJ) grease from the transaxle, crossmember and exhaust system.
3. Clean the SFJ (DOJ) grease from the splined area at the end of the SFJ (DOJ).
(Do not spray brake cleaner onto the parts directly. Spray brake cleaner on a clean rag and clean the SFJ (DOJ).)
SEAL INSTALLATION:
Caution:
The correct seal must be used for this application.
1. Install the seal on the splined end of the SFJ (DOJ) using Loctite adhesive # 4212. After seal installation, rotate the seal approximately 45 degrees and apply pressure for 30 seconds until the seal is fixed to the SFJ (DOJ).
LOCTITE ADHESIVE APPLICATION PROCEDURE:
1. Apply a uniform bead of adhesive as illustrated.
Install the oil seal to the end part of the drive shaft case.
After installing the oil seal, rotate the oil seal approx. 45 degrees and hold the oil seal to the drive shaft for approx. 30 seconds until it is fixed to the drive shaft.
1. Check the oil seal to determine whether or not it has adhered correctly.
After holding the oil seal for approx. 30 seconds, try to rotate the oil seal.
If the oil seal can not be moved, the oil seal adhered correctly.
If the oil seal can be moved easily, the cause is insufficient cleaning of the adhesive applying area and/or insufficient adhesive.
Remove the oil seal and start over again with a new seal.
Caution:
Over application of the adhesive will damage the seal.
Do not allow the adhesive to contact the seal lip surface (B) or protrude past the outer seal edge. The seal will be permanently damaged and need replacement if the adhesive contacts the seal lip surface. Do not attempt to clean the adhesive from the seal lip surface.
Perform the following steps first, allowing the Loctite to dry.
1. Check the transaxle stub axle for burrs or rust.
2. Remove any burrs or rust with fine sandpaper and clean the stub axle.
3. Wrap the splines of the stub axle with vinyl tap.
4. Apply Nox Rust (7703W) as per illustration on the stub axle and remove the tape.
5. Apply silicone grease G30M to the stub axle splines and the seal lip. This is to prevent damage to the seal lip when reinstalling the axle shaft.
(Please use the sealed roll pin contained in the OIL SEAL KIT when reinstalling SFJ (DOJ))
REASSEMBLY
1. Align the hole for spring pin, and install the drive shaft to the transmission spindle.
Caution:
Be careful not to damage the oil seal lip.
2. Insert the sealed spring pin half way.
3. Connect transverse link balljoint to the housing.
Tightening Torque: 49 +/- 10 Nm (36 ± 7 ft.-lb 5 +/- 1 kgf-m)
4. Insert the sealed spring pin all the way.
If grease is pushed out by spring pin, wipe it off.
5. Apply NOX-RUST 7703W to a clean rag and clean the baffle plate of the drive shaft.
6. Install bolts which secure stabilizer to crossmember.
Tightening Torque: 25 ± 4 Nm (18.1 +/- 2.9 ft.-lb 2.5 +/- 0.4 kgf-m)
7. Perform reassembling procedure by following reverse order of procedure 1 through 7
Tightening Torque:
Exhaust pipe to cylinder head: 30 ± 5 Nm (22.4 +/- 3.6 ft.-lb 3 +/- 0.5 kgf-m)
Exhaust pipe to hanger bracket: 35 ± 5 Nm (26 +/- 3.6 ft.-lb 3.5 +/- 0.5 kgf-m)
OWNER NOTIFICATION
SOA will prepare and mail an Owner Notification Letter to owners of the potentially affected vehicles. The owner notification is scheduled for May 1999.
DEALER PROGRAM RESPONSIBILITY
Dealers are requested to promptly inspect and repair all vehicles subject to this Service Program at no charge to owners, regardless of mileage from this time forward in accordance with the service procedures. Dealers are also to correct all affected vehicles in their inventory (new, used, demo) in accordance with the service procedures. Additionally, whenever a vehicle subject to this Service Program is taken into new or used vehicle inventory, or is in your dealership for service in the future, you should take the necessary steps to be sure the Service Program correction has been performed before selling or releasing the vehicle. Dealers are to contact owners of vehicles sold since the date of the computer listing from your new vehicle inventory, provide them with a copy of the notification letter and arrange to make the required repairs according to the service procedure.
Claim Reimbursement and Entry Procedures
Credit to perform this service campaign will be based on the submission of properly completed repair order information. Dealers may enter the applicable claim information through their Dealer Communications System (DCS).
All properly submitted claims will receive an automatic credit for parts and 1.2 labor hours for the installation of the Axle Kit. Parts will be reimbursed at dealer cost plus applicable mark-up.
Claim Entry Information
SERVICE PROGRAM IDENTIFICATION LABEL
Each vehicle corrected in accordance with the instructions outlined in this bulletin will require a service program completion label. Each label provides a space to include the dealer code of the dealer performing the Service Program. The information may be inserted on the completion label with a typewriter or permanent ink pen. After completing the information on the label, attach the label on the upper radiator cowl.
A quantity of labels are being provided to each dealer with this bulletin. Additional quantities of labels are available through your area/distributor service office.