Recall - Transverse Link Inspection/Replacement
NUMBER: WXK-68DATE: 6/29/98
APPLICABILITY:
1996/1997 Legacy Models (As noted below)
SUBJECT:
TRANSVERSE LINK ASSEMBLIES
Subaru of America, Inc. has determined that some 1996 and 1997 Legacy vehicles manufactured from June 3, 1996 through September 30, 1996 may have a defective Transverse Link Assembly. Due to a supplier manufacturing error, some Transverse Links may have been welded incorrectly during production. This recall will involve examination of vehicles with potentially defective Transverse Links, and when required, inspection of the welds according to the check procedure. Links with welds which fail the inspection procedure will require replacement.
Subaru of America, Inc. will notify all owners of the affected vehicles by first class mail and instruct them to contact their nearest servicing dealer for an inspection, and if necessary, repairs will be made.
VEHICLES INVOLVED
The affected vehicles are 1996/1997 Model Year Legacy Wagons and Legacy Outback Wagons and 1997 Model Year Legacy Sedans.
Vehicles with potentially defective transverse links are identified in Chart 1:
^ These vehicles have production dates of June 3, 1996 through September 30, 1996. ALL VEHICLES SHOULD BE CONFIRMED AS APPLICABLE AND OPEN USING THE VEHICLE COVERAGE INQUIRY IN THE DEALER COMMUNICATION SYSTEM (DCS).
OWNER NOTIFICATION
SOA will prepare and mail an Owner Notification Letter to the owners of the potentially affected vehicles. The owner notification is scheduled for mailing on July 6, 1998.
DEALER PROGRAM RESPONSIBILITY
Dealers are requested to promptly inspect, and if necessary, repair all potentially affected vehicles in their inventory (new, used, demo) in accordance with the instructions in the Service Procedure Section of this bulletin. Potentially affected vehicles taken into dealer inventory in the future should be corrected by following these service procedures. Dealers should contact owners of potentially affected vehicles sold after the date of the computer address listing and provide them a copy of the owner notification letter and arrange to make the required inspection and repairs according to the service instructions enclosed. A copy of these supplemental owner notifications should be forwarded to SOA Government Affairs Department for our records.
PARTS INFORMATION
Parts Availability
Each Subaru Dealer with vehicles affected by this Recall Campaign will receive, at no charge, an inspection tool with their potentially affected vehicle VIN list. Dealers will receive approximately 10% of the transverse link assemblies for the vehicles on their VIN list. Additional parts must be ordered from the dealer's facing parts warehouse. Replaced transverse link assemblies should be tagged and maintained for inspection by your DTM.
Parts Pricing
OVERVIEW CHART FOR TRANSVERSE LINK INSPECTION
VEHICLE SERVICE PROCEDURE
This recall campaign will have the following steps:
1) Identification of the VIN according to Chart 1
2) Identification of the Transverse Link applicability according to the "Overview Chart" on page 3. The presence of a "White Dot" on the Transverse Link will determine the next step. If both links have the "White Dot" as shown on Figure 2, then the inspection is complete. If one or both links do not contain the "White Dot," then proceed to Check Procedure 2 (gauge check).
3) After applicable check procedures are completed and the replacement of Transverse Links (if required) is completed, proceed to Claims Reimbursement and Entry Procedures.
The following procedure is for the inspection of the welds that connect the front transverse link to the transverse link bracket. This procedure will determine if the transverse link(s) need replacement.
Verify the specifications of the Transverse Link Check Gauge. Refer to figure 1
Note:
This gauge has two sides (a right side and a left side).
Note:
The procedures on the following pages will illustrate the inspection of the right transverse link. Both right and left transverse links must be inspected. When performing the inspection on the left side, turn the wheels to the right full turn. When performing the inspection on the right side, turn the wheels to the left full turn.
Check Procedure # 1:
Insert a thickness gauge (0.7 mm, 0.0275 in) to check the gap between the transverse link and transverse link bracket which is welded on the upper and lower side of the link body. Weld flashing beads on the Transverse Link may interfere with this check. When performing this check, insert the thickness gauge at different angles. This is to overcome any interference from weld flashing on the surface of the Transverse Link. Perform this procedure on both the left and right transverse links. Refer to figure 4.
Determine if the thickness gauge can be inserted between the transverse link and transverse link bracket. If the thickness gauge can be inserted between the transverse link and transverse link bracket, replace the link(s). If the thickness gauge cannot be inserted between the transverse link and transverse link bracket, the transverse link(s) are within Check Procedure # 1 specification. Proceed to the Check Procedure # 2.
Caution:
Do not remove weld flashing when performing this check. A special paint coating was applied at the factory to prevent rust.
Note:
If one or both of the transverse links pass both upper and lower checks, proceed to Check Procedure # 2. If one or both of the transverse links do not pass both upper and lower checks, replace the failed link(s).
Check Procedure # 2:
Checking Upper Portion of Transverse Links
Step 1) Use the side marked UPR on the gauge and check the welds of the upper portion on the transverse links (LH and RH). Position the gauge marked UPR between both welds. Align the edge of the gauge tight and parallel with the transfer link bracket. Refer to figure 5. Keep the rear of the gauge raised up on a slight angle away from the Transverse Link. This is to prevent any weld flashing bead interference with the gauge. Refer to figure 6.
Step 2) Determine if both Transverse Link welds interfere with the white painted portion of the gauge. If the white painted portions of the gauge contact or overlap both welds, the Transverse Link(s) are within specification. If the white painted portions of the gauge do not contact or overlap both welds, replace the Transverse Link(s) following the procedures outlined in the applicable Subaru Service Manuals. Refer to figures 7 through 9.
Note:
If the edges of the welds are recessed in the link and contact or are under the white painted portion of the gauge, this portion of the check is ok. Refer to figure 10. Make sure the portion of the gauge marked UPR is centered between both welds. Use the RH marked side of the gauge on the right transverse link and the LH marked side of the gauge on the left transverse link.
Checking Lower Portion of Transverse Links
Step 1) Use the side marked LWR on the gauge and check the welds of the lower portion on the transverse links (LH and RH). Position the gauge marked LWR between both welds. Align the edge of the gauge tight and parallel with the transfer link bracket. Refer to figure 11 Keep the rear of the gauge raised up on a slight angle away from the Transverse Link. This is to prevent any weld flashing bead interference with the gauge. Refer to figure 12.
Step 2) Determine if both Transverse Link welds interfere with the white painted portion of the gauge. If the white painted portions of the gauge contact or overlap both welds, the Transverse Link(s) are within specification. If the white painted portions of the gauge do not contact or overlap both welds, replace the Transverse Link(s) following the procedures outlined in the applicable Subaru Service Manuals. Refer to figures 13 through 15.
Note:
If the edges of the welds are recessed in the link and contact or are under the white painted portion of the gauge, this portion of the check is ok. Refer to figure 16. Make sure the portion of the gauge marked LWR is centered between both welds. Use the RH marked side of the gauge on the right transverse link and the LH marked side of the gauge on the left transverse link.
Transverse Link(s) That Do Not Require Replacement.
Reinstall both front wheels and torque wheel lug nuts to proper specifications.
Transverse Link(s) That Require Replacement.
Step 1) Replace the transverse link(s) following the procedures outlined in the applicable Subaru Service Manuals.
Step 2) Reinstall both front wheels and torque wheel lug nuts to proper specifications.
Step 3) Check the front wheel alignment and adjust if necessary.
CLAIM REIMBURSEMENT AND ENTRY PROCEDURES
Credit to perform the WXK-68 Recall 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 of 0.2 labor hours for initial inspection and verification of transverse link identification markings.
Claims for further transverse link inspection with the special gauge tool will be credited a total of 0.5 labor hours. (This includes 0.2 hours for the initial inspection and 0.3 hours for complete inspection with the special gauge tool.) In addition:
If replacement of one transverse link is required an additional 1.4 labor hours will be credited. (This includes the time necessary to perform a front suspension alignment.)
If replacement of both transverse links is required an additional 1.8 labor hours will be credited. (This includes the time necessary to perform a front suspension alignment.)
Parts will be reimbursed at suggested list price.
Listed below is claim entry information:
Inspection Only - Verification of the transverse link identification markings only. Transverse links on vehicle do not require further inspection with the special gauge tool. (0.2 labor hours will be automatically added to the claim upon submission):
Complete Inspection (Using the Special Gauge Tool) with or without Part Replacement - Transverse links that require complete inspection using the special gauge tool - use labor operation 161-201 for 0.3 labor hours.
Note:
A total of 0.5 labor hours will be credited. (This includes 0.2 hours automatically added to the claim for initial inspection.)
Add the following labor operation number if part replacement is required:
Replace One Transverse Link - use labor operation 161-141 for 1.4 labor hours. (This includes the time necessary to perform a front suspension alignment.)
Replace Both Transverse Links - use labor operation 161-144 for 1.8 labor hours. (This includes the time necessary to perform a front suspension alignment.)
Parts will be reimbursed at suggested list price.
SERVICE PROGRAM IDENTIFICATION LABEL
Each vehicle corrected in accordance with the instructions outlined in this bulletin will require a "Recall Campaign" completion label. Each label provides a space to include the dealer code performing the service program. The information may be inserted with a typewriter or permanent ink pen and placed on the upper radiator cowl.
A quantity of 25 labels are being provided to each dealer with this bulletin. Additional quantities of these labels are available through your area/distributor service office.