Recall - Brake Master Cylinder Replacement
NUMBER: WXQ-74DATE: 05/20/99
APPLICABILITY:
All 1998 and some 1999 Model Forester and Legacy Vehicles Equipped with ABS (See Chart 1)
SUBJECT:
Secondary Circuit Failure in Master Cylinder Under Extremely Cold Conditions
Subaru of America, Inc. has determined that in extremely cold weather conditions (approximately 20 degrees below Zero Fahrenheit and colder. -20°F), with normal light brake application, there is a possibility that the brake pedal may have increased pedal travel and increased stopping distances. This is caused by an internal supply valve, which is part of the secondary piston of the master cylinder, that may momentarily stick in the open position and cause a decreased braking pressure in the secondary circuit. The primary circuit of the master cylinder continues to operate properly.
VEHICLES INVOLVED
The affected vehicles are:
Make/Model: Subaru Legacy and Forester with ABS.
Model year: 1998 and some 1999
(1999MY 2.2 Liter Legacy Vehicles are Excluded)
Production dates: April 11, 1997 through March 10, 1999.
OWNER NOTIFICATION
SOA will prepare and mail an Owner Notification Letter to owners of the potentially affected vehicles in 2 stages. Since this is a cold weather related problem, we will mail letters initially to potentially affected owners in cold weather areas. This includes owners in the 10 states of AK, MT, ND, MN, WI, MI, upstate NY, ME, NH, and VT. This initial mailing is planned for early June 1999. As additional parts are received, we will mail notification letters to owners of potentially affected vehicles in all other continental states.
DEALER CAMPAIGN RESPONSIBILITY
Once owner letters are mailed in their area, dealers are requested to replace the master cylinders on 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 repairs according to the service instructions.
PARTS INFORMATION
Replacement Subaru master cylinders will be allocated initially to dealers in the (10) cold weather states in an amount equal to 50% of vehicles on the affected VIN list. As additional part quantities become available, dealers will be sent parts for the remaining vehicles. Additional quantities may be ordered from the dealers' facing warehouse. Please note that orders will be reviewed to ensure that quantities ordered are reasonable.
Parts Pricing
10 Cold Weather States:
Replacement Subaru master cylinders will be allocated initially to dealers in the 10 cold weather states in an amount equal to 50% of vehicles on the affected VIN list. Within a few weeks as more parts become available, dealers in cold weather states will be sent the remaining 50% of parts for the affected VIN list.
Unsold In-Stock Vehicles:
After parts have been allocated to dealers in cold weather states, parts will be allocated to dealers for all unsold in-stock vehicles.
Non cold Weather Areas:
Notification to vehicle owners in non-cold weather areas is likely to be early July. We anticipate having a sufficient parts supply at that time, however, we WILL make an initial allocation parts to dealers in the non-cold weather areas. WE ASK THAT DEALERS IN NON COLD WEATHER STATES NOT ORDER ADDITIONAL PARTS UNTIL AFTER YOUR INITIAL ALLOCATION IS RECEIVED IN LATE JUNE. After that, dealers should order master cylinders on their normal stock order to their facing warehouse. Please note that orders will be reviewed to ensure that quantities ordered are reasonable.
Should a dealer in the non-cold weather area need a master cylinder for a vehicle prior to the official owner notification, the dealer should call his/her Parts Expeditor (SNE & SDC dealers) or Parts Information Coordinator (SOA dealers).
SERVICE PROCEDURE
Repair the vehicle as follows:
CAUTION:
Be extremely careful not to spill brake fluid on any vehicle surface. Brake fluid will harm the painted surfaces. Be sure to protect any painted surface that may be potentially exposed with an appropriate protective cover. Technicians should also wear safety glasses to protect their eyes during the performance of the following procedure.
1. Remove the master cylinder in accordance with the procedures in the appropriate Subaru Service Manual.
2. Install the replacement master cylinder in accordance with the procedures in the appropriate Subaru Service Manual.
3. Perform the brake caliper/wheel cylinder air bleeding procedure in accordance with the procedures in the appropriate Subaru Service Manual.
4. Perform the ABS Sequence Control Air Bleeding in accordance with the procedures in the appropriate Subaru Service Manual.
5. Road test the vehicle to ensure proper function of braking system.
CLAIM REIMBURSEMENT AND ENTRY PROCEDURES
Credit to perform the WXQ74 recall will be based on the submission of properly completed repair order information. Dealers may enter the applicable claim information through their Dealer Communication System (DCS).
All properly submitted claims will receive a credit of 1.0 labor hours for replacement of the Master Cylinder. Parts will be reimbursed at dealer cost plus applicable handling allowance.
Listed below is claim entry information:
Replacement of the Master Cylinder- Use the following claim submission information for replacement of the Master Cylinder. Enter labor operation 153-321 for 1.0 labor hours and the applicable part numbers.
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 of the dealer performing the recall campaign. 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 100 labels are being provided to each dealer with this bulletin. Additional quantities of labels are available through your area/distributor service office.
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