Recall - M/T Mainshaft/Gear Replacement
NUMBER: WVS-29DATE: July 2010
APPLICABILITY:
2O10~11 MY Subaru Legacy & Outback with 6M1
SUBJECT:
6 Speed Manual Transmission Transfer Case
INTRODUCTION
Subaru of America, Inc. has determined that certain 2010 & 2011 Legacy and Outback models equipped with a 6 speed manual transmission were produced with a transmission transfer case that was manufactured without a necessary oil lubrication passage. As a result, certain gears within the transmission could eventually break due to a lack of lubrication. This recall will involve modifying the transmission transfer case by opening the oil lubrication passage at the originally intended location.
Additionally, affected vehicles with 6,250 or more miles will require replacement of the main shaft and 3rd through 6th gear set.
There is a potential safety risk associated with this condition. If the transmission gears are not properly lubricated, a groaning sound may begin to develop alerting the driver of a problem. If the sound is ignored and no action is taken, the gears will eventually break and this condition will lead to vehicle power loss, which might result in a crash.
AFFECTED VEHICLES
^ 2010 & 2011 Subaru Legacy and Outback with 6MT
Potentially affected vehicles are identified in the VIN range chart.
Note: Not all vehicles in the VIN range are affected. Prior to performing repairs, confirm coverage by using the Vehicle Coverage Inquiry function at the website.
OWNER NOTIFICATION
SOA will prepare and mail an Owner Notification Letter to owners of the affected vehicles on or around July 28, 2010.
A copy of the Owner Notification Letter is included at the end of this bulletin.
DEALER PROGRAM RESPONSIBILITY
Dealers are to promptly perform the applicable service procedures defined in this bulletin to correct all affected vehicles in their inventory (new, used, demo). Additionally, whenever a vehicle subject to this recall is taken into dealer new or used inventory, or is in the dealership for service, necessary steps should be taken to ensure the recall correction has been made before selling or releasing the vehicle.
New or used vehicles listed in a recall/campaign that are in dealer stock must be:
^ Immediately identified.
^ Tagged or otherwise marked to prevent their delivery or use prior to inspection and/or repair.
^ Repaired in accordance with the repair procedures outlined in this Product Campaign Bulletin.
Please be advised that it is a violation of Federal law for a dealer to deliver a new motor vehicle covered by a recall under a sale or lease until the defect is remedied. Therefore, any Authorized Subaru Dealer failing to perform the applicable service procedures as defined in this bulletin to correct all affected vehicles in their inventory (new, used, demo) prior to the vehicle being placed in service may be subject to civil penalties of up to $6,000 per violation (i.e., for each vehicle), as provided in 49 CFR section title (symbol) 578.6 and will also be in breach of the Subaru Dealer Agreement.
PARTS INFORMATION
Required part replacement is determined by vehicle mileage as follows:
For vehicles with 6.249 or less miles:
On July 16, 2010, SOA automatically shipped each dealer a quantity of repair parts equivalent to their affected inventory and sold units. Dealers may order any additionally needed parts through normal parts ordering procedures.
For vehicles with 6.250 or more miles:
Please Do Not Stock Order This Part.
Main shaft and gear set replacement is only necessary when odometer mileage is 6,250 or greater. Since the number of affected vehicles with 6,250 or more miles is relatively low and part availability limited, dealers should not stock order this part. To place an order, dealers will need to contact a Parts Information Coordinator for assistance. The VIN and vehicle mileage will be requested at the time the order is placed. The part will be shipped prepaid next day air.
SPECIAL TOOLS
Repairs associated with this recall require the use of a special tool kit. Each dealer that has either sold or has an affected vehicle in inventory was automatically sent a Transmission Drilling Tool Kit p/n SOA008T001 on or around July 15, 2010.
Note:
Due to the low number of affected vehicles, not all dealers will encounter vehicles requiring repair. Therefore, dealers that did not automatically receive a tool kit should only order the tool kit when and if it is needed.
RENTAL CAR
For retail customers, SOA will pay the cost of a one-day car rental when an affected vehicle has 6,250 or more miles and requires transmission main shaft and gear set replacement. Repairs must begin and parts ordered on the same day the vehicle arrives for service. The one-day car rental charges should be included with the Recall/Campaign claim submission. See the Claim Submission section of this bulletin for claim entry instructions.
SERVICE PROCEDURE
This recall will involve modifying the transmission transfer case by opening the oil lubrication passage at the originally intended location.
Check the vehicle odometer.
For vehicles with 6,250 or more miles, see after step 25 in this bulletin.
For vehicles with 6,249 or less miles, proceed as follows:
1) Record preset radio stations
2) Position the vehicle on a lift and put the transmission in neutral.
3) Disconnect the negative battery cable.
4) Refer to Technical Reference Booklet for 2010 New Technology Training (Module 919) to install special tool 1-50135 (Engine Support Bridge).
Note:
For this procedure only, it is not necessary to replace the rear engine support hook with ST J-50136 as the entire engine weight is not being supported.
5) With engine weight supported by ST, remove the horizontal bolt from the front engine mount.
6) Refer to the appropriate service manual to perform the following procedures:
^ Remove the air intake boot assembly
^ Remove the center exhaust pipe
^ Remove the propeller shaft
^ Remove the transmission cross member
^ Remove the rear transmission mount
^ Drain transmission fluid.
7) Use the engine support bridge to raise the front of the engine so the bottom of the engine mount bolt hole is at the top of the engine mount bracket. This will lower the back of the transmission to allow for transfer case removal.
8) Refer back to the service manual to perform the following procedures:
^ Disconnect the wiring harness connectors from transfer case
^ Remove wiring harness bracket
^ Remove shift cables from transmission
9) Remove transmission cover (A) carefully as there is a spring and plunger on the backside of the cover. Be careful not to drop the spring and plunger.
Note:
Remove straight pin (B) and set aside. Selector Lever (A) will remain in place Caution: Do not drop straight pin into transmission.
10) Set and hold the selector lever to the 1st-2nd side, and remove the transfer case and extension case assembly as a unit.
11) Remove oil guide
12) Install clear plastic protector plate into transmission side of transfer case. Push the cover into the transfer case as far as possible. The cover should be bottomed-out so the filings drop out of the case when drilling.
13) Use the included C-clamps to secure the transfer case to a workbench.
14) Before installing the jig to the transfer case, ensure that the drill bit moves freely within the guide. If the drill bit catches the bracket on the backside of the jig, lightly tap the bracket to allow free movement of the drill bit.
15) Install the jig to the transfer case and secure with 2 bolts, one at the top and one at the bottom of the jig.
16) Attach an adequate vacuum source to the suction hose of the jig.
17) With the vacuum running~ drill the transfer case through the drill bit guide. Do not drill past the paint mark on the drill bit.
Caution:
Be sure to wear safety glasses when drilling.
Note:
Drill slowly to prevent large pieces of aluminum from clogging suction hose.
18) Remove the jig.
19) Use a round file to remove any burrs on the newly drilled hole in the transfer case.
20) Remove any remaining filings from both sides of the new hole with brake cleaner and wipe with a clean rag.
21) Remove C-clamps and remove clear plastic protective cover. Again, check for metal filings in the transfer case cavity and clean as necessary.
22) Reinstall oil guide.
23) Reinstall transfer case in reverse order of removal.
24) Reconnect negative battery cable.
25) Reset radio stations.
For vehicles with 6.250 or more miles. replacement of the main shaft and 3rd through 6th gear set will be required. As indicated in the following repair procedure. a special "Transmission Gears and Gasket Set" is available for this repair.
Proceed as follows:
1) Record preset radio stations.
2) Position the vehicle on a lift and put the transmission in neutral.
3) Disconnect the negative battery cable.
4) Referring to the applicable Service Manual, remove the transmission from the vehicle and follow the repair procedure for replacing the main shaft along with the 3rd & 4th, 5th and 6th gear sets including bearings, sleeves and hubs, and syncro set. Since the gears are supplied as sets, it is also necessary to replace related gears on the Pinion Shaft. (Parts requiring replacement are contained in the "Transmission Gears and Gasket Set" part number 32001AA360. In addition, part numbers 803520030 - qty 1 (Locking Washer - Pinion Shaft) and 802620100 - qty 1 (Locking Nut - Pinion Shaft) are also required.)
Note:
The kit contains repair parts for turbo and non-turbo models. Specifically, the 5th and 6th gear sets are different. They can be identified as follows:
5) Before reinstalling the transfer case, open the oil passage by following the procedures beginning with step 11 in this bulletin.
6) Reassemble the transmission and reinstall in vehicle. Add gear oil part number K0322AA093.
7) Reconnect negative battery.
8) Reset radio stations.
9) Road test vehicle to ensure proper operation.
SERVICE PROGRAM IDENTIFICATION LABEL
Type or print the necessary information on a Service Program identification label. The completed label should be attached to the vehicle's upper radiator support. Additional labels are available through the Subaru Claims Helpline.
CLAIM REIMBURSEMENT AND ENTRY PROCEDURES
Credit to perform this service program will be based on the submission of properly completed repair order information. Dealers may submit claims through Vehicle Claim Entry on the website.
For vehicles requiring main shaft and gear replacement only:
Rental Car Charges: If applicable, rental car charges should be entered on the RC claim in the Rental field.