Recall - Potential Sunroof Glass Panel Detachment: Overview
NUMBER: WVW-33DATE: September 2011
APPLICABILITY:
2011 Subaru Legacy & Outback
SUBJECT:
Moonroof (Sunroof) Glass
INTRODUCTION
Subaru of America, Inc. has determined that certain 2011 Legacy and Outback models equipped with a power Moonroof (Sunroof) may have been produced with an insufficient amount of adhesive applied between the moonroof glass panel and frame. As a result, the glass panel could separate from its frame and potentially become loose or detach.
This recall will involve inspecting the moonroof glass and frame to ensure the proper amount of adhesive is present. If the adhesive is sufficient, no further action is required. if not, additional adhesive will need to be added at the appropriate locations. In some rare cases, it may be necessary to replace the glass.
AFFECTED VEHICLES
^ 2011 Subaru Legacy and Outback
Potentially affected vehicles are identified in the VIN range chart. Prior to performing repairs, confirm coverage by using the Vehicle Coverage Inquiry function at the website.
Dealer Affected VIN lists:
Dealers will be sent an affected VIN 114 around the time owner notification letters are mailed.
Affected VIN lists are created and "dealerized" as follows:
^ Original vehicle owners are assigned to the original selling dealer when their current address is within a 100 mile radius of that dealer
^ If the original selling dealer code was found to be inactive, the VIN has been assigned to the nearest active dealer.
^ For any new owners or when original owners live more than 100 miles from the original selling dealer, the VIN has been assigned to the nearest active dealer.
Important:
Dealer affected VIN lists include owner name and address information for vehicles affected by this recall. This information will enable dealers to follow-up with owners of potentially affected vehicles. The lists contain owners' names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is unlawful. Accordingly, dealers are urged to limit the use of these lists for the purpose of completion of this recall.
OWNER NOTIFICATION
SOA will prepare and mail an Owner Notification Letter to owners of the affected vehicles on or around October 3, 2011.
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, only 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 578.6 and will also be in breach of the Subaru Dealer Agreement.
PARTS INFORMATION
Special Tools & Materials
Each dealer will automatically be shipped, at no cost, one adhesive applicator gun
Additionally, each dealer will automatically be sent an initial supply of Lord 7150 A/B
Adhesive in 50ml tubes and adhesive applicator gun nozzles Each 50ml tube provides enough adhesive to repair two vehicles, and is packaged with two applicator gun nozzles
Dealers will need to order any additional supply through normal parts ordering procedures
For claim reimbursement purposes, dealers should use the following part number, which represents 1/2 tube of adhesive and one applicator gun nozzle (per repair):
SERVICE PROCEDURE
This recall will involve inspecting the moonroof glass and frame to ensure the proper amount of adhesive is present If the adhesive is sufficient, no further action is required If not, additional adhesive will need to be added at the appropriate locations In some rare cases, it may be necessary to replace the glass
Please proceed as follows:
Tools and Material Required
Urethane Bead Inspection Procedure
1) Open Sunshade
2) Verify if the urethane beads are present (6 Beads / 40mm or more in length) Imagine the moonroof being divided into 6 equal sections (270mm blue arrow) Inside each of the six squares there should be a 4Ornrn or longer bead (red line) of urethane between the moonroof glass and moonroof frame in each section
NOTE:
Some vehicles may have two long urethane beads, which is also acceptable
To locate the urethane beads, a metal ruler is used as a depth gauge which is inserted between the moonroof glass and moonroof frame.
Slide the ruler between the moonroof glass and moonroof frame. Slide the ruler in a sideways motion until you locate one of the ends of the urethane bead. Using a pencil~ place a small mark on the frame to mark the position.
Slide the ruler along the bead until you can locate the other end of the urethane bead Place a small mark on the frame to mark that position.
Measure the length of the urethane bead between the marks The length of each bead must be at least 40mm. Repeat the step for the other five urethane beads.
If any of the six urethane beads measure less than 4Omm in length, or no beads can be detected (missing), the Adhesive Repair Procedure will need to be performed Refer to the Adhesive Repair Procedure in this bulletin.
3) Erase the pencil marks.
4) If all six beads are 40mm or longer the next step is to inspect the 4 corners of the moonroof glass for separation.
Moonroof Glass Corner Separation Test
1) Using a plastic trim tool, check all four corners of the moonroof glass.
^ Insert the plastic trim tool between the frame and glass starting at the front left corner.
^ Using a reasonable amount of force, attempt to rotate the plastic trim tool up to 90 degrees from the surface of the glass. While rotating the plastic trim tool, listen, look and feel for any separation of the glass from the frame.
^ If adhesion is inadequate the frame will move easily. If adhesion is adequate there will be little to no movement.
^ Check the remaining three comers.
^ If any separation occurs at any of the four corners, replace the moonroof glass/frame.
Refer to the applicable Subaru Service Manual for the replacement procedure.
NOTE:
If the moonroof passes both the Urethane Bead Inspection Procedure and the Moonroof Glass Corner Separation Test~ then no further action or repair is required.
Adhesive Repair Procedure
IMPORTANT:
The moonroof glass must be removed from the vehicle to perform the following procedure. DO NOT attempt to apply adhesive with the moonroof glass installed in the vehicle The adhesive will not bond as intended
1) Remove the moonroof glass
CAUTION:
When removing the clip, use great care not to damage the roof trim.
a) Completely close the glass lid, and then open the sunshade.
b) Disconnect the claws and then remove the lid cover.
CAUTION:
Be careful not to damage or scratch the moonroof glass.
c) Remove the bolts and then remove the moonroof glass
2) Place moonroof glass on a covered workbench frame side up.
3) IMPORTANT: To ensure proper adhesion~ clean the appropriate areas of the glass and frame with a suitable cleaner such as household isopropyl alcohol.
4) Prepare the Adhesive Applicator.
Some Quick Facts about Lord 7150 A/B Adhesive.
^ It begins to harden in 5 to 10 minutes.
^ It reaches full strength in 18 to 24 hours.
^ It's solvent Free and Non-Flammable.
Install 50ml 2:1 slide into applicator gun and adhesive tube. NOTE: Do NOT remove the cap from the adhesive tube until you are ready to apply
NOTE:
The start and stop points are critical for appearance, as well as bead size. Try not to exceed a 7mm bead.
a) Once you are ready to apply the adhesive~ remove the cap and install a new nozzle. Be sure to save the cap so the tube may be sealed to preserve any remaining adhesive.
5) Using the applicator gun, apply adhesive to frame and glass. The material flows easily, do not apply a lot of force when squeezing the trigger.
a) Repeat the procedure on the opposite end.
NOTE:
After installing adhesive remove nozzle and install cap to tube. The adhesion material sets up quickly. If the material in the nozzle hardens the gun could be damaged.
6) Use a damp cloth and clean any streaks or extra adhesive which may be on the glass.
7) Let the moonroof sit for 20 minutes afier applying adhesive before installing in vehicle.
8) Install moonroof and frame in reverse order of removal. Make sure to torque all bolts to 4.5 N.m (0.46 kgf-m 3.3 ft-lb).
9) Moonroof glass must not be opened for at least 24 hours. Install label* over switch to remind the customer.
* Each dealer will be provided a supply of switch labels. The labels will be sent with dealer affected VIN lists.
Additional labels are available through the Subaru Claims Helpline.
RECALL IDENTIFICATION LABEL
Type or print the necessary information on a recall identification label The completed label should be attached to the vehicles upper radiator support.
Additional labels are available through the Subaru Claims Helpline.
CLAIM REIMBURSEMENT AND ENTRY PROCEDURES
Credit to perform this recall will be based on the submission of properly completed repair order information Dealers may submit claims through Vehicle Claim Entry on the website.
Disclaimer