Recall - Brake Master Cylinder Inspection/Replacement
NUMBER: WVY-35R1DATE: December 2011
APPLICABILITY:
2012MY Legacy, Outback & Impreza (except WRX & STI)
SUBJECT:
Brake Master Cylinder
INTRODUCTION
Subaru of America, Inc has determined that certain 2012 Legacy/Outback and Impreza (except WRX & STI) models may be equipped with a brake master cylinder that could malfunction and cause an increase in the amount of brake pedal travel distance required to slow or stop the vehicle. As a result, the driver might misjudge the amount of brake pedal travel required to achieve the desired stopping distance. This could occur unexpectedly and without prior warning.
In vehicles experiencing this condition, the driver will initially encounter a soft pedal feel and may momentarily perceive a sense of loss in braking power while the pedal is being pressed lightly. This will only continue until the pedal is pressed downward approximately two (2) more inches. Effective braking function will be achieved at that point, making it possible to slow or stop the vehicle.
This recall will involve checking the brake master cylinder part number stamped on the housing and, if necessary, replacing the master cylinder.
AFFECTED VEHICLES
^ 2012MY Subaru Legacy & Outback.
^ 2012MY Subaru Impreza (except WRX & STI)
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 Subarunet.com.
OWNER NOTIFICATION
SOA will prepare and mail Owner Notification Letters to owners of affected vehicles on or around December 5, 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, 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 (ie, for each vehicle), as provided in 49 CFR Section 578.6 and will also be in breach of the Subaru Dealer Agreement.
REPAIR PARTS
Parts started to ship to dealers on Wednesday November 23rd. These next day air shipments are prioritized based on the oldest retailed VINs for Legacy / Outback and the oldest sold orders for Impreza. These orders will continue to be shipped next day air on a daily basis as soon as parts are received at our distribution centers Dealers should not attempt to order these parts until further notice. It is anticipated that we will be able to supply all parts requirements for Legacy / Outback retailed units during the week of December 5th and all Impreza sold units by the week of December 12th For reference, these initial shipments will include the applicable VIN as part of the parts order number.
Dealer Priority Process
In line with our shipping priority, we are requesting that dealers prioritize repairs for retailed units for Legacy / Outback and sold orders for 2012 Impreza.
INSPECTION PROCEDURE
The countermeasure parts can be identified by the stamping of the last 5 characters of the part number on the end of the cylinder housing.
REPAIR PROCEDURE
The brake master cylinder must be replaced with a modified part as described. Follow the Subaru Service Manual for the specific model vehicle for instructions Follow all safety and technical practices, etc.
Brake fluid will damage any painted surface Protect all surfaces of the body and chassis from brake fluid drips. Wash any drips off immediately and inspect for damage.
Brake fluid is hydroscopic Only use new Genuine Subaru Brake Fluid from a sealed container.
Cautionary Tips
1. Master Cylinder Removal:
a) To prevent brake fluid from dripping on the chassis, engine and suspension components, insert an industrial absorbent mat under the cylinder.
b) Drain the cylinder completely using a syringe prior to removing the brake pipes or clutch cylinder hose (MT).
c) Immediately plug the brake pipe openings and clutch hose (MT) to prevent leakage and air/contamination entry.
2. Seal Installation on New Master Cylinder:
a) Before installing the seal on the new master cylinder; ensure that the piston rod is free of any contamination or moisture.
b) Apply grease to the piston rod, seal and booster bore.
c) After greasing the piston rod and seal, do not allow the piston rod or seal to become contaminated.
d) Install the seal in the direction shown, and ensure that it is seated with the nibs touching the base on the cylinder bore.
e) Make sure that the piston rod is fully inserted, but not compressed into the cylinder bore before installing the cylinder to the brake booster.
3. Follow Brake Bleeding procedures in the Service Manual for Master Cylinder Replacement, including the "Sequence Control" procedure.
SERVICE PROGRAM 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 Warranty 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 Subarunet corn
OWNER NOTIFICATION LETTER
Disclaimer