product campaign bulletin - negative splits...• 2001-03 my subaru legacy and outback with 4eat....

Bulletin Number:WWK-94; Date: 12/2002Bulletin Number:WWK-94; Date: 12/2002Bulletin Number:WWK-94; Date: 12/2002Bulletin Number:WWK-94; Date: 12/2002Bulletin Number:WWK-94; Date: 12/2002 Page Page Page Page 1111

PRODUCT CAMPAIGN BULLETIN

CAUTION: VEHICLE SERVICING PERFORMED BY UNTRAINED PERSONS COULDRESULT IN SERIOUS INJURY TO THOSE PERSONS OR TO OTHERS.

Subaru Service Bulletins are intended for use by professional technicians ONLY. They are written to informthose technicians of conditions that may occur in some vehicles, or to provide information that could assist inthe proper servicing of the vehicle. Properly trained technicians have the equipment, tools, safety instructions,and know-how to do the job correctly and safely. If a condition is described, DO NOT assume that this ServiceBulletin applies to your vehicle, or that your vehicle will have that condition.

ATTENTION:ATTENTION:ATTENTION:ATTENTION:ATTENTION:GENERAL MANAGER o PARTS MANAGER o

CLAIMS PERSONNEL o SERVICE MANAGER o

IMPORTANT - All Service Personnel Should Read and Initial

NUMBER: WWK-94DATE: 12/2002

APPLICABILITY: 2001-03MY Legacy and Outback 4EAT2002-03MY Impreza 4EAT2002-03MY Forester 4EAT2003MY Baja 4EAT

SUBJECT: 4EAT Parking Pawl Rod

INTRODUCTION

Subaru of America, Inc. (SOA) has determined that affected vehicles may have been producedwith an improperly manufactured transmission parking pawl rod. The parking pawl rod maynot provide sufficient spring tension to immediately engage the parking pawl to the park gearwhen the transmission is placed in the “Park” position. This may allow the vehicle to move/roll prior to engaging.

This recall will involve the replacement of the transmission parking pawl rod and related partson affected vehicles.

AFFECTED VEHICLES

• 2001-03 MY Subaru Legacy and Outback with 4EAT.• 2002-03 MY Impreza with 4EAT.• 2002-03 MY Forester with 4EAT.• 2003 MY Baja with 4EAT

Affected vehicles are identified in the VIN range chart on the following page.

In addition, some vehicles outside of the affected VIN range may have had a new orremanufactured replacement transmission installed that contains an affected parking rod. SOAhas identified these vehicles and included them in this recall.

NOTE: Prior to performing repairs, confirm coverage for potentially affected vehiclesby using the Vehicle Coverage Inquiry in the Dealer Communication System (DCS).

Page Page Page Page 2222 Bulletin Number:WWK-94; Date: 12/2002 Bulletin Number:WWK-94; Date: 12/2002 Bulletin Number:WWK-94; Date: 12/2002 Bulletin Number:WWK-94; Date: 12/2002 Bulletin Number:WWK-94; Date: 12/2002

MODEL FROM TO

2001MY Sedan (4cyl) 17216189 17216424Outback Wagon (6cyl) 17679611 17679731

Legacy(1) 2002MY Sedan (4cyl) 27200031 27216845

Wagon (4cyl) 27300008 27311201Outback Sedan (6cyl) 27200022 27216832Outback Wagon (4cyl) 27600009 27667116Outback Wagon (6cyl) 27601934 27667102

2003MY Sedan (4cyl) 3*200002 3*206617Wagon (4cyl) 3*300001 3*305377

Outback Sedan (6cyl) 37200010 37205761Outback Wagon (4cyl) 37600004 37621761Outback Wagon (6cyl) 37600002 37621700

Impreza 2002MY Sedan 2H509931 2H531625(1) Wagon 2H809582 2H837221

2003MY Sedan 3H500003 3H504370Wagon 3H800001 3H803463

Forester 2002MY 2H718049 2H760039(1) 2003MY 3H700001 3H728406

Baja 2003MY 37100001 37102550(1)

(*) The number 5 or 7 occupy this position.(1) Models with manual transmission are not affected.

OWNER NOTIFICATION

There will be two owner notification letters sent to owners of affected vehicles.

The first owner notification letter was sent in November 2002. The letter will explain theparking rod condition and advise owners that repair parts will be available in January 2003.The letter will also explain the importance and need to use the parking brake.

The second owner notification letter will be sent in January 2003. The letter will adviseowners that repair parts are available.

A copy of both owner notification letters is included at the end of this bulletin.


DEALER PROGRAM RESPONSIBILITY

Dealers are to promptly service all vehicles subject to this recall at no charge to the vehicleowner regardless of mileage, age of the vehicle, or ownership.

For affected vehicles sold after the date on the dealer’s computer list, dealers are to contactthose owners and provide them with a copy of the owner notification letter. They should alsoarrange to make the required correction according to the instructions in the service proceduresection of this bulletin.

Vehicles in Dealer Inventory

Dealers are also to promptly perform the applicable service procedures defined in this bulletinto correct all affected vehicles in their inventory (new, used, demo). Additionally, whenever avehicle subject to this recall is taken into dealer new or used inventory, or is in the dealershipfor service, necessary steps should be taken to ensure the recall correction has been madebefore 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.• Inspected and/or repaired in accordance with instructions outlined in the

Product Campaign Bulletin.

Any Authorized Subaru Dealer failing to perform the applicable service procedures defined inthis bulletin to correct all affected vehicles in their inventory (new, used, demo) prior to thevehicle being placed in service may be subject to civil penalties of up to $5,000 per violation(i.e., for each vehicle), as provided in 49 USC §30165(a) of the Safety Act, and will also be inbreach of the Subaru Dealer Agreement.

PARTS INFORMATION

Each dealer will automatically be sent a quantity of replacement parts (except Dexron III ATF)equal to 60% of the number of affected vehicles allocated to the dealer of record.

MODEL DESCRIPTION PART NUMBER QUANTITY

All Parking Rod Kit Assy. X3197AA043 1Three Bond Sealer (large tube) K0877YA020 --Dexron III ATF (Quart) SOA635003 6

Replacement Transmissions

Affected vehicles that have had a new or remanufactured replacement transmission with anaffected parking rod have been identified. Owners of these vehicles will be notified andincluded in this recall. This may include vehicles that are outside of the affected VIN range.


Any new or remanufactured transmission purchased from SOA after November 18, 2002 willnot require replacement of the parking rod. All new and remanufactured transmissionsshipped from SOA warehouse inventory after November 18, 2002 have been inspected andmodified as necessary. Only those transmissions in warehouse inventory affected by theWWK-94 parking rod recall have had the parking rod replaced. Those transmissions can beidentified in one or more of the ways listed below.

If a replacement transmission, purchased after November 18, 2002, is installed in a vehicleaffected by the WWK-94 parking rod recall, do not perform the recall. Contact the CDSdepartment at SOA to have the recall closed and identified as completed.

Remanufactured Transmissions (part number ending in R1):

· The converter housing of the transmission shall have a self-adhesive label reading“WWK94” affixed to it· “WWK94” is ink stamped or written on the boss next to the transmission serial number ontop of the converter housing· The remanufacturers identification tag (also affixed to the converter housing) shall have“WWK94” stamped into it following the serial number in the serial number field· The plastic shipping container shall have two “WWK94” self adhesive labels applied to it.One on the front and one on the side.· The shipping container may also bear “WWK94” stencil painted in white on the top or sideof the container in lieu of the self-adhesive labels.

New Transmissions (straight part number or part number ending in S1):

· “WWK94” is ink stamped or written on the boss next to the transmission serial number ontop of the converter housing· The shipping container will bear “WWK94” stencil painted on the top or side of thecontainer· The wooden crate will bear “WWK94” stencil painted on the top or side of the crate

REPAIR PROCEDURES

l Park the vehicle over a lift.l Turn the engine off and leave the ignition switch in the “Off” position.l Place the transmission shift selector in the “3” range position.l Raise the vehicle hood and lift the transmission dipstick about 1 inch.l Raise the vehicle on the lift.

Note: It is extremely important that the area in which this repair takes place remainsclean to prevent contamination of internal transmission parts.


Heat Shield Removal (H6 models only)

H6 models only - Remove the heat shield from the left front catalytic converter.

Transmission Oil Pan Removal

1. Drain the transmission fluid by removing the drain plug. While the transmission is draining,remove the oil pan bolts.

2. When the transmission fluid has finished draining and the pan bolts have been removed,reinstall the drain plug with the new gasket. Torque to 18.4 ± 1.4 ft-lb. (25 ± 2 Nm)

3. Separate the oil pan from the transmission case by using a liquid gasket cutter or similartool.

Caution: Do not insert a screwdriver or chisel between the oil pan and the transmissioncase. This will damage the oil pan and transmission case. To prevent damage to theinternal wire harness, do not insert the gasket cutter beyond the lip of the pan.


4. Separate the oil pan from the rear side of the transmission and drain the remaining ATF.

Valve Body Removal

Disconnect the wire connectors from each solenoid.

Note: If the oil temperature sensor is integrated into the wire harness, disconnect the oiltemperature sensor from the clip on the valve body.

Applicable transmission numbers for different types of oil temperature sensor as follows:

Type of oil temperature sensor Separate Oil temperature sensor Oil temperature sensorintegrated into harness

Applicable transmission number Up to 661853 After 661854

Note: Try the following procedure if it is difficult to remove the transfer solenoidconnector.

Caution:- Do not force wire connectors if removal is difficult.- Do not cut wiring.

a) Hold the connector with tweezers.b) Tilt the connector and pull it out of the hole.

PARTS NAME NUMBER OF CONNECTORS

Solenoid 8 ( 9 on GT models only )Oil temperature sensor 1

Grounding harness 1

Ground Wire


If the transfer solenoid connector still can not be removed from the case, it will be necessaryto leave the harness attached during valve body removal. This method should only be used asa last resort and otherwise, is not recommended.

Note: Only remove those bolts identified in the following drawing. It is not necessary toremove the fluid strainer in order to remove the valve body.

Some models have a fluid pipe between the valve body and transmission case. The pipe mustbe removed before removing the valve body bolts. The following chart identifies thosevehicles.

MODEL 2001MY 2002M 2003MY

All (except H6 & GT) No No NoGT No No YesH6 No Yes No

Remove all but two of the valve body attaching bolts (bolts are noted below as A and Btypes). Loosen the two remaining bolts enough to allow the remaining transmission fluid todrain.

A = Short bolts: 7pcs. (Light brown color plating).B = Long bolt: 6 pcs. (Black color paint)


While the transmission is draining, clean the liquid gasket from the transmission pan.

Peel the liquid gasket with a suitable scraper and then remove any remaining gasket with a 3MScotchbright Roll Lock Disk #07481 (red) or equivalent.

While holding the valve body remove the remaining two bolts and remove the valve bodyfrom the transmission assembly. Place the valve body in a clean, secure area.

Parking Rod Replacement

Confirm manual plate is in gear range “3” and drive the straight pin out of the select lever byusing a 4mm diam. pin remover. Remove and discard the old pin. A new pin is provided inthe parking rod kit.

Important: Be sure that thevalve body remains in theupright position, otherwiseoil will drain from theaccumulator valves.


Turn the manual plate until the detent spring is released as pictured.

Rotate the manual plate to align notch and hole and then remove the parking rod.

Install the new parking rod into the transmission case and onto the manual plate.

Note: For identification the new parking rod will have a green band painted on it.

SPRING

Manual Plate

PAINT MARK


Align the manual plate with the select lever and install the new straight pin provided in the kit.Do not reuse the original pin.

Move the manual plate and confirm that it works correctly.

Caution: Do not put the transmission in “P” range, since the shift lock may activate.

Place the manual plate to “N” range.

Remove all liquid gasket from the mating surface of the transmission case.

Peel the liquid gasket with a suitable scraper and then remove any remaining gasket with a 3MScotchbright Roll Lock Disk #07515 (light blue) or equivalent.


Remove the gasket material from the three non-threaded holes in the case as shown below.

Valve Body Installation

Caution: Before installing the valve body, make sure that the seal (pictured below) is inplace.

Install the valve body while aligning the manual plate and manual valve. Do not tighten thevalve body bolts completely until confirming that the wire harness is not pinched.Tightening torque: 70 ± 0.9 in-lb. (8 ± 1 Nm).

Connect the connectors for each solenoid. When connecting, match the color of the harnesswith that of the solenoid.

If oil temperature sensor is integrated into the harness, fix the oil sensor to clip.


Coat the oil pan with liquid gasket (as shown below).

Caution: Install the oil pan within 10 minutes of applying the liquid gasket, or asindicated by the manufacturer’s instructions.

Apply the liquid gasket into the non-threaded holes as shown.

Install oil pan and bolts. Tightening torque: 43 ± 4 in-lb. (5 ± 0.5 Nm).

Reinstall exhaust heat shield cover (H6 Models only).

Tap the heat shield with a rubber or plastic hammer to confirm that it will not rattle.

Note: In case the shield rattles, reposition the shield and retighten it.


Install ATF

Lower the vehicle from the lift.

Pour 5.5 quarts (5.2 liters) of Dexron III ATF into filler pipe.

Check for oil leaks.

Check oil level and oil level gauge. If oil level is incorrect, adjust accordingly.

Note: The level of ATF varies with fluid temperature. Pay attention to the fluidtemperature when checking oil level.

Verify Repair

Check parking mechanism for proper operation by setting vehicle into Park on a slight incline.Confirm vehicle remains stationary.


RECALL CAMPAIGN IDENTIFICATION LABEL

Type or print the necessary information on a Recall Campaign identification label. Thecompleted label should be attached to the vehicle’s upper radiator support.

CLAIM REIMBURSEMENT AND ENTRY PROCEDURES

Credit for performing this recall campaign will be based on the submission of properlycompleted repair order information. Dealers may enter the applicable claim informationthrough their Dealer Communications System.

Listed below is claim entry information:

Parking Pawl Rod Replacement – Use the following information for claim submission:

Enter labor operation 138-381 for 1.3 labor hours.

CLAIM CAMPAIGN LABOR LABOR LABORTYPE CODE OPERATION TIME DESCRIPTION

Recall/Campaign WWK-94 138-381 1.3 Transmission ParkingRC Rod Replace

Enter the applicable part number(s). Parts will be reimbursed at dealer cost plus applicablehandling allowance.

MODEL DESCRIPTION PART QUANTITYNUMBER

ALL Parking Rod Kit Assy. X3197AA043 1Three Bond Sealer SOA635068 1

Dexron III ATF (Quart) SOA635003 6

WWK94


INITIAL NOTICE

Subaru of America, Inc.Subaru PlazaP.O. Box 6000Cherry Hill, NJ 08034-6000www.subaru.com

Important Safety Recall NoticeSubaru Recall Campaign WWK-94NHTSA Recall No. 02V-282November 2002

Dear Subaru Owner:

This notice is sent to you in accordance with the National Highway Traffic and Motor VehicleSafety Act.

SUBARU OF AMERICA, INC. has determined that a defect that relates to motor vehicle safetyexists in certain 2001, 2002 and 2003 model year vehicles equipped with an automatic transmis-sion.

DESCRIPTION OF THE SAFETY DEFECT

Subaru has determined that your vehicle may have been produced with an improperly manufacturedtransmission parking rod. When the transmission selector lever is placed in the “P” (Park) position, thetransmission park mechanism that is intended to hold your vehicle may not engage.

DESCRIPTION OF THE SAFETY HAZARD

Should the transmission park mechanism fail to immediately engage when the transmission selector leveris placed in the “P” (Park) position, your vehicle may move/roll without prior warning. This could resultin personal injury or property damage.

To ensure your vehicle remains stationary while parked, always engage the parking brake.

REPAIRS

In the interest of safety, Subaru is sending this notice to you before repair parts are available. Repair partsare scheduled to arrive at Subaru Dealers in January 2003. Subaru will mail you a second notificationletter when repair parts become available. At that time, Subaru will install a new transmission parking rodand related parts at no cost to you.


WHAT YOU CAN DO

Properly applying the parking brake will ensure your vehicle remains stationary while parked evenif this condition does exist on your vehicle. This is always recommended and is particularly important atthis time. As indicated in your owner’s manual, never rely on the transmission alone to hold the vehicle.To set the parking brake, press the brake pedal firmly and hold it down while pulling up on the parkingbrake lever.

When you receive the second notification letter in January, 2003, please contact your Subaru dealer andschedule an appointment to have the parking rod and related parts replaced at no cost to you.

HOW LONG WILL THE REPAIR TAKE?

The actual time to replace the transmission parking rod and related parts is approximately 1½hours. However, it may be necessary to leave your vehicle the full day of your scheduled appoint-ment to allow your dealer flexibility in scheduling. Please present the second notification letterto your Subaru Dealer at the time this repair procedure is performed.

CHANGED YOUR ADDRESS OR SOLD YOUR SUBARU?

If you have moved or sold your vehicle, please complete the enclosed prepaid postcard and mailit to us.

IF YOU NEED FURTHER ASSISTANCE:

To locate the nearest Subaru Dealer you can access our web site at www.Subaru.com and go to the dealerlocator function. Or, you may call us at 1-800-SUBARU3 (1-800-782-2783) during normal business hoursfor assistance. (Monday through Friday 8:30 AM to 5:00 PM EST.) Please call us immediately if thedealer fails or is unable to make the necessary repairs free of charge or write to the address listed on thefirst page of this letter.

You may also contact The Administrator, National Highway Traffic Safety Administration, 400Seventh Street, S.W., Washington, DC 20590 or call the toll free Auto Safety Hotline at888-327-4236 if you believe the dealer has failed or is unable to remedy your vehicle withoutcharge within a reasonable amount of time.

Your continued satisfaction with your Subaru is important to us. Please understand that we have takenthis action in the interest of your safety and your vehicle’s proper operation. We sincerely apologize forany inconvenience this matter may cause and urge you to schedule an appointment, when notified thatrepair parts are available, to have this repair performed.

Sincerely,Subaru of America, Inc.


RECALL PARTS AVAILABILITY - SECOND NOTICE

Subaru of America, Inc.Subaru PlazaP.O. Box 6000Cherry Hill, NJ 08034-6000www.subaru.com

Important Safety Recall NoticeSubaru Recall Campaign WWK-94NHTSA Recall No. 02V-282January 2003

Dear Subaru Owner:

In November 2002, we notified you that SUBARU OF AMERICA, INC. has determined that adefect that relates to motor vehicle safety exists in certain 2001, 2002 and 2003 model yearvehicles equipped with an automatic transmission. We informed you that parts would be avail-able to repair your vehicle during January 2003. These parts are now available.

DESCRIPTION OF THE SAFETY DEFECT

Subaru determined that your vehicle may have been produced with an improperly manufacturedtransmission parking rod. When the transmission selector lever is placed in the “P” (Park) position, thetransmission park mechanism that is intended to hold your vehicle may not engage.

DESCRIPTION OF THE SAFETY HAZARD

Should the transmission park mechanism fail to immediately engage when the transmission selector leveris placed in the “P” (Park) position, your vehicle may move/roll without prior warning. This could resultin personal injury or property damage.

To ensure your vehicle remains stationary while parked, always engage the parking brake.

REPAIRS

To correct this condition, Subaru will install a new transmission parking pawl rod and related parts at nocost to you.

WHAT YOU SHOULD DO

You should immediately contact your Subaru dealer and schedule an appointment to have the parking rodand related parts replaced at no cost to you.

Properly applying the parking brake will ensure your vehicle remains stationary while parked. Thisis always recommended and particularly important at this time. As indicated in your owner’s manual,never rely on the transmission alone to hold the vehicle. To set the parking brake, press the brake pedalfirmly and hold it down while pulling up on the parking brake lever.


HOW LONG WILL THE REPAIR TAKE?

The actual time to replace the transmission parking pawl rod and related parts is approximately1½ hours. However, it may be necessary to leave your vehicle the full day of your scheduledappointment to allow your dealer flexibility in scheduling. Please present this notification letterto your Subaru Dealer at the time this repair procedure is performed.

CHANGED YOUR ADDRESS OR SOLD YOUR SUBARU?

If you have moved or sold your vehicle, please complete the enclosed prepaid postcard and mailit to us.

IF YOU NEED FURTHER ASSISTANCE:

To locate the nearest Subaru Dealer you can access our web site at www.Subaru.com and go to the dealerlocator function. Or, you may call us at 1-800-SUBARU3 (1-800-782-2783) during normal business hoursfor assistance. (Monday through Friday 8:30 AM to 5:00 PM EST.) Please call us immediately if thedealer fails or is unable to make the necessary repairs free of charge or write to the address listed on thefirst page of this letter.

You may also contact The Administrator, National Highway Traffic Safety Administration, 400Seventh Street, S.W., Washington, DC 20590 or call the toll free Auto Safety Hotline at888-327-4236 if you believe the dealer has failed or is unable to remedy your vehicle withoutcharge within a reasonable amount of time.

Your continued satisfaction with your Subaru is important to us. Please understand that we have takenthis action in the interest of your safety and your vehicle’s proper operation. We sincerely apologize forany inconvenience this matter may cause and urge you to schedule an appointment to have this repairperformed.

Sincerely,Subaru of America, Inc.

Notice to LessorsThe lessor of a vehicle who receives this letter should provide a copy of it to the vehicle lessee(s). The lessor should also keep a record of thelessee(s) to whom this letter is sent, the date sent, and the applicable vehicle identification number (VIN). (For these purposes, a lessor meansa person or entity that in the last twelve months prior to the date of this notification has been the owner, as referenced on the vehicle’s title, ofany five or more leased vehicles. A leased vehicle is a vehicle leased to another person for a term of at least four months.)

product campaign bulletin - negative splits...• 2001-03 my subaru legacy and outback with 4eat....

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