WUC-88 Power Steering Gear Box Inspect/Replacement – 2019 Subaru Forester & Crosstrek

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Bulletin Number: WUC-88R; Revised: 04/08/19 Page 1 of 10
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NUMBER: WUC-88R
DATE: 02/12/19
REVISED: 04/08/19
NHTSA ID: 19V-065
APPLICABILITY: 2019MY Forester and Crosstrek Vehicles
SUBJECT: Power Steering Gear Box Inspect/Replacement
CAUTION: VEHICLE SERVICING PERFORMED BY UNTRAINED PERSONS COULD
RESULT IN SERIOUS INJURY TO THOSE PERSONS OR TO OTHERS.
Subaru Service Bulletins are intended for use by professional technicians ONLY. They
are written to inform those technicians of conditions that may occur in some vehicles,
or to provide information that could assist in the 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
Service Bulletin applies to your vehicle, or that your vehicle will have that condition.
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ISO 14001 Compliant
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excellence in Environmental Management
Systems. Please recycle or dispose of
automotive products in a manner that is friendly
to our environment and in accordance with all
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ATTENTION:
GENERAL MANAGER q
PARTS MANAGER q
CLAIMS PERSONNEL q
SERVICE MANAGER q
IMPORTANT – All
Service Personnel
Should Read and
Initial in the boxes
provided, right.
©2019 Subaru of America, Inc. All rights reserved.
PRODUCT CAMPAIGN BULLETIN
INTRODUCTION:
Subaru of America, Inc. is recalling certain 2019 model year Forester and Crosstrek vehicles to
inspect and, if necessary, replace the power steering gear box. A total of 10,417 U.S. vehicles will be
affected by this recall.
AFFECTED VEHICLES
Coverage for all affected vehicles must be confirmed by using the Vehicle Coverage Inquiry function
on subarunet.com.
This information is now available for all affected VINs currently in the system.
Model Year Carline Production Range Vehicle count
2019 Forester December 27, 2018 – January 16, 2019 6,277
2019 Crosstrek December 27, 2018 – January 16, 2019 4,140
Please be advised that as additional affected VINs are processed into the system, coverage for those
vehicles will be made available.
DESCRIPTION OF THE DEFECT AND SAFETY RISK
A connector inside the Electronic Power Steering (EPS) control unit may form small gaps in the
plastic material molding during the manufacturing process. As a result, connector terminals inside
the plastic molding may have inadequate isolation between terminals.
If a loss in isolation occurs, the EPS warning lamp will illuminate, and the EPS assist may be
disabled. Disabling of the EPS assist could result in higher steering effort, increasing the risk of a
crash.
Bulletin Number: WUC-88R; Revised: 04/08/19 Page 2 of 10
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DESCRIPTION OF THE REMEDY
Retailers will inspect the steering gear box on these vehicles in accordance with the specified repair
procedure and if necessary, replace it with a corrected one.
RETAILER RESPONSIBILITY
Retailers are to promptly perform the applicable service procedures to correct all affected vehicles in
their inventory. Any vehicles listed in a recall/campaign that are in the retailer’s stock must be:
• Immediately identified.
• Tagged or otherwise marked to prevent their delivery or use prior to inspection and, if
necessary, 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 Retailer failing to perform the applicable service procedures to correct all
affected vehicles in their inventory prior to the vehicle being placed in service may be subject
to civil penalties of up to $21,000 per violation (i.e., for each vehicle), as provided in 49 CFR
§578.6 and will also be in breach of the Subaru Dealer Agreement.
OWNER NOTIFICATION
An owner notification will not be necessary because all affected vehicles will be inspected and/or
repaired prior to retail sale.
RETAILER AFFECTED VIN LISTS
Each retailer will receive a detailed list of affected units from their Region/Distributor.
SERVICE PROCEDURE:
This Service Campaign involves inspection and possible replacement of the EPS gear box assembly.
The required repair will depend on the results of an inspection of the Lot Number shown on a label
affixed to the EPS assembly. The label and Lot Number are easily seen from under the vehicle. If the
Lot Number is within the specific range provided in the Service Procedure below, the EPS gear box
(steering rack) assembly must be replaced.
These vehicles can be quickly identified upon receipt by the presence of an
“S” label with blue background on the windshield as shown here. While all
affected vehicles should have this label installed at the ports, retailers should
always check arriving potentially applicable vehicles using vehicle inquiry to
confirm if there are any open recalls/campaigns to be completed. In a small
number of cases, an “S” written with a glass marker may be found on the
windshield in place of the sticker.
Bulletin Number: WUC-88R; Revised: 04/08/19 Page 3 of 10
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PART INFORMATION:
NOTE: There is no need for retailers to order any of these parts. Parts needed to complete this
procedure (both the EPS assembly and Hardware Kit) will be shipped automatically to each Retailer
based upon vehicle allocation. Vehicles trades between Retailers prior to completion of this
repair should be avoided as doing so may delay proper parts supply for the receiving Retailer.
Description Part Number Application
STEERING GEAR BOX ASSEMBLY- EPS
34110SJ040 FORESTER
34110FL130 CROSSTREK
WUC-88 HARDWARE KIT* SOA635317 ALL
*The HARDWARE KIT consists of the following components:
Description Part Number Quantity Notes
FLANGE BOLT 901000462 4 EPS Gear Box Mounting Bolts
COTTER PIN 051030300 OR
051030200 2 Cotter Pins- Part numbers are
interchangeable, OK to mix.
FLANGE NUT 902380017 2 Stabilizer End Link Nut
GASKET-EXHAUST PIPE FRONT 44616AA290 1
Exhaust Pipe Gaskets
GASKET-EXHAUST PIPE REAR 44022AA123 1
REPAIR PROCEDURE:
1) After confirming applicability, raise the vehicle on a lift.
2) The EPS Label and Lot Number are accessible through a hole in the crossmember support as
shown.
Bulletin Number: WUC-88R; Revised: 04/08/19 Page 4 of 10
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3) Inspect the label for black dots to the left of the QR code as shown.
If inspection reveals a label with TWO (2) dots, REGARDLESS OF LOT NUMBER, the Service
Procedure is complete. CAREFULLY copy the Lot Number onto the Repair Order as it will be
needed for Claim Submission. Proceed to Claim Reimbursement and Entry Procedures to process
the claim for Inspection Only.
If inspection reveals a label with either NO or only ONE dot, CAREFULLY copy the Lot
Number onto the Repair Order then compare it to the ranges provided below. NOTE: Parts within
these lot number ranges may be found on either Crosstrek or Forester as both of the vendor’s
production lines produce parts for both carlines.
4) Start of Range – End of Range:
1188Z21674 – 1198199999
118XZ10278 – 119X199999
If the Lot Number falls within either of these ranges, the EPS assembly MUST be replaced.
CRITICAL: Do Not make the OK or NG determination by using just the 5-digit sequence
number at the end of the Lot Number.
Use the image below for interpreting the Lot Number of the EPS gear box assembly.
REMINDER: If inspection reveals a label with TWO (2) dots, REGARDLESS OF LOT NUMBER,
the Service Procedure is complete.
Bulletin Number: WUC-88R; Revised: 04/08/19 Page 5 of 10
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Pre-Installation EPS Gear Box Inspections:
VERY IMPORTANT: The following inspection procedures below MUST be performed BEFORE
installation of the new EPS gear box assembly:
• Before installing a new gear box assembly, ALWAYS confirm the new part is the correct part
number for the vehicle being repaired. The Forester and Crosstrek ESP gear boxes are very
similar in appearance and will bolt into each model but, they are NOT interchangeable.
• There is a VERY SMALL possibility the EPS gear box assembly was not properly centered
before the plastic retainer was installed during manufacturing. If this occurs:
○○ it may be difficult to match up the marks when re-connecting the EPS gear box assembly
to the steering shaft
○○ the number of turns between full steering lock left and right will be different
○○ one tie-rod boot will be collapsed (or extended) more than the other.
OK
Paint Marks Aligned Paint Marks Mis-Aligned
NG
NOTES:
• If a NG condition is identified, see APPENDIX A on page 9 of this bulletin for the EPS Gear
Box Centering Procedure.
• Although the plastic retainer cap is white in the photos, it will likely be either green or blue
depending on application.
5. When the Lot Number inspection procedure determines the EPS gear box assembly requires
replacement, follow the procedure in the applicable Service Manual along with the Helpful Hints
provided below. Pay close attention to the items listed as one-time-use. They are all supplied in
the Hardware Kit and MUST be replaced during reassembly.
After installation, with the front wheels pointed straight ahead, turn the steering wheel full lock right
then full lock left and confirm there is no difference in the number of turns required to reach the stops.
IMPORTANT PRECAUTIONS:
○○ The EPS control module continues to operate after the engine stops. Therefore, before
starting service of the EPS system which requires disconnection of the wiring harness
connector, the ground cable MUST be disconnected from the battery.
○○ Be careful not to let any foreign matter (dust, water, oil, etc.) enter the power steering
control module wiring harness connector when removing or installing it. If any foreign
matter enters, always be sure completely remove it before re-connecting.
6. VERY IMPORTANT: After adjusting the toe-in and steering wheel angle, tighten the lock nut
on the tie rod end, always perform the Active Lane Keep System Learning Value clear (models
with EyeSight) and the VDC sensor midpoint setting mode following the steps below and the
applicable Service Manual.
Bulletin Number: WUC-88R; Revised: 04/08/19 Page 6 of 10
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• Perform Active Lane Keep System Learning Value Clear:
1) Connect the Subaru Select Monitor (SSM).
2) Turn the ignition switch to ON.
3) From the [Start] screen, select [Diagnosis].
4) On [Select Vehicle] screen, input the target vehicle
information and select [Set].
5) On [Main Menu] screen, select [Each
System].
6) Select [EyeSight].
7) Select [Work Support].
8) Select [Clear Active Lane Keep System Learning
Value].
• Perform VDC Sensor 0 Point Setting Mode:
1) Connect the Subaru Select Monitor (SSM).
2) Turn the ignition switch to ON.
3) From the [Start] screen, select [Diagnosis].
4) On [Select Vehicle] screen, input the target vehicle
information and select [Set].
5) On [Main Menu] screen, select [Each System].
6) On [Select System] screen, select [Brake Control],
and then select [Enter].
7) On [Select Function] screen, select [Data monitor].
8) From the Data Monitor list, select [Steering Angle
Sensor], [Longitudinal G Sensor] and [Lateral G
Sensor].
9) Check that the steering angle sensor output
value is”0” +/- 2 degrees. If the output value is
different from the standard value, re-check the
steering wheel position.
10) Check that the output values for the longitudinal
G sensor and lateral G sensor are −2 — 2 m/s2. If
the output value is different from the standard
value, check the installing condition of the
hydraulic unit assembly VDC and the bracket
COMPL hydraulic unit VDC.
11) On [Select Function] screen, select [Work Support].
12) From the work support item list, select [VSC(VDC)
Centering Mode], and perform the setting according
to the procedure displayed on the Subaru Select
Monitor screen.
Bulletin Number: WUC-88R; Revised: 04/08/19 Page 7 of 10
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IMPORTANT: Drive the vehicle for 10 minutes to confirm:
• there are no system malfunctions
• no warning light illumination
• no other DTC(s) are stored.
7. The original (removed) EPS gear box assembly will not be collected therefore, it MUST be “field
scrapped” to render it unusable before discarding. See APENDIX A on page 10 of this bulletin
for the proper procedure to follow.
Helpful Hints When Performing EPS Assembly Replacement:
• Always confirm the part number on the steering gear box assembly label is correct for the
vehicle being repaired BEFORE installation.
• REMINDER: If TWO black dots are identified on the label as shown above, the part EPS
assembly does NOT need to be replaced.
• Remove the left and right stabilizer link lower nuts but do NOT remove the stabilizer bar
itself. These 2 nuts are 1-time-use, included in the Hardware Kit and MUST be replaced at
reassembly.
• Loosen the (upper) universal joint bolt on the steering column side but do NOT remove it.
Leave the universal joint on the vehicle side and remove the steering gear box.
Loosen but do not remove this bolt.
• DO NOT separate the Lower control arm from the knuckle housing. Otherwise, additional
parts will be necessary to complete the work and not only toe, but a complete wheel
alignment / adjustment will be necessary.
Bulletin Number: WUC-88R; Revised: 04/08/19 Page 8 of 10
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• This repair requires a toe adjustment only. A four-wheel alignment is only necessary if
there is deviation from the standard Service Manual procedures.
CLAIM REIMBURSEMENT AND ENTRY PROCEDURES:
Credit to perform this service campaign will be based on the submission of properly completed repair
order information. Retailers may submit claims through Vehicle Claim Entry on subarunet.com.
Labor Description Labor
Operation #
Labor
Time Fail Code Claim
Type
EPS ASSEMBLY- LOT NUMBER INSPECTION ONLY A165-948 0.2
EPS ASSEMBLY- LOT NUMBER INSPECTION & GEAR BOX WUC-88 RC
ASSEMBLY REPLACEMENT (INCLUDES Toe Adjustment) 165-940 2.3
NOTE: The Lot Number from the ORIGINAL Factory-installed EPS gear box assembly MUST be
entered in the Miscellaneous Detail field at Claim submission.
IMPORTANT REMINDERS:
• SOA strongly discourages the printing and/or local storage of service information as
previously released information and electronic publications may be updated at any time.
• Always check for any open recalls or campaigns anytime a vehicle is in for servicing.
• Always refer to STIS for the latest service information before performing any repairs.
Bulletin Number: WUC-88R; Revised: 04/08/19 Page 9 of 10
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APPENDIX A
This Appendix includes:
• EPS Gear Box Centering Procedure
• Original (removed) EPS Gear Box Field Scrap Procedure
Centering Procedure:
There is small possibility the steering gear box center position may be incorrect on the new
replacement EPS gear box. This condition could cause the following two issues:
• Difficult to match the paint markings when connecting the gear box and the steering shaft.
• The steering angle (number of turns) to full steer left and right may be different.
1. Before installing the new EPS gear box, confirm the input shaft paint mark and the housing
paint mark are aligned as shown in the OK photo below.
2. Confirm the tie rods and boots are the same length, left and right.
OK
Paint Marks Aligned Paint Marks Mis-Aligned
NG
If the EPS Gear Box needs to be centered:
• CAREFULLY remove the resin cap.
• Using SST 34099PA100, turn the input shaft to align the marks then reinstall the resin cap.
SST: 34099PA100
Bulletin Number: WUC-88R; Revised: 04/08/19 Page 10 of 10
EPS Gear Box Field Scrap Procedure:
Cut the wiring harness completely off the original rack assembly as close as possible to where it
attaches to the pinion housing area as shown below and discard.