Safety Recall: WRL-21 – Front Axle Housing – 2020 Subaru Ascent

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December 9, 2021 NHTSA CAMPAIGN NUMBER: 21V954000

Tie Rods May Separate

The tie rods may separate from the housing, causing a loss of steering control and increasing the risk of a crash.

 

NHTSA Campaign Number: 21V954

Manufacturer Subaru of America, Inc.

Components STEERING

Potential Number of Units Affected 1,305

 

Summary

Subaru of America, Inc. (Subaru) is recalling certain 2020 Ascent vehicles. Due to an incorrect tapered hole in the housing, the front tie rod ends may not fit properly. The improper fit can result in the tie rods and housings being deformed during assembly and service replacement if excessive torque is applied.

Remedy

Dealers will replace the left and right front tie rod ends and housings, free of charge. Owner notification letters were mailed February 7, 2022. Owners may contact Subaru customer service at 1-844-373-6614. Subaru’s number for this recall is WRL-21.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Subaru has a Recall

 


NUMBER: WRL-21R
DATE:
02/23/2022
NHTSA ID: 21V-954

INTRODUCTION

Subaru of America, Inc. (Subaru) has initiated this safety recall for certain 2020 model year Ascent vehicles in which the front axle housings may have been manufactured with improperly tapered tie rod mounting holes.

 

DESCRIPTION OF THE DEFECT AND SAFETY RISK

The affected vehicles may be equipped with front axle housings that may have been manufactured with improperly tapered tie rod mounting holes. Over time, this condition may cause the tie rod end to separate from the axle housing, increasing the risk of a crash.

 

AFFECTED VEHICLES

The number of U.S. vehicles included in this recall is 1,305.

Model Year Carline Production date range
2020 Ascent February 22, 2020 – March 5, 2020

 

Not all vehicles in the production date ranges listed above may be included in this recall.  Coverage for all affected vehicles must be confirmed by using the Vehicle Coverage Inquiry function on subarunet.com, which is now available.

 

DESCRIPTION OF THE REMEDY

For all potentially affected vehicles, Subaru retailers will replace left front and right front housings, tie rod ends, and all related hardware with new parts at no cost to the customer.

 

OWNER NOTIFICATION

Subaru will notify affected vehicle owners by first class mail on February 7, 2022. A copy of the owner notification letter is included at the end of this bulletin.

 

RETAILER RESPONSIBILITY

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.

Any vehicles listed in any recall/campaign that are in retailer stock must be:

  • Immediately identified
  • Tagged or otherwise marked to prevent their delivery or use prior to repair
  • Repaired in accordance with the repair procedures outlined in the Product Campaign Bulletin

Retailers are to promptly perform the applicable service procedures, to correct all affected vehicles in their inventory (used, demo & SSLP). Whenever a vehicle subject to this recall is taken into retailer inventory necessary steps should be taken to ensure the recall correction has been made before selling or releasing the vehicle.

 

Axle Housing/Tie rod End Mounting Description:

 

PARTS INFORMATION:

Kit Kit Contents (DO NOT Order Individual Components)
Kit Orderable Kit Part Number Part Number Part Description Quantity
WRL-21 KIT SOA635169 28313XC00A HOUSING-FRONT AXLE,RIGHT 1
28313XC01A HOUSING-FRONT AXLE,LEFT 1
34161SA001 TIE ROD END ASSEMBLY 2
901000468 ★ FLANGE BOLT 8
902170049eBay NUT 2
902330007 ★ SELF LOCKING NUT 4
051030300 ★ COTTER PIN 2
023212010 ★ CASTLE NUT 2

 

NOTE: The Service Manual uses a black star (★) in the component breakdown illustration to indicate one-time use parts. The kit contents listed above that are marked with a black star are  one-time use parts required for this procedure, included in the kit.

 

IMPORTANT PARTS ORDERING INFORMATION:

  • The parts required for this repair will be in a kit, part number SOA635169, which is on hold.
  • The WRL-21 kits CANNOT be ordered through PRIME.
  • When placing an order for a WRL-21 kit, please enter the last 8 digits of the affected VIN in the “Customer PO Number” field of the order.
  • Orders will be released by the Parts Information Coordinators (PICs) upon verification of the affected VIN.
  • If the VIN is not provided on the parts order, the order will not be released unless the retailer contacts the PICs by phone to do so; therefore, please be sure to enter the VIN as instructed.
  • If the order does NOT contain the last 8 digits of a valid affected VIN and the retailer does not contact Parts Information Coordinators within 5 business days of the order entry date, the order will be cancelled.

 

SERVICE PROCEDURE / INFORMATION:

REMINDER: Customer satisfaction and retention starts with performing quality repairs.

The service procedures for front axle housing and the tie rod end  replacement remain unchanged, however there are TWO TIPS described below that with help provide a more streamline process when replacing this part combination. Always refer to the applicable Service Manual and review the full requirements of the repair being performed. The Service Manual procedures contain information critical to performing an effective repair the first time, every time. This includes but is not limited to important SAFETY precautions, proper inspection criteria, necessary special tools, required processes and related one-time-use parts needed for a complete and lasting repair.

IMPORTANT NOTE: The tie rod end and axle housing on BOTH left and right sides require replacement.

Tip 1: The stabilizer link mounting nut (902380003) DOES NOT require removal during this procedure. This nut is a one-time use only part and if removed it MUST be replaced with a new one. See the photos listed below for examples.

 

Tip 2: Even with usage of a recommended ball joint separator tool (shown below), there can be difficulty separating the tie rod end from the axle housing. This is caused by possible deformation of housing/tie rod from exceeded torque limits during installation. ALWAYS use eye protection when attempting to apply this method. If there is difficulty found when removing/separating the tie rod end with the axle housing, follow the procedures outlined on the next page.

 

STEP 1: Release the clamp on the outside of the steering rack boot with pliers and slide the clamp toward the tie rod end.

 

STEP 2: While holding the tie rod end (A) with an 18mm wrench, loosen the 19mm locking nut (B).

 

STEP 3: While holding the steering gear box boot (C) and CAREFULLY preventing it from turning, loosen the tie rod (D) with a 14mm wrench. Take note of the number of rotations during removal and apply the rotation number to the new part installation. This will help save time during the alignment. Use CAUTION when performing this STEP to ensure the steering gear box boot does not twist/and or rotate.

Once the tie rod end is removed from the tie rod, proceed to further removing the axle carrier.

 

IMPORTANT NOTE: ALWAYS use new wheel bearing mounting flange bolts, strut self-locking nuts, axle nuts, and tie rod end nuts during assembly. Be sure to torque these items to the correct specification.

Number Part Description Part # Torque Specification
1 WHEEL BEARING FLANGE BOLT 901000468 126 N·m (12.8kgf-m, 92.9ft-lb)
2 STRUT SELF LOCKING NUT 902330007 155 N·m (15.8kgf-m, 114.3ft-lb)
3 AXLE NUT 902170049eBay 220 N·m (22.4kgf-m, 162.3ft-lb)
4 TIE ROD END NUT 023212010 27 N·m (2.8kgf-m, 19.9ft-lb) + 60°

 


URGENT

IMPORTANT SAFETY RECALL

This notice applies to the VIN identified in  the address section below

 

Subaru Safety Recall WRL-21

NHTSA ID 21V-954

February 2022

 

Dear Subaru Owner:

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

 

SUBARU OF AMERICA, INC. has decided that a defect, which relates to motor vehicle safety, exists in certain 2020 model year Ascent vehicles.

You received this notice because our records indicate that you currently own one of these vehicles.

 

DESCRIPTION OF THE DEFECT AND SAFETY RISK

The front axle housings in your vehicle may have been manufactured with improperly tapered tie rod mounting holes. Over time, this condition may cause the tie rod end to separate from the axle housing, increasing the risk of a crash.

 

WHAT SUBARU WILL DO

For all potentially affected vehicles, Subaru will replace left front and right front housings, tie rod ends, and all related hardware with new parts at no cost to you.

 

WHAT YOU SHOULD DO

Please contact your Subaru retailer (dealer) immediately for an appointment to have this repair performed, at no cost to you.

 

HOW LONG WILL THE REPAIR TAKE?

The actual time for this repair is approximately two and a half hours. However, it may be necessary to leave your vehicle for a longer period of time on the day of your scheduled appointment to allow your Subaru retailer flexibility in scheduling.

 

OWNER INFORMATION

Government regulations require that recall notifications be sent to the last known owner of record. That information is based primarily on state registration and title data. If you are a lessor of this vehicle, federal regulations require you to forward this notice to your lessee within ten days.

If you have moved or sold your vehicle, please update this information online at www.subaru. com, select ‘Customer Support,’ then select ‘Address Update’ or ‘Ownership Update’ from the “Quick Links” menu.

 

IF YOU HAVE PREVIOUSLY PAID FOR A REPAIR

If you have already paid for repairs associated with this condition, you may be eligible for reimbursement. Reimbursement consideration will be based on the amount an authorized Subaru retailer in your area would charge for the same repair.

Please send the original service repair order, which has the name of the repair facility, date of repair, mileage at the time of repair, complete 17-digit vehicle identification number (VIN), and your name, with correct mailing address and telephone number to the address listed below.

Subaru of America, Inc.
Customer Advocacy Department, Attention: WRL-21 Recall
P.O. Box 9103, Camden, NJ 08101-9877

 

Please send original receipts only and retain a photocopy for your records.  Please be assured that we will attempt to process your reimbursement request as quickly as possible, but it may take up to 60 days for this process to be completed.

 

IF YOU NEED FURTHER ASSISTANCE:

To locate the nearest Subaru retailer, you can access our website at www.subaru.com and select ‘Find a Retailer.’

For additional information, please go to: https://www.wrl21.service-campaign.com.

If you need additional assistance, please contact us directly:

  • By e-mail: Go to www.subaru.com and select “Customer Support”
  • By telephone: 1-844-373-6614

Monday through Friday between 8:00 a.m. and 7:00 p.m. ET

  • By U.S. Postal mail: Write us at Subaru of America, Inc.

Attn: Customer Advocacy Department

P.O. Box 9103, Camden, NJ 08101-9877

To subscribe to the NHTSA Recall Notification email System, please go to: https://www-odi. nhtsa.dot.gov/nhtsa/subscriptions.

 

Please contact us immediately if the Subaru retailer fails or is unable to make the necessary repairs free of charge.

 

You may also contact the Administrator, National Highway Traffic Safety Administration (NHT-SA), 1200 New Jersey Ave., SE, Washington, DC 20590 or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153) or go to https://www.NHTSA.gov if you believe the Subaru retailer has failed or is unable to remedy your vehicle without charge within a reasonable amount of time.

 

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

 

Sincerely,

 

Subaru of America, Inc.

 

A subsidiary of SUBARU CORPORATION

 


Chronology :

February 18, 2020 – The out-of-specification cutting tool was first used in the manufacturing process of the housing on the supplier’s production line.

February 22 – March 5, 2020 – The subject parts were installed on the vehicle assembly line. The incorrect housing hole was noticed in the vehicle assembly plant and, in collaboration with the supplier, Subaru opened an investigation.

April, 2020 – The supplier completed durability testing determined the reliability was equivalent to standard parts. Subaru continued investigating the potential effect of long-term market usage.

January – July, 2021 – Following another durability test by the supplier and investigation by Subaru, Subaru began considering the potential effect of part replacement for affected vehicles after high mileage field exposure.

July – November, 2021 – Subaru determined that if the castle nut joining the subject components was overtorqued during the assembly process due to the incorrect taper angle in the housing, and then either the tie rod or housing were replaced during repair, and finally components were subjected to unusually large road inputs after high mileage exposure, the tie rod end could separate from the housing. Through data analysis, Subaru confirmed that there were no warranty claims or technical reports related to this condition.

December 2, 2021– Although Subaru is not aware of any warranty claims or technical reports related to this condition, out of an abundance of caution, Subaru decided to conduct a voluntary safety recall.

 


1 Affected Product

Vehicle

MAKE MODEL YEAR
SUBARU ASCENT 2020

 


9 Associated Documents

Defect Notice 573 Report

RCLRPT-21V954-2650.PDF 214.635KB

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Manufacturer Notices(to Dealers,etc) – Date: December 10, 2021 New Subaru Safety Recall: WRL-21 Front Axle Housing

RCMN-21V954-6065.pdf 182.047KB

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Recall Acknowledgement

RCAK-21V954-2744.pdf 704.739KB

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Remedy Instructions and TSB

RCRIT-21V954-8726.pdf 2339.448KB

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Manufacturer Notices(to Dealers,etc) – Date: February 7, 2022 UPDATE Subaru Safety Recall: WRL-21 – Front Axle Housing UPDATE:Owner Notification

RCMN-21V954-6304.pdf 198.176KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V954-5495.pdf 143.711KB

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Remedy Instructions and TSB

RCRIT-21V954-7172.pdf 2254.475KB

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Recall Quarterly Report #2, 2022-2

RCLQRT-21V954-0144.PDF 211.229KB

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Recall Quarterly Report #3, 2022-3

RCLQRT-21V954-1331.PDF 211.313KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V954&docType=RCL

 


NHTSA ID Number: 10208680

Manufacturer Communication Number: WRL-21

Summary

Subaru of America, Inc. (Subaru) has initiated this safety recall for certain 2020 model year Ascent vehicles in which the front axle housings may have been manufactured with improperly tapered tie rod mounting holes.

 

1 Associated Document

Manufacturer Communications

NUMBER: WRL-21R
DATE: 02/23/22
NHTSA ID: 21V-954

https://www.nhtsa.gov/recalls?nhtsaId=10208680

MC-10208680-0001.pdf 2254.475KB

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NHTSA ID Number: 10208678

Manufacturer Communication Number: Subarunet Announ

Summary

Subaru Safety Recall: WRL-21 – Front Axle Housing

 

1 Associated Document

Manufacturer Communications

Date: February 7, 2022
UPDATE Subaru Safety Recall: WRL-21 – Front Axle Housing

https://www.nhtsa.gov/recalls?nhtsaId=10208678

MC-10208678-0001.pdf 194.156KB

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NHTSA ID Number: 10205921

Manufacturer Communication Number: SubaruNet Announ

Summary

Subaru of America, Inc. (Subaru) is initiating a new safety recall for certain 2020 model year Ascent vehicles in which the tie rod end mounting holes in the front axle housings may have an incorrect taper angle.

 

1 Associated Document

Manufacturer Communications

Date: December 10, 2021
New Subaru Safety Recall: WRL-21 – Front Axle Housing

https://www.nhtsa.gov/recalls?nhtsaId=10205921

MC-10205921-0001.pdf 182.047KB

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