Repair Procedure for High-Pitched Sound from Extension Housing Area Using Latest Generation Production Parts – 2000-2009 Subaru Legacy & Outback 1999 and Later Forester & 1999 and Later Impreza

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NHTSA ID Number: 10234829

Manufacturer Communication Number: 037012R-1

Summary

Repair Procedure for High-Pitched Sound from Extension Housing Area Using Latest Generation Production Parts

 


NUMBER: 03-70-12
DATE: 12/13/12
REVISED: 01/15/14

APPLICABILITY: Legacy and Outback 2000-2009MY w/ 5MT
Forester 1999MY and Later w/ 5MT
Impreza (Including WRX) 1999MY and Later w/ 5MT
SUBJECT: Repair Procedure for High-Pitched Sound from Extension Housing Area Using Latest Generation Production Parts

 

INTRODUCTION

This Bulletin provides production change, repair procedure and parts information to address a customer concern of a high-pitched sound coming from the transmission extension housing area.

In cold temperatures, thermal contraction causes shrinking of the transmission case.  In high temperatures, expansion of the case occurs.  These temperature changes affect the amount of preload on the transfer driven shaft bearings.  In some rare cases, when preload is very near the limit of specification combined with unusual driving conditions, this thermally-induced pre-load change may cause damage to the bearings and result in the sound heard by the customer.

A change has been made to the extension case and a new “Dish Plate” added. The machining depth of the extension case has been increased to accommodate the new dish plate. When used along with a selective thrust washer, the spring tension of the dish plate helps to maintain a consistent amount of pre-load on these bearings throughout varying temperature conditions.

 

COUNTERMEASURE IN PRODUCTION

The chart below indicates the starting vehicle identification numbers (VINs) when the new parts were incorporated in to production.

MODEL TYPE STARTING VIN NUMBER
Forester (all) DG424937
Impreza 4-Door DG007208
5-Door DG212655
WRX 4-Door DG007203
5-Door DG213327

 

PART INFORMATION

NEW PART NUMBER DESCRIPTION OLD PART NUMBER INTERCHANGEABILITY NOTES
32130AA350 EXT COMPL 32130AA330 New to Old ONLY All
31668AA250 PLATE-DISHED n/a n/a
806322080 ROLL BRG 22X56X17 806322050 New to Old ONLY T/M# 712031 and before
806330120 ROLL BRG 30X62X17 806330110 New to Old ONLY

 

NOTE: When replacing the extension case, the output oil seal, p.n. 806735210 must also be replaced.

 

SERVICE PROCEDURE / INFORMATION

  • See Service Bulletin 03-68-12R for special tool information and a required bearing prelubrication procedure (shown below) related to this repair.

 

Put 1g (0.035oz) of grease on both roller bearings then rotate the shaft in the outer races to distribute it evenly.

IMPORTANT:  If the transfer driven shaft bearings are damaged or failed, thoroughly clean and inspect all the internal components of the transmission before reassembly.  In very severe cases where metal contamination damage is extensive, transmission assembly replacement may be required.  If within the warranty coverage period, completion of an Assembly Repair vs. Replacement worksheet is required.

  • Follow the procedures in the applicable Service Manual for removal and replacement of the extension case.

NOTE: Both outer races of the transfer driven shaft bearings are hand-fit to their bores and are not press-fit. Turning the outer races slightly will make their installation easier.

 

MEASUREMENT PROCEDURE

  • Measure height “W” between transfer case sealing surface and taper roller bearing outer race on the transfer driven gear.

 

  • With the bearing outer race, dish plate and thrust washer removed, measure depth “X” of the bearing bore of the extension case.

 

  • Calculate the required thrust washer thickness “T” using the revised formula below:

T=  X – W – (1.715 to 1.765 mm (0.0686 to 0.0706”)).

NOTE:  This formula has been revised from the formula shown in the Service Manual to work with the new dish plate and extension case assembly.

  • Select the thrust washer with the closest value from the following table:

Thrust washer Table In PFD Bellow…

 

  • Once the proper thrust washer has been selected, assemble the new extension case as shown in the illustration below.

 

  • Install a new output oil seal before transferring the original metal dust cover over to the new extension case.

 

  • Follow the procedure in the applicable Service Manual for re-installation of the new extension case assembly to the transfer case.

 


70 Affected Products

Vehicles

MAKE MODEL YEAR
SUBARU FORESTER 1999-2023
SUBARU IMPREZA 1999-2023
SUBARU LEGACY 2000-2009
SUBARU OUTBACK 2000-2009

 


1 Associated Document

Manufacturer Communications

NUMBER: 03-70-12R
DATE: 12/13/12
REVISED: 01/15/14

https://www.nhtsa.gov/recalls?nhtsaId=10234829

MC-10234829-9999.pdf 676.694KB

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NHTSA ID Number: 10234828

Manufacturer Communication Number: 037012R

Summary

This Bulletin provides production change, repair procedure and parts information to address a customer concern of a high-pitched sound coming from the transmission extension housing area.

 

1 Associated Document

Manufacturer Communications

NUMBER: 03-70-12R
DATE: 12/13/12
REVISED: 05/22/13

https://www.nhtsa.gov/recalls?nhtsaId=10234828

MC-10234828-9999.pdf 960.672KB

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NHTSA ID Number: 10235830

Manufacturer Communication Number: 037012R

Summary

Repair Procedure for High-Pitched Sound

 

1 Associated Document

Manufacturer Communications

NUMBER: 03-70-12R
DATE: 12/13/12
REVISED: 01/03/13

https://www.nhtsa.gov/recalls?nhtsaId=10235830

MC-10235830-9999.pdf 776.745KB

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NHTSA ID Number: 10234260

Manufacturer Communication Number: 037012

Summary

Repair Procedure for High-Pitched Sound from Extension Housing Area Using Latest Generation Production Parts

 

1 Associated Document

Manufacturer Communications

NUMBER: 03-70-12
DATE: 12/13/12

https://www.nhtsa.gov/recalls?nhtsaId=10234260

MC-10234260-9999.pdf 653.188KB

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NHTSA ID Number: 10234258

Manufacturer Communication Number: 036812R

Summary

5MT Transfer Driven Gear Bearings

 

1 Associated Document

Manufacturer Communications

NUMBER: 03-68-12R
DATE: 07/16/12
REVISED: 12/11/12

https://www.nhtsa.gov/recalls?nhtsaId=10234258

MC-10234258-9999.pdf 413.162KB

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