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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Bulletin Number: 03-70-12R; Date: 01/15/14 Page 1
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.
NUMBER: 03-70-12R
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
SERVICE BULLETIN
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.
Continued…
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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The international standard for excellence
in Environmental Management Systems.
Please recycle or dispose of automotive
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environment and in accordance with all
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Transfer driven shaft
bearing (front)
Transfer driven shaft
bearing (rear)
Dish plate
(New part)
Thrust
washer
Transfer driven
shaft bearing
(rear) outer race
Bulletin Number: 03-70-12R; Date: 01/15/14 Page 2
Continued…
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 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
806330120 ROLL BRG 30X62X17 806330110 New to Old ONLY and before
NOTE: When replacing the extension case, the output oil seal, p.n. 806735210 must be replaced.
If the transmission number is prior to 5588478, and you are replacing the extension case, shorter case
bolts, p.n. 800610940, (quantity 9) must also be installed due to the thinner retaining bolt boss areas
of the replacement extension case (16mm vs. 20mm) as shown in the photos below.
Bulletin Number: 03-70-12R; Date: 01/15/14 Page 3
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.
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.
Continued…
Front Roller Bearing
Transfer Driven Gear
Put 1g (0.035oz) of grease on
both roller bearings then rotate the shaft in
the outer races to distribute it evenly.
Rear Roller Bearing
Bulletin Number: 03-70-12R; Date: 01/15/14 Page 4
• 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:
Continued…
Bulletin Number: 03-70-12R; Date: 01/15/14 Page 5
• 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.
WARRANTY / CLAIM INFORMATION
For vehicles within the Basic New Car Limited Warranty period, refer to the Subaru Labor Time
Guide available on Subarunet for claim submission information.
(A) Bearing outer race
(B) Dish Plate
(C) Thrust washer
Painted (concave) side (D) Extension case
faces the thrust washer
NOTE: the metal
dust cover is a
reusable part.
CAREFULLY remove
and transfer it to the
new extension case
after installing a
new output oil seal.

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