WQG-43 – Brake Line Corrosion – 2005-2009 Subaru Legacy/Outback

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NHTSA ID Number: 10232540

Manufacturer Communication Number: WQG43R

Summary

Brake Line Corrosion

 


NUMBER: WQG-43R
DATE: May 2013
REVISED: July 2014

APPLICABILITY: 2005-2009MY Subaru Legacy/Outback
SUBJECT: Brake Line Corrosion

 

July, 2014:

This recall has been superseded to the WQK-47 brake line corrosion recall issued in July, 2014. Please refer to the WQK-47 bulletin for more detail.

IMPORTANT NOTE:  If the WQG-43 brake line corrosion recall repair was already performed, the WQK-47 recall repair must also be performed to ensure that all affected areas of the brake lines are acceptable and treated with anti-corrosion material as a preventative measure.

Any incomplete WQG-43 recall applicability is now expired in SOA’s system.  Claims for WQG43 repairs performed after the expiration date will not be processed.

Subaru of America, Inc. has determined that a defect, which relates to motor vehicle safety, exists on certain 2005-2009 model year Subaru Legacy / Outback vehicles currently or formerly registered in at least one of the “salt-belt” states listed below. These vehicles may have been manufactured with brake lines that could, over time, corrode in the area of the fourway joint connector if exposed to salt. Excessive corrosion could eventually cause perforation of a brake line(s) resulting in a brake fluid leak.

Should a brake line corrode to the point of developing a perforation, brake fluid will leak from the line(s) causing the related circuit to eventually lose effectiveness. In this situation, there would be an increase in the amount of brake pedal travel distance and foot pressure required to slow or stop the vehicle. This might cause the driver to misjudge the amount of brake pedal travel required to achieve the desired stopping distance, increasing the risk of a crash.

This recall will involve cleaning, inspecting and testing the brake lines in the area of the fourway joint connector for perforation. If the lines are found to be acceptable, as a preventative measure it will be necessary to apply an anti-rust material to the areas of concern. If any brake lines are found to be leaking, all four will require replacement.

 

AFFECTED VEHICLES

Certain 2005-2009 model year Subaru Legacy / Outback vehicles currently or formerly registered in at least one of the following “salt-belt” states and Washington D.C.:

Connecticut Maine New Hampshire Vermont
Delaware Maryland New Jersey West Virginia
District of Columbia Massachusetts New York Wisconsin
Illinois Michigan Ohio
Indiana Minnesota Pennsylvania
Iowa Missouri Rhode Island

Affected vehicles are identified in the VIN range chart below.  NOTE: Not all vehicles within the range are affected. Coverage for all affected vehicles must be confirmed by using the Vehicle Coverage Inquiry function at Subarunet.com.

’05 – ‘09MY SUBARU LEGACY MODELS
MO DEL VIN RANGES
From To
2005MY Sedan 5*200004 5*230151
Wagon 5*300005 5*393157
2006MY Sedan 6*200005 6*220857
Wagon 6*300006 6*364139
2007MY Sedan 7*200021 7*215147
Wagon 7*300016 7*346285
2008MY Sedan 8*200003 8*227207
2009MY Sedan 9*210001 9*236940
’05 – ‘09MY SUBARU OUTBACK MODELS
MODEL VIN RANGES
From To
2005MY Outback 5*200016 5*393923
2006MY Outback 6*200006 6*364201
2007MY Outback 7*200022 7*346352
2008MY Outback 8*300003 8*367430
2009MY Outback 9*310001 9*348625

*Various Characters may occupy this position

 

OWNER NOTIFICATION

Notification letters will be sent to owners of vehicles that are currently or previously registered in at least one of the “salt-belt” states. Owner notification began on May 30th, 2013.

A copy of the Owner Notification Letter is included at the end of this bulletin.

 

OWNERS LOCATED OUTSIDE THE AFFECTED “SALT-BELT” STATES

Notification letters will only be mailed to owners of vehicles that are currently or previously registered in at least one of the “salt-belt” states.  However, there are circumstances under which vehicles that were not previously or ever registered in a “salt-belt” state are covered by this recall campaign.  These circumstances may include:

  1. Vehicles not currently or previously registered in a “salt-belt” state that have relocated into a “salt-belt” area and/or vehicles registered in a “non-salt belt” state, and driven in a “saltbelt” area. We request that dealers located in “salt-belt” states check all vehicles within the affected VIN range for recall coverage. If it is determined that an owner of a vehicle, within the affected VIN range, relocates or uses his or her vehicle in a “salt-belt” area, the dealer should perform the recall procedure.
  2. Vehicles in “non-salt belt” states that have experienced the defect. In the unlikely event that an owner in a “non-salt belt” state experiences the defect or otherwise requests the procedure be performed on their vehicle, the dealer should perform the recall procedure. This applies to both “salt-belt” and “non-salt belt” state dealers.

The dealer should perform the recall procedure at no cost to the customer. For claim submission, please contact the Warranty Claims Helpline to have the VIN added to the recall.

 

DEALER PROGRAM RESPONSIBILITY

Dealers are to promptly perform the applicable service procedures defined in this bulletin to correct all affected vehicles in their inventory (new, used, demo & SSLP). Additionally, whenever a vehicle subject to this recall is taken into dealer new or used inventory, or in the dealership for service, necessary steps should be taken to ensure the recall correction has been made before selling or releasing the vehicle.

New, used, demo or SSLP 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.
  • 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 Dealer failing to perform the applicable service procedures as defined in this bulletin to correct all affected vehicles in their inventory (new, used, demo & SSLP) prior to the vehicle being placed in service may be subject to civil penalties of up to $6,000 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.

 

PARTS INFORMATION

Rust-proofing Materials 

Note: The rust-proofing material is packaged in 11 ounce aerosol cans. Each can contains enough material to treat 33 vehicles.

During the week of June 3rd, 2013, only dealers located in affected “salt-belt” states will automatically be shipped two cans of rust-proofing material. This provides enough material to treat 66 vehicles. It will be necessary for dealers located outside of affected “salt-belt” states to order rust-proofing material as needed.

Additional quantities of the rust-proofing material are available through the “Genuine Subaru Automotive Chemical” program. In order to maintain an adequate part supply, SOA requests that Dealers only order quantities necessary to satisfy anticipated demand.

Note: SOA will notify owners of vehicles that are currently or previously registered in at least one of the “salt-belt” states. In cases where the vehicle was previously registered in a salt-belt state, it will be necessary for dealers located outside the “salt-belt” area to order materials to service these affected vehicles.

PART NUMBER DESCRIPTION
SOA868V9360 Nox-Rust® 712AM Aerosol

For claim reimbursement purposes, dealers should use the part number below, which represents rust proofing materials sufficient for one vehicle application:

PART NUMBER DESCRIPTION QUANTITY
SOA635115 Rust-proofing Material

(non-orderable part number for claim purposes only)

1

 

REPAIR PROCEDURE

Exposure Controls for use of Nox-Rust® 712AM Aerosol

The Material Safety Data Sheet (MSDS) which provides storage and handling procedures for this product is included at the end of this bulletin.

 

INTRODUCTION

This Recall involves the inspection and cleaning of the brake piping at the 4-way connector located on the right side of the vehicle ahead of the rear wheel area as shown in Photo 1.

  • If no leakage is found, rust proofing material will need to be applied to the affected area.
  • If leakage is found at the 4-way connector, the center and rear brake piping must be replaced then treated with rust proofing material.

The affected components are:

 

PARTS INFORMATION

NOX-RUST 712 AM Aerosol Spray Anti-Rust Wax

Both center and both rear brake pipes depending on inspection results.

 

SERVICE PROCEDURE

The flow chart below provides a brief overview of the WQG-43 Service Procedure.  Detailed instructions will be provided for each step.

 

STEP 1.  Raise the vehicle on a twin-post (symmetrical) lift to perform the inspection of the 4-way connector area of the brake piping for any sign of brake fluid leakage.  Open the inspection door located on the right-hand plastic fuel tank cover shown in Photo 1 below.  This will provide access to inspect the 4-way connector area of the brake piping which is the focus of this recall.

 

Using a dry non-metallic bristled brush, clean away any dirt and debris from the 4-way connector area as shown in Photo 2.  Be sure to wear safety glasses.

NOTE:  This area may be covered in road dirt, debris or wet residue.  To determine if the wet condition is caused by road material or brake fluid it is necessary to clean and dry the area.

IMPORTANT:  Do not use a metal brush as the hard bristles may cause damage to the brake piping.

Move the parking brake cable out of the way to gain better access if needed.

Use compressed air to dry the area thoroughly if necessary.

After a thorough cleaning, inspect the area closely for any sign of brake fluid leakage, concentrating on the areas circled in red in Photo 3 below.

If no brake fluid leakage is found, proceed to Step 2.

If brake fluid leakage IS found, proceed to Step 4.

 

STEP 2.  Perform a second inspection of the 4-way connector area of the brake piping for any sign of brake fluid leakage with the brake piping under pressure using the brake pedal to pressurize the system.

Follow the procedure outlined below:

A. Lower the vehicle.

B. Start engine and allow it to idle.

C. Depress brake pedal 110mm (4.3 inches) and hold for approximately 3 seconds.

D. Release the brake pedal then shut off the engine.

E. Raise vehicle again.

F. Inspect closely to determine if there is any brake fluid leakage around the affected areas highlighted in the red circles shown in Photo 3 above.

If NO brake fluid leakage is found in Step 1 or Step 2, proceed to Step 3

If brake fluid leakage IS found, proceed to Step 4.

 

STEP 3.  Rust Proofing Application

Follow the rust proofing procedure outlined below:

IMPORTANT NOTES:

  • For your protection, be sure to wear safety goggles and a particle mask.
  • The NOX-RUST 712AM product is flammable. Always take proper precautions and follow all the safety warnings on the label closely.

 

A. Shake the aerosol can vigorously. Once the ball inside the can is heard rattling, continue to shake the can for another 10 seconds to insure thorough mixing of the contents.

B. Install the plastic spray nozzle applicator tube as shown in Photo 5 below.

C. Spray the rust proofing material onto the applicable areas for 3 seconds or more at all 4 of the affected areas shown in Photo 6. Confirm the rust proofing material has been adequately applied to the total circumference of the brake piping. If necessary, use a small mirror to inspect areas which are hard to see.

D. Make sure the rust proofing drips off of the brake piping as shown in Photo 7. This will insure enough of the material has been applied.  Catch any dripping material with a shop cloth.

 

After the rust proofing procedure is complete, close the inspection door and lower the vehicle to complete the WQG-43 Recall.

 

STEP 4.  If brake fluid leakage IS found while performing Step 1 or Step 2, BOTH center brake pipes and BOTH rear brake pipes MUST all be replaced together (4 pipes total).

Refer to the applicable Parts Catalog to identify the proper part numbers for the vehicle.

Be sure to follow all the installation precautions and related procedures outlined in the applicable Service Manual when replacing these components.

Once the brake piping replacement has been completed, the system refilled and bled, the rust proofing procedure outlined in Step 3 MUST be performed.

After the rust proofing procedure is complete, close the inspection door and lower the vehicle to complete the WQG-43 Recall.

 

RECALL IDENTIFICATION LABEL

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

 


OWNER NOTIFICATION LETTER

Important Safety Recall Notice

Subaru Recall Campaign WQG-43

NHTSA Recall No. 13V-110

May 2013

 

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 some 2005 – 2009 model year Subaru Legacy and Outback vehicles currently or formerly registered in at least one of the following states:

Connecticut Maine New Hampshire Vermont
Delaware Maryland New Jersey West Virginia
District of Columbia Massachusetts New York Wisconsin
Illinois Michigan Ohio
Indiana Minnesota Pennsylvania
Iowa Missouri Rhode Island

 

DESCRIPTION OF THE SAFETY DEFECT

Subaru has determined that your vehicle may have been manufactured with brake lines that could, over time, corrode in the area of the four-way joint connector if exposed to salt.

Depending on driving conditions, salt water could splash on the brake lines in the area of the four-way joint connector resulting in corrosion of the lines.  Excessive corrosion could eventually cause perforation of a brake line(s) resulting in a brake fluid leak.

 

DESCRIPTION OF THE SAFETY HAZARD

Your vehicle has a dual circuit braking system. Each circuit works independently and diagonally across the vehicle. If one circuit of the brake system fails, the other half of the system still works. Should a brake line corrode to the point of developing a perforation, brake fluid will leak from the line(s) causing the related circuit to eventually lose effectiveness. In this situation, there would be an increase in the amount of brake pedal travel distance and foot pressure required to slow or stop the vehicle. This might cause the driver to misjudge the amount of brake pedal travel required to achieve the desired stopping distance, increasing the risk of a crash.

 

INSPECTION / REPAIR

Subaru will inspect and test the current condition of your vehicle’s brake lines. If they are found to be acceptable, anti-rust material will be applied to the areas of concern as a preventative measure. If any of the lines are found to be unacceptable, they will be replaced and anti-rust material will be applied to the uncoated brake line areas. These repairs will be performed at no cost to you.

 

WHAT YOU SHOULD DO

You should immediately contact your Subaru Dealer for an appointment to have the brake lines inspected and repaired as indicated in the “Inspection / Repair” section of this letter.

There are several important precautions you should take until this repair has been performed:

  • If you experience the condition described above while braking, continue to apply steady pressure on the brake pedal until the vehicle comes to a stop. Immediately contact your Subaru dealer for assistance.
  • If you notice fluid leaking from the vehicle, do not operate the vehicle. Immediately contact your Subaru dealer for assistance.
  • If the brake system warning light remains illuminated on the instrument panel with the parking brake fully released, do not operate the vehicle. Immediately contact your Subaru dealer for assistance.
  • Always maintain a safe distance from other vehicles while driving. The normally recommended minimum distance is one car length of space for every 10 mph of speed.
  • As a precautionary measure, it is highly recommended that you use extra care while operating the vehicle in confined areas such as parking lots and while parking your vehicle in a garage, car port or other structure.

 

HOW LONG WILL THE REPAIR TAKE?

The time to inspect the brake lines and apply anti-rust material is approximately 18 minutes. If it is determined that the brake lines require replacement, the total estimated repair time is 7 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 dealer flexibility in scheduling.  Please present this letter to your Subaru Dealer at the time this repair procedure is performed.

 

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 dealer 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 vehicle identification number (17 digits), and your name, with correct mailing address and telephone number to the address listed below.

Subaru of America, Inc.
Customer Dealer Services Department
Attention: WQG-43 Recall
P.O. Box 6000
Cherry Hill, NJ 08034-6000

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.

 

CHANGED YOUR ADDRESS OR SOLD YOUR SUBARU?

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

 

IF YOU NEED FURTHER ASSISTANCE:

To locate the nearest Subaru Dealer you can access our website at www.subaru.com and select “Find a Dealer”.

For additional information and for the most Frequently Asked Questions, please go to:

  • E-mail: Go to www.subaru.com and select “Contact Us”.
  • Telephone: 1-800-SUBARU3 (1-800-782-2783)
    Monday through Thursday between 7:30 a.m. and 8:00 p.m. ET.
    Friday between 10:30 a.m. and 5:00 p.m. ET
    Saturday between 9:00 a.m. and 3:30 p.m. ET
  • U.S. Postal mail: Write us at Subaru of America, Inc.
    Attn: CDS Department, P.O. Box 6000, Cherry Hill, NJ 08034-6000.

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

You may also contact the Administrator, National Highway Traffic Safety Administration, 1200 New

Jersey Ave. SE, West Building, Washington, DC 20590 or call the toll free Auto Safety Hotline at 1-888327-4236 (TTY: 1-800-424-9153) or go to http://www.safercar.gov if you believe the dealer 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 to have this repair performed.

Sincerely,

Subaru of America, Inc.

Notice to Lessors: Under Federal law the lessor of a vehicle who receives this letter must provide a copy of it to the vehicle lessee(s) within 10 business days from receipt. The lessor must also keep a record of the lessee(s) to whom this letter is sent, the date sent, and the applicable vehicle identification number (VIN). (For the purposes of this section, a lessor means a 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, of any five or more leased vehicles. A leased vehicle is a vehicle leased to another person for a term of at least four months.)

A subsidiary of Fuji Heavy Industries Ltd.

 


10 Affected Products

Vehicles

MAKE MODEL YEAR
SUBARU LEGACY 2005-2009
SUBARU OUTBACK 2005-2009

 


1 Associated Document

Manufacturer Communications

NUMBER: WQG-43R
DATE: May 2013
REVISED: July 2014

https://www.nhtsa.gov/recalls?nhtsaId=10232540

MC-10232540-9999.pdf 740.826KB

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NHTSA ID Number: 10234886

Manufacturer Communication Number: WQG43

Summary

Brake Line Corrosion

1 Associated Document

Manufacturer Communications

MC-10234886-9999.pdf 1013.44KB

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NHTSA ID Number: 10234887

Manufacturer Communication Number: WQG43-1

Summary

Subaru Recall Campaign WQG43: Brake Line Corrosion

 

1 Associated Document

Manufacturer Communications

Date: May 30, 2013
Update: Subaru Recall Campaign WQG43: Brake Line Corrosion

https://www.nhtsa.gov/recalls?nhtsaId=10234887

MC-10234887-9999.pdf 130.434KB

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