WRP-23 – Front Driveshaft Assemblies May Crack and Break – 2024 Subaru Crosstrek, Impreza, 2023-2024 Forester, & 2023 WRX

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November 9, 2023 NHTSA CAMPAIGN NUMBER: 23V754000

Front Driveshaft Assemblies May Crack and Break

A broken driveshaft can cause a loss of drive power while driving or vehicle rollaway when the vehicle is in park without the parking brake engaged. Either of these scenarios can increase the risk of a crash.

 

NHTSA Campaign Number: 23V754

Manufacturer Subaru of America, Inc.

Components POWER TRAIN

Potential Number of Units Affected 3,732

 

Summary

Subaru of America, Inc. (Subaru) is recalling certain 2024 Crosstrek, Impreza, 2023-2024 Forester, and 2023 WRX vehicles. The front driveshaft assemblies’ outer race may develop cracks and break.

 

Remedy

Dealers will inspect and replace the left and right front driveshafts as necessary, free of charge. Owner notification letters were mailed January 8, 2024. Owners may contact Subaru’s customer service at 1-844-373-6614. Subaru’s number for this recall is WRP-23.

 

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: WRP-23
DATE: 12/19/23
NHTSA ID: 23V-754

APPLICABILITY: 2023MY WRX
2024MY Crosstrek
2024MY Impreza
2023-2024MY Forester
SUBJECT: Safety Recall – Driveshaft Failure

 

Subaru of America, Inc. (Subaru) has initiated a safety recall for certain 2023 model year WRX vehicles, certain 2024 model year Crosstrek and Impreza vehicles, and certain 2023-2024 model year Forester vehicles.

The vehicles included in this recall may be equipped with a front drive shaft assembly with an outer race that could crack, due to improper cooling during the manufacturing process.

Over time, a cracked outer race could break, potentially resulting in loss of motive power. Additionally, if the outer race breaks, the vehicle may roll when parked if the parking brake is not applied. Both conditions increase the risk of a crash.

 

REMEDY:

For all potentially affected vehicles, Subaru dealers will inspect the left-hand and right-hand front drive shafts and where necessary, replace them with a new one at no cost to the customer.

 

AFFECTED VEHICLES:

A total of 3,732 U.S. vehicles will be included in this recall as listed below. Not all vehicles in the production range listed below are affected by this recall. Coverage must be confirmed by using the Vehicle Coverage Inquiry function on subarunet.com prior to repair.

Model Year Carline Production Date Range
2023 WRX 9/1/2023 – 9/13/2023
2024 Crosstrek 9/5/2023 – 9/13/2023
2024 Impreza 9/6/2023 – 9/7/2023
2023-2024 Forester 9/4/2023 – 9/14/2023

 

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 $26,315 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.

 

OWNER NOTIFICATION:

Subaru will notify affected vehicle owners by first class mail on January 8, 2024.

 

PART INFORMATION:

IMPORTANT: The drive shaft assemblies apply to both left and right sides. ALWAYS confirm the correct number of drive shafts required before placing an order.

Drive Shaft Part Information
Model Part Name Part Number Qty Part Identification Label on The Box
Impreza DRV SFT ASSY 28321FN0009S 1
Crosstrek DRV SFT ASSY 28321FN0309S 1
Forester DRV SFT ASSY 28321SJ0109S 1
WRX DRV SFT ASSY 28321VC0209S 1
All (If required) One-Time Use Parts Kit X803926090eBay 1 N/A
80W-90 LSD Gear Oil SOA427V1800 1 N/A
75-90 H.P. Gear Oil

(Suitable Alternative)

SOA427V1700eBay 1 N/A
Oil Seal 803918060 As

Needed

N/A

IMPORTANT: All orders MUST be placed through RPM and not via PRIME or any other channel.  Part orders should be placed ONLY after vehicle inspection reveal a need for parts. Any orders placed for parts and one-time use parts must be placed with the last 8 digits of open recall VIN listed in the PO reference field. Orders placed without a valid open recall VIN in the PO reference field will be canceled.

Valid open recall orders will be released within 24 hours without having to call the PICs for release.

If you have any questions contact the PIC line at (866) 782-2782 option 1.

 

REQUIRED TOOLS:

Tool Name Tool Number Details
Axle Shaft Puller or Equivalent Tool 926470000

+

28099PA110

For removing drive shaft (As needed)
Differential Side Oil Seal Installer or Equivalent Tool 18675AA000 For installing the oil seal
Oil Seal Protector 28399SA010 For installing drive shaft (As needed)
Torx Socket T70 N/A For removing drain plug
Tire Lever or Suitable Pry Bar N/A For removing drive shaft and oil seal
Wooden Block N/A For removing drive shaft and oil seal
Clean Cloth N/A For protecting ball joint boot

 

SERVICE PROCEDURE FLOWCHART:

Refer to the Information In PDF below…

 

SERVICE PROCEDURE INFORMATION:

STEP 1: Lift the vehicle according to the lift manufacturer’s instructions.

 

STEP 2: Rotate the left/right front wheel to find the 2-Line engraving located on both the left and right outer race portions of the inner drive shaft joints.

CAUTIONS:

  • There are three engraves on the drive shaft outer race. One is the lot number, and the others are NOT lot numbers. The lot number engraving is shown in the images below.
  • SLOWLY rotate the wheel to find the lot number. Remove and dust and/or dirt using a clean cloth to make the numbers more visible. A flashlight will also aid in the reading.

 

STEP 3: Confirm the lot number engraving type and read the lot number. See the tables below for further detail.

 

STEP 4: Do any of the drive shafts require replacement?

YES: Review the additional service procedure tips listed below. Replace the affected drive shaft  as per the applicable Service Manual. Refer to STIS: Driveline/Axle > PROPELLERSHAFT /  DRIVE SHAFT / AXLE > Front Drive Shaft

NO: The procedure is complete. Record the lot numbers and include them in the repair order  notes.

 

DRIVE SHAFT REPLACEMENT SERVICE PROCEDURE TIPS:

TIP 1: The Service Manual states it is necessary to disconnect the battery terminal. This step can be avoided if the temperature of the Center Information Display (CID), Multi-Function Display (MFD), and the Combination Meter is 41°F (5°C) or higher. Performing the steps below can avoid battery disconnection.

  1. Turn the ignition switch to the “OFF” position.
  2. Start the engine.
  3. Turn the ignition switch to the “OFF” position.
  4. Wait for at least five minutes.

IMPORTANT: This procedure is only to be used for this campaign. Always perform battery disconnection when requested by the applicable Service Manual for other procedures.

TIP 2: The applicable Service Manual may state it is necessary to perform the “VDC Sensor Midpoint Setting Mode” and/or “Lane Keep Assist Learning Value Clearing” procedures. Front drive shaft replacement does not affect the wheel alignment therefor it is not necessary to perform these procedures for this campaign.

TIP 3: When disconnecting the lower control arm, covering the ball joint boot with a clean cloth can protect the boot from possible damage.

TIP 3: When removing the front differential side seal(s), place the removal tool such as a tire lever or suitable pry bar on the back side of the seal lip and remove. A wooden block can also be used to assist the leverage of the removal tool and prevent damage to the differential case.

CAUTION: DO NOT hit or strike the removal tool. Doing so may cause damage to the sealing surface.

CAUTION: The left and right differential side seals are left and right side specific. There are L and R markings located on the seals indicating left and right installation position.

TIP 4: The Service Manual states it is necessary drain and refill the front differential gear oil during the front drive shaft replacement. The front differential oil does NOT require replacement for this procedure. Any fluid loss can be rectified by adding new gear oil when required.

 

SERVICE PROGRAM IDENTIFICATION LABEL:

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

 


IMPORTANT SAFETY RECALL

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

Subaru Safety Recall WRP-23
NHTSA ID 23V-754
January 2024

 

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 2023 model year WRX vehicles, certain 2024 model year Crosstrek and Impreza vehicles, and certain 2023-2024 model year Forester 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 drive shaft assemblies on your vehicle may have an outer race that could crack, due to improper cooling during the manufacturing process.

Over time, a cracked outer race could break, potentially resulting in loss of motive power. Additionally, if the outer race breaks, the vehicle may roll when parked if the parking brake is not applied. Both conditions increase the risk of a crash.

 

WHAT SUBARU WILL DO

Subaru will inspect the left-hand and right-hand front drive shafts and where necessary, replace them with a new one 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 time to inspect the lot numbers is less than 20 minutes. If one or both driveshafts need to be replaced, the time required to perform this repair will take up to two 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 go to https://www.subaru.com/support/customersupport.html to send us your information.

 

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: WRP-23 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: http://www.wrp23.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 (NHTSA),

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 http://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

 

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Chronology :

August 30, 2023 – The supplier identified quench cracking on the outer diameter of the outer race during magnetic particle inspection. The supplier’s initial findings indicated that there had been no outflow to Subaru.

September 14, 2023 – After a reevaluation of scope, the supplier determined that affected product had been shipped to Subaru. Subaru received information from the supplier indicating a crack on the surface of an outer race of the front drive shaft assembly. Subaru and the supplier initiated a joint study to determine the safety impact of a crack in the outer race.

October 2023 – The supplier presented their findings of the scope of affected parts shipments. Subaru worked with the part supplier to trace the affected parts based on the lot number information.

November 2, 2023 – For the entire population of potentially affected vehicles, Subaru is not aware of any field reports, warranty claims, or VOQs. However, out of an abundance of caution, Subaru decided to conduct a safety recall.

Subaru is not aware of any reports involving accident or injury related to this condition.

 


5 Affected Products

Vehicles

MAKE MODEL YEAR
SUBARU CROSSTREK 2024
SUBARU FORESTER 2023-2024
SUBARU IMPREZA 2024
SUBARU WRX 2023

 


10 Associated Documents

Recall 573 Report

RCLRPT-23V754-4039.PDF 217.484KB

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Recall Acknowledgement

RCAK-23V754-2941.pdf 710.385KB

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Manufacturer Notices(to Dealers,etc) – Date: November 16, 2023 UPDATE Safety Recall/STOP SALE: WRP-23 Driveshaft Failure

RCMN-23V754-3259.pdf 576.682KB

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Manufacturer Notices(to Dealers,etc) – Date: November 10, 2023 New Safety Recall/STOP SALE: WRP-23 Driveshaft Failure

RCMN-23V754-7419.pdf 575.163KB

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Manufacturer Notices(to Dealers,etc)

RCMN-23V754-3642.pdf 566.162KB

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Recall 573 Report – 12/14/2023

RCLRPT-23V754-7121.PDF 217.483KB

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Remedy Instructions and TSB

RCRIT-23V754-6157.pdf 1718.537KB

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Remedy Instructions and TSB

RCRIT-23V754-6156.pdf 1714.029KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-23V754-8436.pdf 757.484KB

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Miscellaneous Document – In-Vehicle/In-App Communication – Safety Recall Reminder

RMISC-23V754-8256.pdf 109.244KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=23V754&docType=RCL

 


NHTSA ID Number: 10248194

Manufacturer Communication Number: SubaruNet Announ

Summary

Subaru of America, Inc. (Subaru) has initiated a safety recall for certain 2023 model year WRX vehicles, certain 2024 model year Crosstrek and Impreza vehicles, and certain 2023-2024 model year Forester vehicles.

 

1 Associated Document

Manufacturer Communications

Date: December 14, 2023
UPDATE Safety Recall/STOP SALE: WRP-23 Driveshaft Failure

https://www.nhtsa.gov/recalls?nhtsaId=10248194

MC-10248194-0001.pdf 578.331KB

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