12-176-14R

ATTENTION:
CLAIMS PERSONNEL q
IMPORTANT - All
Service Personnel
Should Read and
Initial in the boxes
provided, right.
SERVICE MANAGER
© 2014 Subaru of America, Inc. All rights reserved.
GENERAL MANAGER q
PARTS MANAGER
q
q
SERVICE BULLETIN
APPLICABILITY: 2015-16MY Legacy and Outback Models
NUMBER: 12-176-14R
DATE: 12/05/14
REVISED: 10/16/15
SUBJECT:	
Service Procedure to Address a Wind Rushing
Sound from the Front Door Sash Area
INTRODUCTION
This bulletin provides a service procedure to address customer concerns of a wind rushing-type
sound which seems to come from the front door glass sash area. Customers may report a concern
with one or both front doors. It is only necessary to address the side with the confirmed condition.
The door glass sash separates the main door glass from the small partition glass on each door. The
procedure involves replacement of the front door glass run channel (weatherstrip), partition glass/
weatherstrip, sash and both the inner and outer door glass weatherstrips (sweeps). In addition, two
pre-cut pieces of self-adhesive EPT foam, 1 piece of non-woven tape (will be cut into 3 pieces) and
a 320mm section of butyl (adhesive rubber) sealing material will be added in specific locations.
PRODUCTION CHANGE INFORMATION
The latest changes in production were implemented during September, 2015 starting with the
following VINs: G3014581 (LEGACY) and G3230683 (OUTBACK).
PART NAME
PART NUMBER
REPAIR KIT LEG/OBK F RH
61099AL00A
REPAIR KIT LEG/OBK F LH
61099AL01A
320MM SECTION OF BUTYL TAPE
SOA635138**
**included with all kits with a Pack Date after May 1, 2015
PART INFORMATION
The parts kit will consist of the following components: (p.n. 61099AL00A (Right Front Kit is
shown)
ID
DESCRIPTION
QUANTITY
A
B
C
D
E
F
G
Weatherstrip Inner
Glass Assy.
Sash
Glass Run Channel
Weatherstrip Outer
EPT Foam Piece #1
EPT Foam Piece #2
1
1
1
1
1
1
1
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.
Bulletin Number: 12-176-14R; Revised: 10/16/15
Continued...
SUBARU OF AMERICA, INC. IS
ISO 14001 COMPLIANT
ISO 14001 is the international standard for
excellence in Environmental Management
Systems. Please recycle or dispose of
automotive products in a manner that is friendly
to our environment and in accordance with all
local, state and federal laws and regulations.
Page 1
ID
DESCRIPTION
QUANTITY
H
I
J
Rivets
Non-Woven Tape
Butyl Tape
3
1
1
NOTE: If you have in stock or receive a repair kit with an 80mm section of butyl tape included
(item “J” in the photo below), a much longer, (320mm) section, p.n. SOA635138 must be ordered to
properly complete these repairs. All repair kits with a Pack Date after May 1st, 2015 will include the
longer 320mm section of butyl tape. The repair kit part numbers will remain unchanged.
VERY IMPORTANT - Always verify the customer’s concern and read through this procedure
completely BEFORE proceeding with any repairs.
SERVICE PROCEDURE / INFORMATION
STEP 1 - Disassembly
IMPORTANT: Always take proper precautions to protect the outside paint finish and the door panel
interior trim surfaces from becoming scratched / damaged throughout this procedure.
•
Position the door glass 4” up from the top edge of the door trim panel.
•
Disconnect the battery ground (-) cable from the battery sensor.
Bulletin Number: 12-176-14R; Revised: 10/16/15
Continued...
Page 2
•
CAREFULLY remove the affected door trim panel following the procedure outlined in
the applicable Service Manual. Release the control cables from the inner door handle as
shown in the photos below. Align the cable with the slot then lift up and out of the lever to
disengage it.
TIP: After disconnecting the control cables from the door handle, rotate the door panel 90 degrees
clockwise as shown below. This will allow for much easier access to disconnect the door lock and
power window switch harness connectors.
•
After disconnecting the wiring harness connections for the power window and door lock
switches, armrest pocket lamp, courtesy foot lamp and the speaker, put the trim panel in a
safe place to protect it until needed.
NOTE: Pay close attention to the small sealing gaskets used on the door trim and pad insert
retaining clips. All of these gaskets must be in place as shown below before reassembly to properly
seal their respective component and further reduce the chance of a rattling or wind rushing sound.
Continued...
Bulletin Number: 12-176-14R; Revised: 10/16/15
Page 3
•
CAREFULLY release the vapor barrier from the bottom only as much as is required
to remove the pad insert, access the window glass and sash retaining bolts and the wiring
harness connections the inside door. Tape the vapor barrier to the undisturbed top portion to
keep it out of the way. Using a trim clip removal tool, release the retaining clips and remove
the plastic pad insert. Use a Philips screwdriver to remove the door speaker.
IMPORTANT: If the vapor barrier and / or pad insert become damaged, they must be replaced.
•
As shown in the illustrations below, remove the 2- 10mm hex bolts securing the door glass
to the window regulator. CAREFULLY tilt the glass toward the front as shown then lift
to remove. Set the door glass aside in a safe place. Do not remove the window regulator
assembly.
•
After removing the door glass, completely remove the rubber glass run channel.
•
Remove the #2 Philips screw securing the partition glass sash to the door frame. The screw
is accessed by partially removing the outer door seal directly above where the sash meets the
door frame. Remove the 2- 10mm hex bolts securing the sash to the inner door structure then
remove the sash, partition glass and the run channel as shown in the illustrations below.
Continued...
Bulletin Number: 12-176-14R; Revised: 10/16/15
Page 4
NOTE: If the vehicle is equipped with the Genuine Subaru accessory Side Window Deflectors, (p.n.
F0010AL500 - Outback or F0010AL900 - Legacy), the 2-sided tape securing the front leading edge
of the front door deflector must be CAREFULLY cut in order to remove the sash from the door. A
thin, sharp utility knife or box cutter used in the photo below works well for this purpose. Once the
sash is removed, remove the residual adhesive from the inside of the deflector using your fingers to
“roll” it off then clean any remainder with a mild solvent on a clean shop cloth.
STEP 2 - Remove the outer door glass weatherstrip / chrome trim:
•
Apply masking tape to protect the paint finish and mark it 40mm back from the front edge
and 35mm forward of the rear edge as shown below.
•
CAREFULLY slide a small metal straight edge (or equivalent) under the edge of the outer
door glass weatherstrip / chrome trim at the marks to press on and release the 2 retaining
clips. Hold the straight edge at the angle shown in the photo below for best results.
Continued...
Bulletin Number: 12-176-14R; Revised: 10/16/15
Page 5
STEP 3 - Place the door trim panel on a clean surface (e.g. a blanket or cloth fender cover) and
access the inner weatherstrip mounting claws. Use a small flat-blade screw driver to lift and
straighten the retaining claws which along with “pop” rivets, secure it to the door trim panel. Note
the direction of the metal retaining claws as the claws on the replacement part must be folded in
the same direction as the originals. For example: on the front door, the 3 claws ahead of the center
retaining rivet point toward the rear while the 3 claws behind the center rivet point toward the front.
Using an electric drill with a 5/32” drill bit turning at LOW SPEED, CAREFULLY drill out the
retaining rivets found between the “flaps” of the weatherstrip.
The photo below shows the drill being held at an angle to minimize the tendency for the rivet to spin.
A ¼” drive, 5mm deep-well socket was used as a drill stop and an additional “grip” to provide extra
control of the drill bit while drilling out the rivets. Always make sure to vacuum away any remaining
metal chips after drilling is complete.
Continued...
Bulletin Number: 12-176-14R; Revised: 10/16/15
Page 6
Fit the replacement inner weatherstrip to the trim panel. After confirming the new weatherstrip is
fitted properly as shown in the illustrations below, left (sweeps pointing upward and the “flap” portion
NOT pinched in between the weatherstrip and the trim panel), proceed with “clamping” it to the door
trim panel. Using your thumbs and fingers as shown below, bend the retaining claws over in the
same direction as the originals (referenced earlier in this step) using your forefinger. The metal used
for the backing and retaining claws is relatively pliable and easily bent into position.
Once all the new claws are bent over and holding the weatherstrip tight against the door panel, install
the new retaining rivets using a pop rivet installation tool.
After installation, the back side of each new rivet will mushroom or “bloom” as shown below (Fig.
1). Pinch the inside flap of the weatherstrip and the lower glass-side flap together (Fig. 2). Using
a pair of slip-joint pliers, CAREFULLY crush the bloom, one part at a time. The rivet material is
aluminum so, only a small amount of clamping force is needed to achieve the desired result (Figs. 3
and 4). They do not need to be crushed flat. Maximum height is 3mm. Using the supplied piece
of non-woven tape, cut it into thirds (3 pieces) and apply one piece over each rivet bloom (Fig. 4).
Smooth the tape for proper adhesion.
Fig. 1
Fig. 2
Fig. 3
Continued...
Bulletin Number: 12-176-14R; Revised: 10/16/15
Page 7
Fig. 4
STEP 4 - Application of the EPT Foam Sealing Material
•
EPT Foam Piece #1 is applied to top REAR inside corner of the door trim panel where the
trim material wraps around the back edge as shown in the “Before” and both the proper and
improper installation “After” photos below. The NG photo shows an excessive gap between
the foam and edge of the trim panel.
“BEFORE” Shows
Location for Piece #1
Continued...
Bulletin Number: 12-176-14R; Revised: 10/16/15
Page 8
•
EPT Foam Piece #2 is applied to the top front of the door trim panel at the front edge of the
inner door glass inner weatherstrip. This piece seals the inside face of the sash and has been
pre-cut so it can be properly folded into position as shown in the illustration and photos below.
Continued...
Bulletin Number: 12-176-14R; Revised: 10/16/15
Page 9
STEP 5 - Application of Butyl Tape
•
To better secure the upper front corner of the REAR DOOR frame weatherstrip to the
door frame, release the plastic retaining clip and pull back the weatherstripping to access the
area where the 320mm section of butyl tape will be applied. Be sure to clean the area where
the butyl tape will be applied with a mild solvent on a clean shop cloth. After drying the area
completely, apply the butyl tape to the door frame where indicated in the illustrations and
completed installation photo below.
Continued...
Bulletin Number: 12-176-14R; Revised: 10/16/15
Page 10
After the butyl tape is applied, refit the weatherstrip and make sure the retaining clip “clips” back into
the hole as shown to properly secure and position it. Work the weatherstrip onto the butyl tape with
your thumbs making sure it is smooth and any bumps or high spots have been worked out.
To complete this step, make sure the front of the weatherstrip is properly tucked in behind the chrome
outer molding as shown below.
STEP 6 - Reassembly
•
Install the new partition glass assembly, sash and glass run channel into the door frame in
reverse order of removal. The rubber edges (lips) of all components must be smooth and flat.
•
Confirm the alignment tab on the top of the sash is properly located in the hole in the door
frame as shown below before installing the Philips retaining screw.
Top of
Sash
Alignment
Tab
Hole for Philips
Retaining Screw
Continued...
Bulletin Number: 12-176-14R; Revised: 10/16/15
Page 11
IMPORTANT:
•
Before torqueing the sash hardware, inspect the partition glass weatherstrip / seal closely for
proper fit with no gaps or bunching up of the seal outer lip. An example of a proper and an
improper fit are shown below.
NG
OK
•
Always follow the torque sequence shown below when tightening the sash hardware.
While applying substantial forward pressure on the sash against the partition glass, fully torque
the top Philips retaining screw to 19 inch-pounds (1.6 ft. lbs.) then torque the 10 mm hex sash retaining
bolt #2 to 66 inch-pounds (5.5 ft. lbs). While keeping forward pressure on the bottom of the sash,
tighten and torque the 10mm hex sash bolt #3 to 66 inch-pounds (5.5 ft. lbs). Do not snug the hardware
then go back and final torque it. The initial tightening must be right up to the specified torque.
Apply forward
pressure
19 inchpounds
66 inchpounds
Continued...
Bulletin Number: 12-176-14R; Revised: 10/16/15
Page 12
IMPORTANT: After the sash hardware
has been torqued, make sure the face of
the sash is parallel to the top edge of the
door as shown in the photo on the right.
Face of Sash
IMPORTANT NOTE: If the vehicle
After torqueing the
is equipped with the Genuine Subaru
hardware, the face
accessory Side Window Deflectors,
of the sash must be
apply a new piece of double-sided
parallel to the door’s
top edge.
mounting tape to the inside front edge
of the deflector to re-attach it to the sash
Base of Outside Mirror
BEFORE installing the new sash back
into the door. A small piece (2” long x
3/8” wide) of 3M .030” thick, Automotive Attachment Tape Part # 06377 (available from any auto body
supply jobber) is recommended for this purpose. Leave the adhesive backing in place on the sashside of the tape until the sash has been reinstalled. Once the sash is in its final position and fasteners
properly torqued, pull the deflector out enough to access the sash-side backing of the tape. Peel the
backing and press the deflector onto the new sash securing it in place.
Install the new rubber glass run channel into the door frame starting at the top front “corner” area.
Confirm the locating tab portion is seated in the hole just behind the Philips screw securing the top of
the sash to the door frame as shown in the photos below. Continue to fit the run channel into the door
frame and all the way to the bottom in both the new partition glass sash (front) and the channel for the
rear edge of the glass.
Apply pressure in the direction of the arrows shown in the illustration below to make sure it is fully
seated paying close attention to the upper rear corner. Use the photos below to confirm a proper fit in
this area. Again, all the rubber component edges (lips) must be smooth and lay flat.
Start installation of the
replacement rubber glass
run channel in this area.
Continued...
Bulletin Number: 12-176-14R; Revised: 10/16/15
Page 13
•
CAREFULLY reinstall the door glass into the new glass run channel and slide it down to meet
the regulator. Reinstall the 2 mounting bolts and torque to 5.5 ft. lbs. (66 inch pounds).
•
Reinstall the pad insert then refit the vapor barrier making sure it is completely resealed just as
it was prior to the repair. Reinstall the door speaker.
REMINDER: If the vapor barrier and / or pad insert become damaged, they must be replaced.
•
Install the new replacement outer door weatherstrip / chrome trim in reverse order of removal
making sure it is fully seated onto the door and fully secured on both ends by the retaining
clips.
•
Reconnect the door lock and latch control cables and all removed wiring harness connectors.
IMPORTANT: When reinstalling the door lock and latch control cables, always confirm the outer
casings are fully locked back into place in their respective retaining grooves.
•
Always verify proper power window, power door lock, door latch, armrest pocket lamp,
courtesy foot lamp and speaker operation before final installation of the door trim panel.
•
Once proper operation is confirmed, verify all the retaining clip sealing gaskets are in place and
reinstall the door trim panel in reverse order of removal.
IMPORTANT: When reinstalling the door trim panel, keep EPT Foam Piece #1 (located on the top
REAR corner of the door trim panel) from binding or “bunching up”,by holding the lower portion of the
door trim panel away from the door while sliding it down into position.
STEP 7 - Reconnect the negative battery cable and torque the 12mm nut to 7.5 Nm (5.5 ft. lbs).
•
Reset the customer’s radio station presets and navigation system favorites.
Continued...
Bulletin Number: 12-176-14R; Revised: 10/16/15
Page 14
NOTE: For the power window Auto Up / Down feature to operate, the system will need to be reinitialized, regardless of which front door was repaired. Always confirm Auto Up / Down feature is
working on BOTH front windows after reassembly. Follow the steps below to complete the reinitialization procedure:
1. Begin with the window fully closed. Push the switch down to open the window about
halfway.
2. Pull the switch up to close the window fully in steps (it will only close about 2” each time the
switch is operated).
3. Once the window is fully closed, pull up and hold the switch again for 1 second to complete
the initialization procedure.
STEP 8 - Road test the vehicle to confirm the repair has been successful to complete the procedure.
WARRANTY / CLAIM INFORMATION
For vehicles within the Basic New Car Limited Warranty period, this repair may be claimed using the
following information:
LABOR DESCRIPTION
LABOR
OPERATION #
2015 Legacy and Outback Front Door Wind
Rushing Sound Repair- 1 Side
B912-503
2015 Legacy and Outback Front Door Wind
Rushing Sound Repair- Both Sides
B912-504
Models With Side Window Air Deflectors
(Add this labor operation ONE TIME
for each side.)
C912-505
FAIL
CODE
LABOR
TIME
1.1
WAZ-48
1.7
0.1
NOTE: Up to $1.00 can be claimed in sublet to cover the cost of the 3M Attachment Tape where
applicable.
IMPORTANT REMINDERS:
•
SOA strongly discourages the printing and/or local storage of service information as
previously released information and electronic publications may be updated at any time.
•
Always check for any open recalls or campaigns anytime a vehicle is in for servicing.
•
Always refer to STIS for the latest service information before performing any repairs.
Bulletin Number: 12-176-14R; Revised: 10/16/15
Page 15