037012R

ATTENTION:
GENERAL MANAGER
PARTS MANAGER
CLAIMS PERSONNEL
SERVICE MANAGER
q
q
q
q
IMPORTANT - All
Service Personnel
Should Read and
Initial in the boxes
provided, right.
SERVICE BULLETIN
APPLICABILITY:	Legacy and Outback 2000-2009MY w/ 5MT			
NUMBER: 03-70-12R
Forester 1999MY and Later w/ 5MT				 DATE: 12/13/12
Impreza (Including WRX) 1999MY and Later w/ 5MT REVISED: 05/22/13
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.
Transfer driven shaft
bearing (front)
Transfer driven shaft
bearing (rear)
Dish plate
(New part)
Thrust
washer
Transfer driven
shaft bearing
(rear) outer race
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.
Bulletin Number: 03-70-12R; Date: 05/22/13
SUBARU OF AMERICA, INC. IS
“ISO 14001 COMPLIANT”
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
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
4-Door
5-Door
4-Door
5-Door
DG424937
DG007208
DG212655
DG007203
DG213327
Forester
Impreza
WRX
PART INFORMATION
NEW PART
NUMBER
32130AA350
31668AA250
806322080
806330120
DESCRIPTION
EXT COMPL
PLATE-DISHED
ROLL BRG 22X56X17
ROLL BRG 30X62X17
OLD PART
NUMBER
32130AA330
n/a
806322050
806330110
INTERCHANGEABILITY
NOTES
New to Old ONLY
n/a
New to Old ONLY
New to Old ONLY
After T/M#
712031
T/M# 712031
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.
Continued...
Bulletin Number: 03-70-12R; Date: 05/22/13
Page 2
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.
Transfer Driven Gear
Rear Roller Bearing
Front Roller Bearing
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.
Continued...
Bulletin Number: 03-70-12R; Date: 05/22/13
Page 3
•
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: 05/22/13
Page 4
•
Once the proper thrust washer has been selected, assemble the new extension case as shown in the
illustration below.
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.
(A) Bearing outer race
(B) Dish Plate
Painted (concave) side
faces the thrust washer
(C) Thrust washer
(D) Extension case
•
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.
Bulletin Number: 03-70-12R; Date: 05/22/13
Page 5