WQL48Ra

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.
PRODUCT CAMPAIGN BULLETIN
APPLICABILITY:	 2003-2004

Subaru Legacy and Outback
2003-2004 Subaru Baja
2004 Subaru Impreza (including WRX and STI)
SUBJECT:	Front Passenger Air Bag Inflator Replacement
NUMBER:
DATE:
REVISED:
NHTSA ID:
WQL-48R
August 2014
August 25,2014
14V-399
Subaru of America, Inc. (SOA) has determined that a defect, which relates to motor vehicle
safety, may exist on certain 2003-2004 model year Subaru Legacy, Outback, and Baja
vehicles, and certain 2004 model year Subaru Impreza (including WRX and STI) vehicles.
The subject vehicles are equipped with front passenger air bag inflators which could have
been assembled with improperly manufactured propellant wafers. In the event of a crash
necessitating deployment of the passenger side frontal air bag, improperly manufactured
propellant wafers inside the inflator could cause the inflator to rupture with metal fragments
striking and potentially seriously injuring the vehicle occupants.
Although the percentage of affected vehicles is unknown, this recall will involve replacing the
front passenger air bag inflator on all of the potentially affected vehicles.
AFFECTED VEHICLES
This condition may exist on certain 2003-2004 model year Legacy, Outback, and Baja
vehicles, and certain 2004 model year Impreza, WRX, and STI vehicles listed below.
Not all vehicles within these production date ranges are affected by this recall. The
potentially affected vehicles were identified based on the serial number of the front passenger
air bag inflator installed during vehicle production.
Coverage for all potentially affected vehicles must be confirmed by using the Vehicle
Coverage Inquiry function on subarunet.com. This data will be available when owner
notification begins.
MODEL YEAR
MODEL
STARTING
PRODUCTION DATE
ENDING
PRODUCTION DATE
2003
Legacy
01/22/2003
05/14/2003
2004
Legacy
03/17/2003
02/10/2004
2003
Outback
02/18/2003
04/15/2003
2004
Outback
02/28/2003
02/11/2004
2003
Baja
01/22/2003
05/06/2003
2004
Baja
03/03/2003
07/21/2004
2004
Impreza,
WRX, STI
01/08/2003
05/15/2003
Continued...
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 1
OWNER NOTIFICATION
Notification letters will be sent to owners of all potentially affected vehicles. Owner
notification is currently scheduled to begin on August 11, 2014. A copy of the Owner
Notification Letter is included at the end of this bulletin.
RETAILER AFFECTED VIN LISTS
Each Subaru retailer will receive an affected VIN list from their Zone Office when owner
notification begins. Vehicles will be assigned to retailers in the affected VIN list as follows:
•
Original vehicle owners are assigned to the original selling retailer when their current
address is within a 100 mile radius of that retailer.
•
If the original selling retailer is inactive, the VIN has been assigned to the nearest
active retailer.
•
For any new owners or when original owners live more than 100 miles from the
original selling retailer, the VIN has been assigned to the nearest active retailer.
Important: Retailer affected VIN lists include owner name and address information for
vehicles affected by this recall. This information will enable retailers to follow-up with
owners of potentially affected vehicles. The lists contain owners’ names and addresses
obtained from State Motor Vehicle Registration Records. The use of such motor vehicle
registration data for any other purpose is unlawful. Accordingly, retailers are urged to
limit the use of these lists for the purpose of completion of this safety recall.
SUBARU RETAILER PROGRAM RESPONSIBILITY
Retailers are to promptly perform the applicable service procedures to correct all affected
vehicles in their inventory (new, used, demo & SSLP). Additionally, whenever a vehicle
subject to this recall is taken into retailer new or used inventory, or in 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 (Subaru Service Loaner Program) vehicles listed in a recall/
campaign that are in the retailer’s 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.
Continued...
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 2
PARTS INFORMATION
The parts required for this recall are the passenger air bag inflator module kits listed below:
PART NUMBER
APPLICABILITY
98279AE00A
Legacy, Outback, and Baja
98279FE000
Impreza, WRX, and STI
DESCRIPTION
WQL-48 Air Bag Inflator
Module Kit
WQL-48 Air Bag Inflator
Module Kit
ORDER
QUANTITY
1
1
These parts are available through normal parts ordering channels. In order to maintain an
adequate part supply, SOA requests that retailers only order quantities necessary to satisfy
anticipated demand.
PART RETURN PROCEDURES
IMPORTANT:
Each removed air bag inflator must be returned directly to the supplier, Takata USA, in the
same box in which the new one was received.
As the shipper, you are responsible for proper packing and document completion. The
person packaging the inflator must have received hazardous material training per 49CFR
172.702, and the training records must be on file at your dealership. The US Department
of Transportation will impose substantial fines and/or penalties on the shipper if either
packaging, labeling or documentation is not properly prepared and the Customer Copy of
OP 900PRP form is not kept on file for a minimum of 2 years.
IMPORTANT: Do not deploy any inflator. Return the used inflator within 1-2 business
days. The person packing the used inflator must read and follow the provided instructions.
•
The shipping box contains a bar code with the serial number of the new air bag
inflator, which will be used by Takata USA to document the replacement of the old
inflator with the new inflator. Therefore, it is very important that the removed
inflator be returned in the exact same box that contained the newly-installed
inflator for that vehicle. If the original box cannot be re-used, please refer to the
shipping instructions under “Requesting a new box/shipping labels.”
•
Prepaid FedEx shipping documents and shipping instructions will be included with
each new air bag inflator kit. A copy of this information is included as ‘Appendix A’
of this bulletin.
•
A completed SOA Warranty Parts Tag (MSA5W402A) must be attached to the
returned inflator. The tag must contain the following information: claim number,
repair date, full 17-digit VIN, and mileage.
•
Takata USA has assigned each Subaru retailer a ChemTrec Contract Number
(CCN). As shown in step 5 of the shipping documentation instructions, the shipping
retailer must fill in their name, address, and CCN.
оо ChemTrec is a company that provides 24-hour emergency response and
information to hazardous material shippers.
оо The assigned CCN allows the Subaru retailer to ship hazardous material as an
affiliate to Takata USA’s registration with ChemTrec. This number is required
on the return shipping form.
Continued...
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 3
A list of all Subaru retailers along with their assigned CCN information is included as
‘Appendix B’ of this bulletin. It is SOA’s intention to include a copy of this list with each new
air bag inflator kit, however the first shipment of parts will not include this list as it was not
available at the time the parts were packed. Future shipments will include this document for
reference.
The CCN list included with future shipments will be updated periodically to include new
Subaru retailer information. If a Subaru retailer is unable to find their CCN, they should
contact Takata USA as described in step 5 of the shipping documentation instructions.
SOA PART RETURN NOTICE
Upon claim approval, Subaru of America, Inc. will generate a Part Return Notice requesting
information only. To ensure proper claim credit, the following information must be recorded
on the SOA Part Return Notice and sent to SOA Part Collection Center (PCC) as instructed on
the return notice:
•
The FedEx Shipper Receipt # (from shipping form)
•
The OLD and NEW air bag inflator serial numbers
The Part Return Notice should then be returned using UPS 3rd party billing to the address
listed at the bottom of the notice. Please keep the UPS tracking number for your records.
Under no circumstances should the air bag inflator be returned to Subaru of America, Inc.
SERVICE PROCEDURE
This Campaign involves the replacement of the inflator portion of the passenger-side front
airbag assembly. The subject inflators could have been assembled with improperly manufactured
propellant components which may affect how the assembly inflates in the event of a collision
resulting in an increased risk of injury to vehicle occupants. This procedure will outline removal
of the passenger-side airbag assembly and replacement of the inflator component and related
wiring harness.
VERY IMPORTANT: Failure to follow these service procedures carefully and correctly
may result in an accidental deployment of the inflator and potentially cause serious injury.
Please read through and understand these procedures COMPLETELY before beginning
repairs. In addition, proper operation of the airbag after reassembly may be compromised
if these service procedures are not followed.
Continued...
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 4
Tools Required
DESCRIPTION
Pliers
BRAND OR TYPE
-
Wire Cutters
Needle-Nose Pliers
Torque Wrench
Safety Goggles
Flat-Blade Screwdriver
Scissors
Ratchet
8 mm Socket
Inch-Pound
1/4” Drive
QUANTITY
1
1
1
1
1
1
1
1
1
NOTE: Although the service procedure is similar for both Legacy / Outback / Baja and
Impreza models, there are some significant differences. For this reason, procedures for both
models will be outlined.
CAUTION: Before starting this service procedure, perform a visual inspection of both front
airbags looking for any damage or abnormality. Next, turn the ignition switch to the “ON”
position and confirm the airbag warning lamp illuminates then extinguishes normally. If it
does not or if ANY concern is noted with the airbag system, STOP and report these findings
to the customer BEFORE proceeding further. Any concerns identified with the airbag system
(when no airbag deployment has occurred), are not related to this campaign and must be addressed separately. Even if the system has a concern, this may not preclude completion of this
campaign. If you are unsure about proceeding, document and fully diagnose the concern then
contact the SOA Technical Helpline to review your findings. It is in the best interest of the
retailer to fully document any concerns found during this preliminary inspection and review
with the customer BEFORE proceeding with the campaign service procedure.
*SERVICE PROCEDURE FOR LEGACY / OUTBACK AND BAJA MODELS*
CAUTION: Refer to the “CAUTION” section in the General Description portion
of Airbag System AB in the Body Section of the Service Manual before handling or
servicing any airbag module!
STEP 1- PREPARATION:
•
Turn the ignition “OFF”.
•
Disconnect the Negative (ground) cable from the battery and wait at least 20 seconds
before proceeding further.
•
Remove the glove box assembly following the procedure in the applicable Service
Manual and using the tips below.
The glove box is held in place by 8 screws.
оо The 2 upper left and right hand corner screws have a distinctive gold finish and
10mm hex head. It is helpful to leave these 2 screws until last when removing and
install first during replacement to support the weight of the assembly.
оо It is necessary to remove the knockout plugs (stopper in the Service Manual) to
gain access to all the mounting screws.
оо It is possible to leave the stoppers in place during servicing by carefully bending
in the sides of the glove box until the stoppers are cleared.
•
To prevent damage, do not bend them in any further than necessary.
Bulletin Number: WQL-48R; Revised: August 25, 2014
Continued...
Page 5
IMPORTANT: Whenever beginning to remove (or install) the airbag assembly, and
periodically while performing the procedure or after stepping away, remove any possible
static charge from your body by momentarily touching a clean, bare metal ground point
on the vehicle (e.g. the door striker). Remove from your person all electronic devices
including cell phones before proceeding.
•
Disconnect the airbag module harness connector (A) and release it from the support
beam bracket.
•
Remove the 3 retaining bolts and CAREFULLY remove the airbag module from
the vehicle and place it on a clean cloth to protect the dash trim outer surface portion
from damage.
IMPORTANT: DO NOT destroy or damage the Kit Box as it MUST be used for the
original inflator’s return shipping.
•
Open the Kit Box and confirm all the necessary components are included:
4 Self-Locking nuts
New Inflator (yellow tape applied to one end to identify it as the replacement part)
New Inflator Harness
Electro-Tap (red shorting crimp connector)
Shipping Declaration document, FedEx document pouch and return shipping label
Continued...
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 6
•
Throughout the inflator replacement procedure, keep the airbag assembly in a
position perpendicular to the edge of the work table as shown in the photo below.
With the airbag assembly in this position, should a deployment occur, risk of injury
would be reduced as force would be directed toward the side, not directly toward the
Technician. Always perform this work in an area away from others to reduce chances
of inadvertent injury should any deployment occur. Take your surroundings into
account to avoid possible hazards should inadvertent deployment occur or sources of
static or other electricity that could potentially induce such a deployment.
STEP 2- Remove the harness clip from the retainer bracket by rotating the harness / clip 90
degrees then releasing it from the bracket with needle-nose pliers.
STEP 3- CAREFULLY cut the yellow harness cover (approximately 1 1/2 inches) enough
to expose the 2 yellow wires inside and provide enough room to install the Electro-Tap
(shorting) connector using a scissor or wire cutter (no knives or razors). TAKE YOUR
TIME AND BE CAREFUL TO NOT CUT THE 2 YELLOW WIRES!
Continued...
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 7
STEP 4- Short the 2 yellow wires together by installing the Electro-Tap connector. The
connector creates a short circuit which acts as a safeguard to prevent against static discharge
that may deploy the removed inflator. The tab portion of the Electro-Tap connector MUST
be cut off prior to use to insure a good short-circuit is made as shown in the illustration below.
Follow the sequence below for installing the Electro-Tap connector. Use pliers to squeeze
closed the two sections of the connector together, one section at a time.
Insert 1 wire in
the Electro-Tap
This tab MUST
be cut off
Fold
1
2
3
Place the other
wire in the
Electro-Tap,
fold then crimp
closed with pliers
Crimp closed
with pliers
4
5
STEP 5- Once the Electro-Tap connector is fully crimped in place, cut the 2 yellow wires on
the body harness connector side of the Electro-Tap connector.
CUT
Continued...
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 8
STEP 6- Remove the two 8mm self-locking nuts securing the stopper plate. Loosen but do
not remove the other two nuts on the mounting bracket as leaving them in place will help
keep the airbag assembly together.
NEVER ATTEMPT TO REMOVE THE HARNESS CONNECTORS FROM THE
INFLATOR!
Stopper Plate
STEP 7- Slide the original inflator out of the mounting bracket while feeding the cut off
portion of the wiring harness through the “D-Shaped” hole in the end plate. NEVER
ATTEMPT TO REMOVE THE HARNESS CONNECTORS FROM THE INFLATOR!
Place the removed original air bag inflator in the “cradle” of the Kit Box insert.
Continued...
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 9
STEP 8- VERY IMPORTANT: Record the FedEx Shipper Receipt Number (located at
the top of the return shipping label included with the new inflator) and the 11-digit alphanumeric serial number for both the new and the removed inflators on the hard copy of
the Repair Order. This information will be required for completion of the Part Return Notice
which will be forwarded by the retailer to the PCC.
STEP 9- Install the new inflator into the mounting bracket so the yellow taped end aligns
with the removed stopper plate. Make sure the “D-shaped” portion of the inflator harness
connector boss aligns with the “D-shaped” portion of the hole in the end of the mounting
bracket as shown below. When properly installed, the end of the inflator will be seated tight
against the mounting bracket. Do not peel the white connection dust cover at this time.
Inflator properly
seated against
mounting bracket
(NO GAP)
STEP 10- Reinstall the stopper plate using 2 of the NEW self-locking nuts but do not tighten
them fully. Remove the nuts still installed on the mounting bracket and replace them with 2
NEW self-locking nuts. Once all 4 NEW nuts are in place, torque to 31 - 38 inch pounds
in the sequence shown below. Use a marker to mark the nuts after torquing indicating they
have been fully tightened.
Continued...
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 10
STEP 11- The new inflator wiring harness has a “long side” and a “short side” with round
2-pin connectors on both ends. The short side with red wires will connect to the end of the
inflator with the round wiring harness connector boss, yellow tape and removable stopper plate.
Peel off the white dust cover from the round connector boss end of the inflator ONLY.
CAREFULLY align the pins with the female terminals of the harness connector (2 red
wires) as shown in the sequence below. IMPORTANT: NEVER PEEL BOTH THE
WHITE DUST COVERS OFF AT THE SAME TIME! Once pin alignment is confirmed,
push down firmly to engage the connector’s 3 locking tangs into the locking groove inside
the connector boss. Confirm the connector is locked by prying up LIGHTLY with a small
flat-blade screwdriver. Repeat the procedure on the D-shaped connector boss end (2 yellow
wires). Reinstall the black wiring harness retaining clip into the mounting bracket to
complete the airbag reassembly.
Locking Groove
STEP 12- Reinstall the airbag assembly into the vehicle in reverse order of disassembly.
Before installing the glove box assembly, reconnect the negative battery cable. Turn the
ignition key “ON” and confirm the AIRBAG warning light comes on then cycles off properly.
Once proper warning light operation is confirmed, reinstall the glove box assembly to
complete the procedure.
STEP 13- Place the removed original air bag inflator in the “cradle” of the Kit Box insert,
with a completed SOA warranty parts tag (MSA5W402A) attached to it. The tag must
contain the following information: Claim Number, Repair Date, 17-digit VIN, and vehicle
mileage. Refer to the “PARTS RETURN PROCEDURES” section of this bulletin (page
3) for further return shipping instructions and information. Ensure both the removed and
installed inflator serial numbers along with the FedEx Shipper Receipt number have
been recorded correctly as previously instructed on the repair order hard copy before
returning the removed part to your Parts Department.
IMPORTANT: UNDER NO CIRCUMSTANCES SHOULD ANY AIR BAG
INFLATORS BE RETURNED TO SUBARU OF AMERICA, INC.
Continued...
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 11
Refer to Page 18 for instructions on completing and installing the Recall Identification Label.
*SERVICE PROCEDURE FOR IMPREZA, WRX and STI MODELS*
CAUTION: Refer to the “CAUTION” section in the General Description portion
of Airbag System AB in the Body Section of the Service Manual before handling or
servicing the airbag module!
STEP 1- PREPARATION:
•
•
•
Turn the ignition “OFF”.
Disconnect the Negative (ground) cable from the battery and wait at least 20 seconds
before proceeding further.
Remove the glove box assembly following the procedure in the applicable Service
Manual.
IMPORTANT: Whenever beginning to remove (or install) the airbag assembly, and
periodically while performing the procedure or after stepping away, remove any possible
static charge from your body by momentarily touching a clean, bare metal ground point
on the vehicle (e.g. the door striker). Remove from your person all electronic devices
including cellphones before proceeding.
•
Disconnect the airbag module harness connector
from the support beam bracket.
•
Remove the 3 retaining bolts and CAREFULLY
remove the airbag module from the vehicle and
place it on a clean cloth to protect the dash trim
surface portion from damage.
NOTE: There may be a Security Module secured with the lower airbag module
mounting bolt on some models.
IMPORTANT: DO NOT destroy or damage the kit box as it MUST be used for the
original inflator’s return shipping.
•
Open the Kit Box and confirm all the necessary components are included:
4 Self-Locking nuts
New Inflator (yellow tape applied to one end to identify it as the replacement part)
New Inflator Harness
Electro-Tap (red shorting crimp connector)
1 ½” X 2 ¼” piece of self-adhesive Sponge Tape
Shipping Declaration document, FedEx document pouch and return shipping label
Continued...
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 12
•
Throughout the inflator replacement procedure, keep the airbag assembly in a position
perpendicular to the edge of the work table as shown in the photo below. With the
airbag assembly in this position, should a deployment occur, risk of injury would be
reduced as force would be directed toward the side, not directly toward the Technician.
Always perform this work in an area away from others to reduce chances of inadvertent
injury should any deployment occur. Take your surroundings into account to avoid
possible hazards should inadvertent deployment occur or sources of static or other
electricity that could potentially induce such a deployment.
STEP 2- Peel the Sponge Tape and remove the harness clip from the retainer bracket by
pushing the tangs inward with a flat-blade screwdriver as shown below. Always remove any
Sponge Tape adhesive residue from the airbag mounting bracket using mild solvent on a clean
shop cloth. CAUTION: Never use any silicone-based products for this purpose.
STEP 3- CAREFULLY cut the yellow harness cover enough (approximately 2 inches) to
expose the 2 red or yellow wires inside and provide enough room to install the Electro-Tap
(shorting) connector using a wire cutter or scissor (no knives or razors). TAKE YOUR
TIME AND BE CAREFUL TO NOT CUT THE 2 WIRES!
Red Wires
Yellow Wires
Continued...
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 13
STEP 4- Short the 2 wires together by installing the Electro-Tap connector. The connector
creates a short circuit which acts as a safeguard to prevent against static discharge that may
deploy the removed inflator. The tab portion of the Electro-Tap connector MUST be cut off
prior to use to insure a good short-circuit is made as shown in the illustration below. Follow
the sequence below for installing the Electro-Tap connector. Use pliers to squeeze closed the
two sections of the connector together, one section at a time.
Insert 1 wire in
the Electro-Tap
This tab MUST
be cut off
Fold
1
2
3
Place the other
wire in the
Electro-Tap,
fold then crimp
closed with pliers
Crimp closed
with pliers
4
5
STEP 5- Once the Electro-Tap connector is fully crimped in place, cut the 2 wires on the
body harness connector side of the Electro-Tap connector.
CUT
STEP 6- Remove the two 8mm self-locking nuts securing the stopper plate. Loosen but do
not remove the other two nuts on the mounting bracket as leaving them in place will help
keep the airbag assembly together.
Remove
Continued...
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 14
STEP 7- Slide the inflator out of its mounting while feeding the cut off portion of the
wiring harness through the “D-Shaped” hole in the end of the mounting bracket. NEVER
ATTEMPT TO REMOVE THE HARNESS FROM THE INFLATOR! Place the
removed original air bag inflator in the “cradle” of the Kit Box insert.
STEP 8- VERY IMPORTANT: Record the FedEx Shipper Receipt Number (located at
the top of the return shipping label included with the new inflator) and the 11-digit alphanumeric serial number for both the new and the removed inflators on the hard copy
of the Repair Order. This information will be required for completion of the Part Return
Notice which will be forwarded by the retailer to the PCC. The new serial number is also a
requirement for claim entry.
STEP 9- Install the new inflator into the mounting bracket with the harness connector end going
in first toward the mounting bracket. Make sure the “D-shaped” portion of the inflator harness
connector boss aligns with the “D-shaped” portion of the hole in the end of the mounting
bracket as shown below. When properly installed, the end of the inflator will be seated tight
against the mounting bracket. Do not peel the white connection dust cover at this time.
Inflator properly
seated against
mounting bracket
(NO GAP)
Continued...
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 15
STEP 10- Reinstall the stopper plate using 2 of the NEW self-locking nuts but do not tighten
them fully. Remove the nuts still installed on the mounting bracket and replace them with 2
NEW self-locking nuts. Once all 4 NEW nuts are in place, torque to 31 - 38 inch pounds in
the sequence shown below. Use a marker to mark the nuts after torquing indicating they have
been fully tightened.
STEP 11- The new inflator wiring harness (with 2 red wires inside) connects to the end
of the inflator with the “D-shaped” connector boss. Peel off the white dust cover and
CAREFULLY align the 2 inflator pins with the female terminals of the harness connector as
shown in the sequence below. Once pin alignment is confirmed, push down firmly to engage
the connector’s 2 locking tangs into the locking groove of the connector boss. Confirm the
connector is fully locked by prying up LIGHTLY with a small flat-blade screwdriver.
Locking Groove
STEP 12- Reinstall the wiring harness retaining clip into its position on the mounting bracket.
Continued...
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 16
STEP 13- Peel the adhesive backing and install the new Sponge Tape onto the yellow harness
tube first then adhere it to the airbag mounting bracket as shown in the illustrations below.
Placement of Sponge Tape
IMPORTANT: The
Sponge tape must be
installed more than
half-way around the
yellow harness tube.
Harness
Sponge Tape
STEP 14- Reinstall the airbag assembly into the vehicle in reverse order of disassembly.
NOTE: If the accessory security module is installed to one of the airbag module mounting
bolts, torque that specific bolt to 7.5 +/-1ft. lb. rather than the normal 5.4 ft. lb. specified in
the Service Manual. Before installing the glove box assembly, reconnect the negative battery
cable. Turn the ignition key “ON” and confirm the AIRBAG warning light comes on then
cycles off properly. Once proper warning light operation is confirmed, reinstall the glove box
assembly to complete the procedure.
STEP 15- Place the removed air bag inflator in the “cradle” of the Kit Box insert, with a
completed SOA warranty parts tag (MSA5W402A) attached to it. The tag must contain the
following information: Claim Number, Repair Date, 17-digit VIN, and vehicle mileage.
Refer to the “PARTS RETURN PROCEDURES” section of this bulletin (page 3) for further
return shipping instructions and information.
IMPORTANT: UNDER NO CIRCUMSTANCES SHOULD ANY AIR BAG
INFLATORS BE RETURNED TO SUBARU OF AMERICA, INC.
Continued...
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 17
RECALL IDENTIFICATION LABEL
Type or print the necessary information on a Service Program identification label. The
completed label should be attached to the vehicle’s upper radiator support.
Additional labels are available through normal parts ordering channels. The part number is
MSA6P1302. Ordering qty 1 = 1 sheet of 20 labels.
PART NUMBER
APPLICABILITY
DESCRIPTION
ORDER QUANTITY
MSA6P1302
All models
Campaign Completion Labels
(contains one sheet of 20 labels)
1
WQL-48
CLAIM REIMBURSEMENT AND ENTRY PROCEDURES
Credit to perform this recall will be based on the submission of properly completed repair order
information. Retailers may submit claims through ‘Vehicle Claim Entry’ on Subarunet.com.
Listed below is claim entry information:
CLAIM
TYPE
CAMPAIGN
CODE
LABOR
DESCRIPTION
LABOR
TIME
RC
WQL-48
A182-031
Front Passenger Air Bag Inflator Replacement
0.7
PART NUMBER
98279AE00A
98279FE000
APPLICABILITY
Legacy, Outback,
and Baja
Impreza, WRX, and
STI
Miscellaneous Detail
DESCRIPTION
QUANTITY
WQL-48 Air Bag Inflator Module Kit
1
WQL-48 Air Bag Inflator Module Kit
1
Enter the serial number of the NEW air bag inflator installed in the
“Misc. Details” field.
Continued...
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 18
OWNER NOTIFICATION LETTER
IMPORTANT SAFETY RECALL
This notice applies to the VIN identified
in the address section printed below.
Subaru Recall Campaign WQL-48
NHTSA Recall No. 14V-399
August 2014
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 2003-2004 model year Legacy, Outback, and Baja vehicles, and certain 2004 model year Impreza,
WRX, and STI vehicles.
You received this notice because our records indicate that you currently own one of these vehicles.
DESCRIPTION OF THE SAFETY DEFECT AND SAFETY HAZARD
Subaru was notified by its supplier that the subject vehicles are equipped with front passenger air bag
inflators which could have been assembled with improperly manufactured propellant wafers. In the
event of a crash necessitating deployment of the passenger side frontal air bag, improperly manufactured
propellant wafers could cause the inflator to rupture with metal fragments striking and potentially
seriously injuring the vehicle occupants.
REPAIR
Subaru will replace the inflator for your front passenger air bag at no cost to you.
WHAT YOU SHOULD DO
You should immediately contact your Subaru retailer (dealer) for an appointment to have the front
passenger air bag inflator replaced with a new one.
HOW LONG WILL THE REPAIR TAKE?
The time to replace the front passenger air bag inflator is approximately 40 minutes. 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. Please present this letter to your Subaru retailer at the
time this repair procedure is performed.
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.
Or, if you prefer to update this information online, please go to www.subaru.com, select Contact Us then
select Update Address from the drop down menu.
Continued...
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 19
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 the most Frequently Asked Questions, please go to:
• http://www.wql48.service-campaign.com
If you need additional assistance, please contact us directly:
• 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 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, 1200 New
Jersey Ave. SE, West Building, Washington, DC 20590 or call the toll free Auto Safety Hotline at
1-888-327-4236 (TTY: 1-800-424-9153) or go to http://www.safercar.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 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.
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 20
SHIPPING DOCUMENTATION AND INSTRUCTIONS (Appendix A)
CAMPAIGN WQL48 – 48 STATE FEDEX GROUND SHIPMENT PREPARATION
As the shipper, you are responsible for proper packing and document completion. The person packaging the inflator must have received hazardous material training per
49CFR 172.702, and the training records must be on file at your dealership. The US Department of Transportation will impose substantial fines and/or penalties on the
shipper if either packaging, labeling or documentation is not properly prepared and Customer Copy of OP 900PRP form is not kept on file for a minimum of 2 years.
IMPORTANT: Do not deploy any inflator. Return the used inflator within 1-2 business days. The person packing the used inflator must read and follow the provided
instructions.
NOTE: Dealers in Alaska, Canada, Hawaii, and Puerto Rico CANNOT follow these shipping instructions. The dealer MUST contact the following Takata USA representative
directly for shipping instructions: Miguel Prigadaa – Tel #: 210-250-5078 or Email: [email protected]
1. Shipping Documents
5. Shipping Documentation Instructions (Cont.)
OP 900PRP Hazardous Materials Certification Form
a) Fill in the following on the FedEx
Copy and the customer copy:
FedEx Ground Shipping Label
•
•
•
Shipper Name
(dealer)
1)
Address
CCN (The CCN # can be found
in the enclosed Subaru dealer list. If
you are unable to locate your CCN,
please contact Cheryl Malloy at Takata:
[email protected] or
TEL # 843-537-8284 )
FedEx Ground Shipping Envelope
b) Date the FedEx Copy and
Customer copy (MM/DD/YY)
2)
Dealership Name
Address
CCN
1)
2)
Dealership Name
Address
CCN
1)
2)
6. Shipping Documentation Instructions (Cont.)
a) Peel off the SHIPPER RECEIPT from the top of the FedEx Ground PRP Shipping
label, place it in the Tracking ID box on the Customer Copy of the OP 900PRP
form.
3)
2. Packing Instructions
a) Confirm box is in acceptable condition. If a new box
is needed, follow the New Box instructions located
on the next page.
b) Peel off the RECEIPT & SHIPPER NUMBER from the top of the FedEx Ground
PRP Shipping label, and place it in the Tracking ID box on the FedEx copy. 4)
b) Place the un-deployed air bag inflator in
the “cradle” of the box insert, with a completed SOA
warranty parts tag (MSA5W402A) attached to it. The
tag must contain the following information: Claim No,
Repair Date, 17-digit VIN, and Mileage
3. Closure Instructions
a) Close the top box flap, per box closure instructions located on front panel of
box.
4)
3)
7. Shipping Documentation Instructions (Cont.)
a) Separate the FedEx Copy and
Customer Copy of the OP 900PRP
form. Keep the FedEx copy with
the box. Attach the Customer
Copy to the Repair Order.
Note: Dealers must retain the Customer
Copy of OP 900PRP form in their records
for 2 years.
Dealership Copy
4. Shipping Documentation Instructions
a) Separate the bottom 4 labels (OP 900PRP form), place them in the FedEx
Ground envelope, remove the backing and firmly place on bottom side of box.
b) Peel off the Box Copy of the OP 900PRP form and firmly apply to the front
side of the box.
8. FedEx Ground PRP Shipping label
a) Fill in Shipper Name & Address in the upper section of the
FedEx Ground Shipping label. Note: (RMA# is not required).
b) Peel off the backing of the FedEx Ground PRP Shipping label
and affix to top of box to left of the Class 9 label.
2)
•
Use the scribe line on the box as a guide
•
The FedEx Ground PRP Shipping label must not touch any
portion of the printing to the right of the
scribe line.
c) Provide the package and the FedEx Copy of
The OP 900PRP form to the FedEx Ground Driver.
Note: If you don’t
receive regular
pickups from FedEx, call 888-7776040 to schedule
a pickup of the
package.
1)
1)
2)
Continued...
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 21
Requesting a New Box / Shipping Labels
If a new box or replacement shipping labels are needed, please contact a Takata USA representative listed below by phone or email to request
replacement materials.
Primary Contact: Miguel Prigadaa - Tel #: 210-250-5078
E-Mail: [email protected]
To help expedite your request, please be prepared to provide the following information:
a) Serial number on the original box
b) What Type of shipping material needed
• OP-900prp Hazardous Materials Certification Form
•
FedEx Ground Shipping Label
•
FedEx Ground Shipping Envelope
c) Dealer Shipping Information
•
Contact name
•
Dealer address
•
Phone Number
ATTENTION SOA DEALERS 
IMPORTANT: All removed air bag inflators must be returned directly to Takata USA as described in this shipment document and in the recall
bulletin.
Upon claim approval, Subaru of America, Inc. will generate a parts return notice to you, requesting the following information:
• The FedEx Shipper Receipt #
• The OLD and NEW air bag inflator serial numbers
To ensure proper claim credit, the above information must be recorded on the Part Return Notice and sent to SOA Part Collection Center as
instructed on the Return Notice.
The instructions on the Return Notice will read as follows:
IMPORTANT: Part should be returned to Takata as instructed in Recall Bulletin. Note the FedEx Shipper #, the OLD and NEW serial number on
this form and return to the address below.
Under no circumstances should the air bag inflator be returned to Subaru of America, Inc.
Continued...
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 22
CCN list.xlsx
CCN LIST (Appendix B)
If you are unable to locate your CCN, please contact Cheryl Malloy at Takata: [email protected] or TEL # 843-537-8284
Subaru
Dealer code
010101
010108
010126
010132
010141
010143
010145
010147
010150
010153
010157
010166
010168
010172
010182
010185
010187
010191
010194
010199
010201
010205
010209
010212
010217
010220
010225
010231
010232
010237
010241
010243
010246
010255
010261
010266
010270
010287
010296
010335
010350
010351
010355
010356
010357
010358
010359
010371
010372
010373
010377
010378
010379
010383
010384
010385
010386
010387
010388
010389
010390
010391
010392
020125
020128
020131
CCN
708201
708240
708228
708241
708189
708215
708229
708230
708216
708190
708242
708202
708217
708203
708191
708243
708244
708204
708231
708218
708232
708233
708234
708192
708219
708245
708205
708220
708206
708235
708221
708222
708207
708246
708247
708193
708208
708209
708248
708210
708194
708195
708211
708249
708236
708237
708223
708224
708212
708196
708225
708213
708197
708198
708214
708238
708239
708226
708199
708250
708200
708251
708227
708296
708306
708285
Subaru
Dealer code
020138
020143
020144
020145
020148
020151
020155
020161
020162
020163
020165
020166
020167
020171
020175
020182
020183
020184
020186
020187
020190
020194
020196
020197
020198
020199
020200
020204
020205
020206
020207
020208
020209
020211
020215
020216
020218
020219
020220
020222
020223
020224
020225
020227
020229
020230
020236
020244
020249
020250
020255
020256
020259
020264
020273
020279
020283
020284
020286
020287
020289
020290
030102
030112
030114
030118
CCN
708274
708297
708275
708252
708276
708307
708277
708298
708286
708253
708287
708308
708288
708278
708309
708254
708255
708263
708256
708289
708264
708257
708290
708310
708311
708258
708291
708292
708279
708312
708265
708266
708267
708293
708259
708299
708268
708269
708270
708271
708260
708280
708300
708301
708302
708294
708295
708303
708304
708281
708282
708283
708261
708313
708272
708314
708315
708305
708273
708284
708262
708316
708331
708356
708345
708317
Subaru
Dealer code
030121
030129
030130
030131
030132
030133
030134
030135
030136
030139
030141
030142
030143
030144
030145
030149
030150
030151
030158
030161
030162
030164
030168
030169
030170
030172
030180
030181
030182
030186
030197
030201
030207
030210
030212
030214
030219
030220
030225
030226
030230
030232
030235
030237
030242
030247
030249
030258
030260
030263
030268
030277
030281
030290
030291
030292
030294
030295
030296
030301
030302
030306
030310
030311
030313
030314
CCN
708346
708332
708366
708318
708333
708319
708334
708335
708367
708336
708347
708320
708321
708322
708368
708357
708358
708359
708348
708360
708337
708369
708370
708371
708323
708324
708372
708325
708373
708338
708412
708339
708374
708388
708375
708376
708326
708327
708340
708349
708361
708362
708341
708363
708413
708377
708389
708414
708378
708390
708379
708415
708391
708416
708328
708350
708364
708380
708351
708352
708342
708353
708329
708381
708382
708330
Subaru
Dealer code
030315
030356
030378
030415
030481
030560
030618
030619
030648
030660
030661
030672
030674
030675
040100
040103
040123
040132
040135
040171
040198
040209
040221
040229
040232
040238
040261
040272
040294
040301
040339
040346
040357
040384
040398
040399
040403
040404
040427
040428
040438
040446
040451
040458
040459
040475
040477
040483
040486
040491
040503
040533
040535
040554
040561
040565
040566
040573
040574
040576
040577
040578
040582
040585
040586
040587
CCN
708392
708383
708393
708394
708384
708395
708417
708396
708385
708418
708419
708420
708386
708399
708400
708446
708447
708401
708402
708433
708423
708403
708448
708434
708404
708472
708459
708405
708460
708435
708424
708496
708449
708473
708474
708436
708450
708421
708437
708475
708451
708476
708406
708452
708461
708477
708407
708462
708453
708438
708425
708463
708426
708454
708464
708455
708627
708408
708465
708439
708497
708409
708628
708427
708639
708486
Subaru
Dealer code
040588
040589
040599
040602
040605
040617
040621
040622
040623
040624
040632
040634
040635
040641
040643
040644
040647
040650
040654
040657
040658
040659
040669
040673
040682
040690
040698
040721
040724
040725
040730
040731
040733
040736
040738
040739
040741
040743
040750
040756
040757
040833
040835
040910
040917
040928
040929
040950
040963
040982
070100
070101
070116
070117
070128
070129
070136
070141
070145
070151
070155
070161
070173
070174
070179
070203
CCN
708456
708498
708466
708629
708487
708499
708640
708630
708410
708467
708631
708500
708488
708478
708632
708489
708501
708428
708440
708429
708411
708441
708479
708490
708605
708606
708633
708442
708491
708634
708502
708503
708641
708651
708652
708635
708653
708654
708468
708469
708504
708655
708656
708657
708642
708658
708643
708659
708644
708645
708564
708507
708617
708535
708607
708521
708593
708608
708579
708536
708618
708550
708609
708594
708595
708537
Continued...
Bulletin Number: WQL-48R; Revised: August 25, 2014
Page 1
PageCCN
23 list.xlsx
CCN list.xlsx
If you are unable to locate your CCN, please contact Cheryl Malloy at Takata: [email protected] or TEL # 843-537-8284
Subaru
Dealer code
070218
070225
070233
070240
070241
070243
070261
070263
070283
070291
070298
070347
070359
070361
070362
070370
070372
070378
070379
070399
070416
070420
070421
070425
070433
070436
070438
070440
070443
070449
070453
070454
070456
070457
070458
070459
070464
070467
070469
070471
070473
070475
070479
070480
070481
070484
070485
070486
070490
070491
070492
070495
070497
070502
070521
070527
070528
070529
070532
070534
070548
070550
070551
070552
070553
070554
070557
070560
CCN
708522
708596
708580
708538
708508
708551
708581
708523
708582
708565
708509
708583
708524
708610
708584
708552
708597
708525
708553
708510
708526
708554
708511
708611
708619
708585
708539
708540
708612
708598
708512
708513
708586
708566
708541
708620
708621
708542
708543
708514
708599
708622
708600
708527
708544
708545
708555
708613
708528
708515
708516
708601
708567
708568
708556
708569
708570
708557
708558
708571
708572
708529
708573
708559
708546
708623
708560
708587
Subaru
Dealer code
070568
070572
070573
070575
070578
070579
070587
070590
070593
070594
070596
070598
070599
070602
070751
070844
070874
090179
090180
090183
090185
090207
090223
090342
090345
090473
090491
090507
090525
090528
090535
090537
090542
090543
090597
090651
090652
090664
090667
090670
090677
090681
090694
090707
090747
090752
090753
090754
090768
090771
090772
090775
090777
090782
090784
090787
090794
090796
090797
090798
090799
090801
090802
140100
140101
140111
140138
140140
CCN
708530
708574
708561
708602
708614
708517
708588
708589
708531
708562
708615
708575
708576
708590
708563
708532
708533
708680
708662
708681
708663
708682
708664
708665
708666
708670
708683
708684
708667
708685
708686
708671
708672
708673
708801
708782
708773
708792
708783
708793
708674
708794
708795
708802
708784
708687
708675
708796
708797
708668
708774
708803
708775
708804
708776
708798
708785
708786
708669
708805
708660
708676
708806
708712
708713
708722
708765
708744
Subaru
Dealer code
140151
140156
140162
140172
140175
140189
140192
140193
140203
140214
140230
140240
140242
140243
140245
140246
140258
140265
140274
140275
140276
140278
140279
140377
140383
140389
140408
140409
140413
140486
140494
140511
140514
140516
140524
140529
140533
140538
140548
140550
140552
140555
140560
140588
140593
140596
140647
140659
140666
140668
140671
140676
140689
140697
140705
140714
140717
140718
140768
140769
140771
140772
140773
140776
140777
140779
400005
400009
CCN
708745
708723
708755
708733
708766
708714
708701
708702
708734
708715
708690
708735
708716
708703
708736
708724
708691
708737
708738
708692
708704
708705
708706
708693
708694
708739
708717
708695
708696
708767
708756
708768
708757
708769
708746
708747
708697
708707
708740
708748
708718
708770
708758
708708
708749
708725
708698
708719
708699
708726
708720
708741
708742
708677
708727
708721
708750
708751
708771
708743
708709
708759
708752
708760
708761
708710
708624
708492
Page 2
Bulletin Number: WQL-48R; Revised: August 25, 2014
Subaru
Dealer code
400020
400043
400048
400054
400058
400059
400060
400061
400063
400064
400065
400069
400071
400072
400099
400101
400103
400105
400106
400144
400145
400159
400183
400201
400202
400205
400210
400230
400293
400310
400316
400331
400332
400350
400353
400370
400391
400432
400453
400472
400532
400552
400572
400612
400712
400732
400852
400960
400992
401014
401032
401047
401068
401120
401136
401139
401146
401147
401157
401158
401187
401190
401191
401192
401213
401214
401232
401252
CCN
708807
708787
708728
708577
708480
708481
708636
708518
708519
708762
708625
708763
708482
708637
708387
708483
708430
708431
708788
708626
708493
708777
708772
708470
708646
708778
708764
708799
708647
708729
708779
708688
708397
708678
708789
708800
708730
708471
708494
708780
708520
708505
708790
708661
708443
708444
708638
708591
708753
708495
708354
708648
708603
708547
708711
708578
708616
708604
708649
708506
708484
708731
708700
708457
708398
708791
708548
708485
Subaru
Dealer code
401271
401277
401278
401285
401286
401289
401312
401313
401346
401374
401395
401396
401408
401559
401560
401605
401606
401607
CCN
708650
708808
708365
708754
708432
708592
708534
708679
708422
708445
708732
708355
708549
708343
708781
708344
708458
708689
CCN list.xlsx
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