SB-10045042-4505
ATTENTION:
GENERAL MANAGER
PARTS MANAGER
CLAIMS PERSONNEL
SERVICE MANAGER

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IMPORTANT - All
Service Personnel
Should Read and
Initial in the boxes
provided, right.

SERVICE BULLETIN
APPLICABILITY:
SUBJECT:

2010MY Outback
Sunroof Binds When Opening

NUMBER:
DATE:
REVISED:

12-122-10R
08/03/10
06/06/12

INTRODUCTION
This bulletin is only applicable to 2010MY Outback models. Do not attempt to perform
this procedure on any other model year/model, which includes Legacy. Damage as result
of performing this procedure on other vehicles is not a matter for warranty.
If you encounter a customer complaint that the sunroof binds when opening, there is the
possibility that the sunroof is binding on the roof flange. To remedy the condition refer to the
service procedure listed. Please note that this repair procedure may be sublet to a body shop if
necessary.

COUNTERMEASURE IN PRODUCTION
A countermeasure was made to the flange starting with VIN A*363658.

TOOL INFORMATION
The plastic block can be ordered directly from Meyer Plastics at 1-800-968-2195.
Subaru Sunroof Repair Tool - Part Number 1840-BNBH.
The price of the block is $15.95 + shipping.

SERVICE PROCEDURE/INFORMATION
Ideal Flange Condition: Flange should be vertical.
Note: Do not move the flange past vertical (negative). Lower flange point should not be
further back
Possible Binding

Good

Not Good

1) Determine where the binding is occurring. Evidence will vary from vehicle to vehicle.
A) Look for residue (black rubber material) from the weather-seal on the rear roof flange.
B) Visually observe the roof panel along the rear edge of the sunroof while opening
the sunroof, look for shock waves. This indicates a tight clearance area.
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: 12-122-10R; Date: 06/06/12

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.

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C) Review flange area for a more pronounced transition area.

2) Use available indicators listed above to determine focus area for finessing the flange.
Note: At times there may be no visual indicators or the sunroof will not open due to binding.
In those cases, a general working of the flange all the way across will be required.
Caution: Move the flange in small increments to avoid cracking the paint.
Using a dead blow hammer & plastic block (block pictured is 19mm high by 46mm wide by
400mm long).
Note: The only critical dimension is the height (19mm). This is required since the process
involves using the sunroof glass to hold the block consistent as the flange is adjusted. Contact
to the radius must be avoided, to prevent cracking of the paint.

19mm

Bulletin Number: 12-122-10R; Date: 06/06/12

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3) Keep the block perpendicular to the flange vertical surface with the contact on the
lower half of the flange. Keep the angle of attack as low as possible (pictured below).

Note: Marks in the paint may be left by the plastic block. This cannot be avoided at times
even with the best positioning of the plastic block.
4)

5)

Take your time re-checking the function of the sunroof as you go. Do not move the
flange any farther than is required to restore the function of the sunroof. Reason being,
there is always a risk of cracking the paint when modifying a finished panel.
Once the sunroof function is improved & the modification of the flange is completed,
inspect the rear radius of the sunroof opening very carefully for cracks. Any cracks
regardless of size will require the roof to be repainted.

Bulletin Number: 12-122-10R; Date: 06/06/12

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Note: As with any paint and/or body repair exceeding $500.00, prior authorization is required
through the TechLine, along with a completed e-QMR (refer to the Policy and Procedure
Manual).

WARRANTY/CLAIM INFORMATION
For vehicle within the Basic New Car Limited Warranty period, this repair may be claimed
using:
LABOR DESCRIPTION
Sunroof Opening, Roof Flange
Modification

LABOR
OPERATION#
B850-948

FAIL CODE

LABOR TIME

XAA-48

0.3

Roof Panel, Refinish

C994-221

4.5

Roof Panel, Blend

C994-223

0.5

Sublet Repair (Administration Expense)

C101-108

0.3

Note: Labor operation C101-108 may only be claimed if the repair is performed by and
outside Body Shop.

Bulletin Number: 12-122-10R; Date: 06/06/12

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