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

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q

SERVICE BULLETIN
APPLICABILITY: 2015MY Legacy and Outback Models

NUMBER: 12-176-14

SUBJECT:
Service Procedure to Address a Wind Rushing Sound
from the Front Door Sash Area

DATE: 12/05/14

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
1 piece of butyl (adhesive rubber) sealing material will be added in specific locations.
COUNTERMEASURE IN PRODUCTION
Countermeasures were incorporated into production on October 10, 2014 starting with the following
VINs: F3028031 (LEGACY) and F3243546 (OUTBACK).
PART INFORMATION
The chart below provides a required part list for the Service Procedure described in this bulletin. This
list is provided as a reference only and may not be totally complete depending on the needs of your
specific repair. Always verify with your Parts Department that all needed parts with the most up-todate part numbers are ordered.
PART NAME

PART NUMBER

REPAIR KIT LEG/OBK F RH
REPAIR KIT LEG/OBK F LH

61099AL00A
61099AL01A

The parts kit will consist of the following components: (p.n. 61099AL00A (Right Front Kit is
shown)
ID

DESCRIPTION

QUANTITY

A
B
C
D

Weatherstrip Inner
Glass Assy.
Sash
Glass Run Channel

1
1
1
1
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: 02-157-14; Revised: 12/05/14

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

E
F
G
H
I
J

Weatherstrip Outer
EPT Foam Piece #1
EPT Foam Piece #2
Rivets
Non-Woven Tape
Butyl Tape

1
1
1
3
1
1

SERVICE PROCEDURE / INFORMATION
VERY IMPORTANT: Always verify the customer’s concern and read through this procedure
completely BEFORE proceeding with any repairs.

STEP 1 - Disassembly
IMPORTANT: Always take proper precautions to protect 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.
Continued...

Bulletin Number: 02-157-14; Revised: 12/05/14

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. These gaskets must be in place as shown below before reassembly to properly seal
their respective component and help eliminate the possibility of a rattling sound.

Continued...
Bulletin Number: 02-157-14; Revised: 12/05/14

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.

•

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.

•

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: 02-157-14; Revised: 12/05/14

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. 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 - Using a plastic trim tool under each end, CAREFULLY unseat the retaining clips and
remove the outer door glass weatherstrip / chrome trim.

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.

Continued...
Bulletin Number: 02-157-14; Revised: 12/05/14

Page 5

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: 02-157-14; Revised: 12/05/14

Page 6

Fit the replacement inner weatherstrip to the trim panel. “Clamp” the new part to the door trim
panel with your thumbs and fingers as shown below then 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 of the weatherstrip 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.
Continued...
Bulletin Number: 02-157-14; Revised: 12/05/14

Page 7

FIg. 1

FIg. 2

FIg. 3

FIg. 4

STEP 4 - Application of the EPT Foam Sealing Material
•

EPT Foam Piece #1 is applied to the door trim panel at the top rear corner where the trim
material wraps around the back edge as shown in the “Before” and “After” photos below.

Continued...
Bulletin Number: 02-157-14; Revised: 12/05/14

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.

Sealer in Proper Position

Complete

Continued...
Bulletin Number: 02-157-14; Revised: 12/05/14

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 gain
access to the area where the 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 80mm long piece of butyl tape to the door frame as indicated in red in
the illustration and shown in the completed installation photo below.

Continued...
Bulletin Number: 02-157-14; Revised: 12/05/14

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.

IMPORTANT: Follow the torque sequence shown in the illustration below when reinstalling the
sash into the door. While applying substantial forward pressure on the sash, fully torque the top
Philips retaining screw to 1.6 ft. lbs. (19 inch pounds) then torque the 2- 10 mm hex sash retaining
bolts to 5.5 ft. lbs (66 inch pounds), top bolt first. Do not snug the hardware then go back and final
torque it. The initial tightening must be right up to the specified torque.
Continued...
Bulletin Number: 02-157-14; Revised: 12/05/14

Page 11

NOTE: If the vehicle is equipped with the Genuine Subaru accessory Side Window Deflectors, apply
a new piece of double-sided mounting tape to the inside front edge of the deflector to re-attach it to the
sash 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 sash-side 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.
•

Remove the original glass run channel. When installing the new glass run channel, make sure
to apply pressure in the direction of the arrows shown in the illustration below making sure it
is fully seated into the door frame, paying close attention to the upper rear corner. It is also
important to confirm the run channel is completely seated all the way to the bottom in both the
new sash (front) and the channel it fits into at the rear edge of the glass.

Bulletin Number: 02-157-14; Revised: 12/05/14

Continued...
Page 12

•

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 properly sealed as it was
prior to the repair. Reinstall the door speaker.

•

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 make sure 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, complete the installation of the door trim panel in reverse
order of removal.

IMPORTANT: To prevent EPT Foam Piece #1 from binding or “bunching up”, hold the lower part of
the door trim panel away from the door while sliding it down into position.

STEP 7 - Install the new replacement outer door weatherstrip / chrome trim in reverse order of
removal as outlined previously in STEP 3.

STEP 8 - Reconnect the negative battery cable and torque the 12mm nut to 7.5 Nm (5.5 ft. lbs).

Continued...
Bulletin Number: 02-157-14; Revised: 12/05/14

Page 13

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 9 - 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 and / or Powertrain 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 Attachment Tape where
applicable.
REMINDER: 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 refer to STIS for the latest service information before performing any repairs.

Bulletin Number: 02-157-14; Revised: 12/05/14

Page 14