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.

PRODUCT CAMPAIGN BULLETIN
APPLICABILITY: 2003-2004

Subaru Legacy and Outback
NUMBER: WQL-48
2003-2004 Subaru Baja
DATE: August 2014
2004 Subaru Impreza (including WRX and STI) NHTSA ID: 14V-399
SUBJECT: Front Passenger Air Bag Inflator Replacement
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-48; Date: August 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-48; Date: August 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-48; Date: August 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-48; Date: August 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-48; Date: August 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-48; Date: August 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-48; Date: August 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-48; Date: August 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!