ATTENTION:
GENERAL MANAGER

q

PARTS MANAGER

q

CLAIMS PERSONNEL

q

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

SERVICE MANAGER

q

© 2003 Subaru of America, Inc. All rights reserved.

PRODUCT CAMPAIGN BULLETIN
APPLICABILITY:

SUBJECT:

2000-2002MY Subaru Legacy
and Outback Vehicles

NUMBER: WWM-96R

Rear Suspension Sub-frame Corrosion

REVISED: 02/10/25

DATE: July 2003

INTRODUCTION
Subaru of America, Inc. (SOA) has determined that affected vehicles, listed below, may have been
manufactured with improperly applied paint to the rear suspension sub-frame. If an affected vehicle is
operated for an extensive period in a “salt-belt” area (see list of states below that use large amounts of
salt on the roads in the winter), continued exposure to the salt could cause the rear sub-frame to rustout and possibly break. If the rear sub-frame were to rust-out and break, control of the vehicle could
be affected.
This recall will involve cleaning and applying rust proofing material at the affected area.

AFFECTED VEHICLES
All 2000, all 2001 and most 2002 model year Legacy/Outback vehicles (and approximately 45 very
early production 2003 Legacy, Outback and BAJA models) are affected. This recall will be limited
to vehicles in regional areas known as “salt-belt” states and affects vehicles originally sold in or
currently registered in the states of:
Connecticut
Delaware
District of Columbia
Illinois
Indiana
Iowa

Kentucky
Maine
Maryland
Massachusetts
Michigan
Minnesota

Missouri
New Hampshire
New Jersey
New York
Ohio
Pennsylvania

Rhode Island
Vermont
Virginia
West Virginia
Wisconsin

Affected vehicles are identified in the VIN range chart on the following page. NOTE: Coverage
for all affected vehicles must be confirmed by using the Vehicle Coverage Inquiry in the Dealer
Communication System (DCS).
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.

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.

Continued...
Bulletin Number: WWM-96R; Revised: 02/10/25

Page 1 of 36

MODEL YEAR

MODEL

FROM

TO

2000

Sedan
Wagon
Outback

Y*200001
Y*300001
Y*600001

Y*218478 Y*313778
Y*674127

2001

Sedan
Wagon
Outback

1*200001
1*300001
1*600001

1*216426
1*311949
1*679753

2002

Sedan
Wagon
Outback

2*200001
2*300001
2*600001

2*216493
2*310877
2*664483

2003

Sedan
Wagon
Outback
BAJA

3*200001
3*300001
3*600001
3*100001

3*200022
3*300011
3*600031
3*100017

* Various Characters may occupy this position

OWNER NOTIFICATION
Notification letters will be sent to owners of vehicles originally sold in or currently registered in “saltbelt” states. SOA will prepare and mail those letters on or around July 7, 2003. A copy of the Owner
Notification Letter is included at the end of this bulletin.
OWNERS LOCATED OUTSIDE THE AFFECTED “SALT-BELT” STATES
Notification letters will only be mailed to owners of vehicles that were originally sold, or at one time
registered, in “salt-belt” states.
After release of this recall, vehicles previously registered in a non-“salt-belt” state may relocate into
a “salt-belt” area. In some cases, the vehicle may be registered in a “non-salt belt” state, and driven in
a “salt-belt” area. These vehicles may not show coverage when checked using the Vehicle Coverage
Inquiry in the Dealer Communication System (DCS). SOA requests that dealers located in “salt-belt”
states check all vehicles within the affected VIN range for recall coverage. If it is determined that an
owner of a vehicle, within the affected VIN range, relocates or uses the vehicle in a “salt-belt” area,
dealers are requested to contact the CDS department at 1-800-782-2783 and request a WWM-96
recall control number be issued. The dealer should perform this procedure on the vehicle at no cost to
the customer.
DEALER PROGRAM RESPONSIBILITY
Dealers are to promptly service all vehicles subject to this recall at no charge to the vehicle owner
regardless of mileage, age of the vehicle, or ownership.
For affected vehicles sold after the date on the dealer’s computer list, dealers are to contact those
owners and provide them with a copy of the owner notification letter. They should also arrange to
make the required correction according to the instructions in the service procedure section of this
bulletin.
Continued...
Bulletin Number: WWM-96R; Revised: 02/10/25

Page 2 of 36

Vehicles in Dealer Inventory
Dealers are also to promptly perform the applicable service procedures defined in this bulletin to
correct all affected vehicles in their inventory (new, used or demo). Additionally, whenever a vehicle
subject to this recall is taken into dealer new or used inventory, or is in the dealership for service,
necessary steps should be taken to ensure the recall correction has been made before selling or
releasing the vehicle.
New or used vehicles listed in a recall/campaign that are in dealer stock must be:
1. Immediately identified.
2. Tagged or otherwise marked to prevent their delivery or use prior to inspection and/or repair.
3. Inspected and/or repaired in accordance with the instructions outlined in this Product
Campaign Bulletin.
Any Authorized Subaru Dealer failing to perform the applicable service procedures defined
in this bulletin to correct all affected vehicles in their inventory (new, used, demo) prior to the
vehicle being placed in service may be subject to civil penalties of up to $5,000 per violation (i.e.,
for each vehicle), as provided in 49 USC §30165(a) of the Safety Act, and will also be in breach
of the Subaru Dealer Agreement.
PARTS INFORMATION
Special Tools
Each dealer located in the affected “salt-belt” states will automatically be shipped, at no cost, one rustproofing spray gun set that contains a spray gun and necessary lines, nozzles and wands.
Dealers located outside of the affected “salt-belt” states can order the spray gun kit by contacting their
District Service Operations Manager.
Rust-proofing Materials
Note: The rust-proofing material is packaged in kits containing one 29oz container of Nox-Rust
X-210 and one 32oz container R576-108).
Prior to the release of this recall, only dealers located in affected “salt-belt” states will automatically
be shipped a quantity of rust-proofing material equivalent to 40% of their vehicle sales, or up to a
maximum of 15 cases. It will be necessary for dealers located outside of affected “salt-belt” states to
order rust-proofing material as needed.
Note: SOA will notify owners who either purchased or at one time resided in a “salt- belt” state.
Some of these owners may no longer live in a “salt-belt” area. In these cases, it will be necessary
for dealers located outside the “salt-belt” area to order supplies to rust-proof these affected
vehicles.

Continued...
Bulletin Number: WWM-96R; Revised: 02/10/25

Page 3 of 36

Additional quantities of the rust-proofing material will be available through the “Genuine Subaru
Automotive Chemical” program on Subarunet after 6/21/03. In order to maintain an adequate part
supply, SOA requests that Dealers only order quantities necessary to satisfy anticipated demand.
MODEL

DESCRIPTION

PART NUMBER

All Affected

WVX34 RUSTPROOF 5 REPAIRS

SOA868V9355

REPAIR PROCEDURES
This repair procedure involves cleaning and applying anti-rust material to the inside and
outside of the rear sub-frame assembly.
Exposure Controls for use of Nox-Rust X-210 and R576-108
Material Safety Data Sheets (MSDS) for these products are included in each product carton and
available in the electronic version of this bulletin posted on Subarunet.
Respiratory Protection
NIOSH-approved respirator for organic vapor and mist to control exposure where ventilation is
inadequate. Example: 3M Maintenance-free Half Facepiece Respirator 07191, 07192, 07193 or LowMaintenance Half Facepiece Respirator 07177, 07178, 07179.
Ventilation
General and local exhaust.
Personal Protective Equipment
Caution: Avoid prolonged skin contact.
Protective Gloves: Impervious gloves (Viton, PVOH, etc.)
Eye Protection: Safety glasses with side-shields or chemical goggle.
Other Protective Clothing or Equipment: If splashing is anticipated, wear a rubber apron and boots or
other protective equipment to minimize contact.
Necessary tools and supplies:
NO

PARTS / MATERIAL NAME

PARTS NUMBER / MODEL

1

Protective glasses

---

2

Protective mask

---

3

Cloths and paper

---

4

Oil pan or container

---

5

Vehicle lift

---

6

Pressure washer

---

7

Spray gun

Refer to page 6

8

Anti-rust oil

NOXRUST X-210
5oz (150cc) per vehicle

9

Anti-rust wax

NOX RUST R576-108 Black
1Qt (1,000cc) per vehicle

Continued...
Bulletin Number: WWM-96R; Revised: 02/10/25

Page 4 of 36

SPRAY EQUIPMENT OPERATING INSTRUCTIONS
The pressure pot is equipped with an adjustment valve (or stop screw) to adjust the ratio of product to
air. This adjustment valve will have to be adjusted in order to achieve optimal spray pattern for each
material. The adjustment valve is identified in the diagram below.

Before filling the gun, turn the stop screw clockwise until completely closed. Draw a line down the
middle of the stop screw using a marker. This line will be used to determine the number of turns
needed for optimal spray of the waxes.

Continued...
Bulletin Number: WWM-96R; Revised: 02/10/25

Page 5 of 36

Settings For Nox-Rust® X-210 Corrosion Preventive Penetrant
When using the 360o flexible wand, turn the stop screw counterclockwise 1/2 turn from closed, and
adjust the air supply pressure to 40 psi.
Settings For Nox-Rust® R576-108 Corrosion Preventive Coating
(Note: Product should be room temperature for proper application.)
When using the 360o flexible wand, turn the stop screw counterclockwise 3 turns from closed, and
adjust the air pressure to 80 psi.
When using the 90o hook wand, turn the stop screw counterclockwise 3 turns from closed, and adjust
the air pressure to 80 psi.
Gun Disassembly And Cleanout
Important: The spray equipment must be cleaned between vehicle applications. X-121B (Black
Wax) must be removed from the gun and lines prior to applying the X-121 (Oil) to the next vehicle.
Use the following procedure for equipment cleaning.
1. Turn the spray gun stop screw (as pictured above) clockwise until completely closed.
2. Blow the 360o flexible and 90o hook wands clear with air by pulling the spray gun trigger.
3. Disconnect the gun from the air supply.
4. Remove the spray tube using the quick disconnect.
5. Relieve the pressure from the gun by slowly turning the paint pot to the left until all the air
escapes. Do not use the gun trigger to relieve pressure from the pot. This will cause the wax to
flow into the air line supply of the gun.
6. Remove the paint pot and drain any remaining wax. Rinse the pot with mineral spirit based
solvent.
If the gun is to be stored for more than 4 weeks, completely clean the gun with mineral spirits. Always
store the gun assembled. Do not soak the 360o flexible or 90o hook wands in solvent. Prolonged
exposure to solvent will cause damage.

Continued...
Bulletin Number: WWM-96R; Revised: 02/10/25

Page 6 of 36

REPAIR PROCEDURES DETAILS
Step 1: Raise vehicle on a lift.
Step 2: Remove the left and right rear wheels.
Step 3: Identify the component name of the rear sub-frame assembly as follows:
(A) Front Crossmember
(B) RH/LH Side Member
(C) Rear Crossmember

Step 4: Clean the entire rear sub-frame assembly.
Note: It is important that the rear sub-frame be properly cleaned in order for the rust
proofing process to be effective. Use caution not to damage components such as emission
lines.
(a) Clean the outside of the entire sub-frame assembly of mud, dirt, salt and other debris using
a high pressure washer.
(b) Clean the inside of the entire sub-frame assembly by carefully applying high pressure water
through the bottom holes of the sub-frame.
(c) Dry the inside and outside of the sub-frame assembly using high pressure air at the same
locations identified in the cleaning process. Use a clean rag to remove any remaining
moisture.

Continued...
Bulletin Number: WWM-96R; Revised: 02/10/25

Page 7 of 36

Step 5: Vehicle Preparation
Important: Be sure the following items have adequately cooled before applying protective
covers.
(a) Cover rotors, calipers, and exhaust parts near the sub-frame with a cloth or paper to
prevent wax from adhering to these surfaces.

(b) Place a suitable container (such as an oil drain pan) below the vehicle’s subframe to
capture any anti-rust agent and anti-rust wax that could leak from the drain holes during
the application process.
Step 6: Application of anti-rust agent (NOX RUST X-210)
Use the flexible 360o type nozzle for spraying. Turn the spray gun stop screw
counterclockwise 1/2 turn from closed, and adjust the air supply pressure to 40psi Sprayed
amount: 5oz. (150cc). Refer to the chart on page 9 for spray times and follow the detailed,
step-by-step process.

Continued...
Bulletin Number: WWM-96R; Revised: 02/10/25

Page 8 of 36

The holes in which the spray nozzle should be inserted and the direction from which the spray nozzle should
be applied are identified in the figure on page 8. (The letter- identified areas show nozzle insertion
points and dotted lines show the direction in which nozzles should be inserted.)
Spray time of anti-rust agent and length of spray nozzle to be inserted into the sub- frame
corresponding to the holes located at bottom of the frame are identified in the following information.
HOLE LOCATION

PARTS NAME

WORK HOLE LOCATION

TIME (SEC.)

LENGTH TO INSERT
INCH (MM)

A

CROSS MEMBER FT

Beside right side bushing
at right end of the
crossmember front

8

35 (880)

B

SIDE MEMBER RH

Front end of the side
member right

5

19 (480)

C

SIDE MEMBER LH

Front end of the side
member left

5

19 (480)

D

CROSSMEMBER RR

Right end of the
crossmember rear

6

23 (590)

Important: Place a container under the vehicle to catch any excess anti-rust agent from the drain holes.
Anti-rust Agent Application Details:
CROSSMEMBER FRONT
Insert the 360o spray nozzle into the opening (A) until it touches the bushing outer tube at the other
side. Spray anti-rust agent for 8 seconds while pulling the spray nozzle back to the original opening
(A).
Spray time: 8 seconds.

Continued...
Bulletin Number: WWM-96R; Revised: 02/10/25

Page 9 of 36

SIDE MEMBER LEFT & RIGHT HAND
Insert the 360o spray nozzle into the hole (B or C) located at front end of the bottom of the side
member until it touches the rear bushing outer tube at the other end. This area is approximately 19
inches (480mm) long. Spray anti-rust agent for 5 seconds while pulling the spray nozzle back to the
original opening (B or C).
Spray time: 5 sec. (2 locations = 10 sec.)

CROSSMEMBER REAR
Insert the 360o spray nozzle into opening (D) located in bottom of the crossmember rear at the right
end connected to the side member until it touches the side member of the other side. This area is
approximately 23 inches (590mm) long. Spray anti-rust agent for 6 seconds while pulling the spray
nozzle back to the original opening (D).
Spray time: 6 sec.

Continued...
Bulletin Number: WWM-96R; Revised: 02/10/25

Page 10 of 36

Step 7: Application of anti-rust wax (NOX RUST R576-108).
Use flexible 360o type nozzle. Turn the stop screw counterclockwise 3 turns from closed, and adjust
the air pressure to 80 psi. Sprayed amount: 13.5oz (400cc).

The holes in which the spray nozzle should be inserted and the direction from which the spray nozzle
should be applied are depicted in the figure above. (The letter-identified areas show nozzle insertion
points and dotted lines show the direction in which nozzles should be inserted.)
Spray time of anti-rust wax and length of the spray nozzle to be inserted into the sub-frame
corresponding holes are described on the next page.

Continued...
Bulletin Number: WWM-96R; Revised: 02/10/25

Page 11 of 36

WORKING HOLE LOCATION
LOCATION OF NOZZLE
INSERTION HOLE AND
NOZZLE DIRECTION

NOZZLE
INSERTION
DIRECTION

TIME
(SEC.)

LENGTH TO
INSERT INCH
(MM)

CROSS
MEMBER FT

Electro deposition
hole at right side of the
crossmember front

Red line

12

31 (790)

B

CROSS
MEMBER FT

Electro deposition
hole at left side of the
crossmember front

White line

12

31 (790)

C

SIDE
MEMBER RH

Hole at front end of
the side member right
toward rear

Red line

8