Tokyo – Jan. 31, 2019 – Subaru has paused production of multiple vehicle types at its factory in Japan due to the possibility of a defect in the cars’ power steering systems. The automaker is deciding how to proceed with the 14,000 affected cars, some of which were sold in Japan and others of which are destined for export to other territories. Most of the cars impacted are likely bound for the U.S. The Forester, XV and Impreza are the three models that may include the defective component.

A report from Nikkei noted that recent years have seen over 500,000 cars recalled by Subaru. While past recalls have been caused by potential faults in components such as valve springs, as well as actions such as regulatory compliance failures. The most recent plant shutdown has not turned into a fully declared recall, but it has impacted cars even beyond those that may have the defective part, as the factory equipment is employed to produce multiple vehicle types.

The Defect

The problem that has caused the concern involves part of the electrical assembly used in power steering. The component in question is a third-party item produced by Hitachi Automotive systems and used in the three Subaru models. The Nikkei report explained that when the part fails, a warning light activates on the dashboard, and steering the car becomes harder for the driver. Xinhua noted there have been two instances of such a failure happening, though no one has been reported injured yet.

The fact that Subaru cars use a unique engine configuration known as the “boxer” layout may have exacerbated the challenges of the situation. The components for these engines are not compatible with generic hardware that work in more standardized engines. Subaru technicians searched for a solution to the current issue that did not require manufacturing and ordering a “made from scratch” replacement part. That meant isolating the exact issue causing the fault and correcting it.

To remove the defective parts from the supply chain, Subaru shut down its main production facility in Gunma Prefecture, Japan, which produces 2,600 cars a day when operational. Most of the vehicles produced in the plant – 80 percent – are exported, and Nikkei added that 60 percent of those cars go to U.S. dealerships. After ascertaining which part would have to be replaced to resume production, Subaru reopened its plant on schedule, according to Xinhua.

As the component is produced by an outside supplier, Hitachi has also been contacted for input. Hitachi stated that problems during car assembly are unlikely, which may mean the electronics within the steering components are faulty.

Timeline of Events

The potential recall at Subaru has developed over a relatively short time frame. All the affected vehicles that contain the potentially defective part were produced between late December 2018 and the Jan. 16 shutdown of the Gumna plant. Upon discovery of the fault, Subaru declared a week-long shutdown and sent out recall notices for roughly 780 vehicles that were made at the facility in question and sent to be sold on the Japanese market instead of overseas, according to the Xinhua report.

Nikkei added that the quality control division within Subaru, which has been the subject of some of the automaker’s recent scandals in the Japanese market, did not catch the potential power steering problem. Instead, two reports of problems with steering were used to determine the part responsible. Fortunately, there were no collisions or injuries of any kind reported due to the power steering issues. While the vehicles may have become hard to control, they didn’t crash.

The automaker’s recent series of scandals, as described by Nikkei, began in late 2017. At that time, Subaru revealed that some of its inspections were performed by staff without the proper certifications. After that, more troubling details emerged. In November 2018, a valve spring problem caused the recall of 101,000 vehicles, with 100,000 more added because of legal compliance issues.

These recalls have taken a toll on the company’s finances. In the immediate aftermath of the plant closure notice, Subaru’s stock price fell 6 percent on the Tokyo exchange. The announcement that the stoppage would only last a week provided some relief, but the impact was still a net negative, demonstrating the lasting financial impact of repeated recall events and quality-control problems.

The Solution

Due to several complicating factors, the exact course of action Subaru will take is unclear. The roughly 14,000 exported cars that may contain faulty Hitachi steering components have not been officially recalled. Since the vehicles have all been produced over the past few months, many of them are likely still in the custody of dealers rather than customers.

The automaker is pondering sending replacement parts overseas to replace the faulty components, according to Xinhua, rather than recalling the vehicles to Japan to be refitted. The domestic recall has been the most straightforward part of the process, with the under-1,000 vehicles produced for the Japan market already recalled.

Since the production facility impacted is primarily used to produce export vehicles, and most of those cars are bound for the U.S., there is a chance American regulators may soon be involved in the recall process. Recent weeks have seen no new announcements from the National Highway Traffic Safety Administration, as it shut down operations along with other Federal agencies during the budget impasse. During that silence, some automakers have still issued their own recall notices for U.S. vehicles, including the latest wave of Takata air bag inflator repairs.

Camden, New Jersey, Jan. 28, 2019 – In November 2018, Subaru of America issued a recall for 165,534 vehicles across the Impreza, BRZ, and XV Crosstek models. The recall was brought on by engine springs that are prone to fracturing. In the event that these components break, the cars may make unnatural noises, or the engines may malfunction or stall. Recently, the Burlington Free Press revealed additional details of the recall, including the fact that some dealers may not be able to replace the part until late 2020.

The vehicles that potentially contain compromised value screws include the 2013 Subaru BRZ, the 2013 Subaru XV Crosstek, and the 2012-2014 Subaru Impreza. Owners of these vehicles should have already received letters regarding the recall, which is how the Free Press determined how long the repair timeline will be in high-demand areas such as Vermont.

The Defect

Reacting to reports of compromised valve springs within vehicle engines, Subaru issued its recall for the cars in question. In addition to strange noises and other unspecified malfunctions, engine stalling may make it impossible for drivers to start their cars again. Subaru recommended in its letter to vehicle owners that if they experience noise or vibrations while driving, they pull over as soon as it is safely possible, to ensure they do not suffer the heightened collision risk that would come with stalling out.

Timeline of Events

The report from the Free Press brings more clarity to how long the recall will take to carry out. The National Highway Traffic Safety Administration named the defect Nov. 1, 2018. When the first notice went out, there had been 11 reports of cars suffering from operational problems due to insufficiently strong springs in their engines. Letters went out to Subaru owners shortly thereafter instructing them to bring their vehicles into a dealership for repairs as soon as possible. When the Free Press’s reporter set a date to have her own Subaru repaired, the local dealership explained the earliest slot it has available is in November 2020.

Representatives from the dealership explained that due to the large number of Subarus on the roads of Vermont, as well as the time-consuming nature of the repairs and the need for specialized training, the timeline of repairs will stretch well into next year. Dealership personnel needs to be briefed on the spring replacement operation. At the dealership in question, this tutorial is scheduled for February.

The Solution

In a 7-to-13-hour procedure, mechanics will replace the affected parts in affected vehicles. The procedure uses specialized tools. In addition to the relatively time-consuming nature of the work, as well as the limited number of tools present at each dealership, only one vehicle is serviced each day. This procedure explains the long wait time in areas such as Burlington.

In its recall notice, Subaru noted that if a vehicle stalls and cannot start again due to spring problems, owners should make arrangements to have the car towed to the nearest Subaru dealer. For vehicle owner reference, the recall number is 18V-772 in Subaru’s system and WTY-84 according to the NHTSA’s records.

Laguna Hills, CA – November 12, 2018 – Subaru of America, Inc. (Subaru) is recalling certain 2018 Subaru Legacy and Outback vehicles due to a software issues that affects the vehicle’s fuel display. This recall is expected to affect 228,648 Subaru vehicles in North America.

The Defect

According to the NHTSA Recall Safety Report, due to a software error, the low fuel warning light may not light up to indicate the intended remaining fuel level and the distance-to-empty (DTE) display may incorrectly indicate a positive number even if the fuel tank is empty. This inaccuracy in the fuel display may cause a driver to unexpectedly run out of fuel and the vehicle to stall, increasing the risk of a crash.

Timeline of Events

In December of 2017, SUBARU CORPORATION (Subaru) received a technical report regarding the driving range indicator (DTE) in the multi-information display. The report indicated a positive distance-to-empty (DTE) when no usable fuel was remaining. A field part collection was requested, and between December 2017 and March 2018 p arts were collected from the field and sent to the supplier for an investigation which subsequently took place during April and June of 2018. In July 2018, the supplier submitted the investigation report to Subaru, whereupon, from August to October 2018, Subaru assessed their field data and the supplier’s investigation report to assess risk. On October 25, 2018, Subaru completed the investigation and determined that a voluntary safety recall should be ordered.

The Solution

Subaru will notify owners, and dealers will reprogram the combination meter software, free of charge. The manufacturer has not yet provided a notification schedule. Owners may contact Subaru customer service at 1-844-373-6614. Subaru’s number for this recall is WTW-82. Owners may also call the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153). The NHTSA Campaign Number for this recall is 18V-773.

USA – Aug. 18, 2018 – In an unlikely move, the automaker Subaru has chosen to replace nearly 300 vehicles with defects, rather than reimbursing or repairing the offending SUVs. The faulty 2019 Ascent SUV model is missing key welds on the back-door hinges, and spokespeople from Subaru have chosen to pull the cars with the issue from the market.

The Defect

In key areas of the weld, there are spots missing along the B-pillar, which is located on the second-row door hinges. Subaru stated that the issue was due to incorrect programming in the welding software for the robots that manufacture the vehicles. If these doors or other car parts came loose due to the defect, it can cause risks of injury and accidents.

According to a Subaru representative, only nine of the defective vehicles were sold to the general public. They will replace all vehicles made and sold due to the severity of the defect. However, there have been no reports of any crashes or injuries of the Ascent SUV falling under this specific issue.

Timeline of Events

On July 21, the issue of defective welds was discovered on-property at a routine inspection. Due to the manufacturing error being contained swiftly, vehicles made between July 13-21 are affected. The total is 293 SUVs that are part of this specific recall.

There are 383,101 Subaru vehicles involved in the massive Takata airbag recall this year, which does not include the new Subaru Ascent SUV, according to Edmunds. Six models between 2003-2011 were affected.

The Solution

If consumers or retailers would like to contact Subaru’s customer service department directly, they can do so at 844-373-6614. Also, the National Highway Traffic Safety Administration (NHTSA) can provide additional information with the claim number 18V-508 on the NHTSA website. Subaru stated they plan to inform owners who bought the SUVs directly.

Cherry Hill, N.J. – Nov. 30, 2017 – Subaru of America has recalled more than 2,300 vehicles potentially equipped with defective floor mat brackets, according to documentation submitted to the National Highway Transportation Safety Administration. The campaign affects 2018 Subaru Crosstrek sport utility vehicles produced between May 16, 2017 and Sept. 7, 2017. The automaker estimates that all of the models referenced in the recall contain the defective parts.

The Defect

The affected models feature defective driver-side floor mat retention brackets that do not sufficiently secure floor mats. As a result, these fixtures can move out of position during vehicle operation and interfere with pedal usage, posing a serious threat to drivers. However, Subaru has yet to receive any reports linking the defective components to any accidents or injuries.

Timeline of Events

On Oct. 17, 2017, the automaker received a field report detailing an instance in which the driver-side floor mat in a 2018 Crosstrek slipped out of position. Over the next 12 days, Subaru engineers conducted an internal investigation, eventually determining that the floor mat retention brackets installed in the vehicle were defective. On Oct. 31, quality assurance and safety officials for the company decided that the features posed a serious hazard to owner and chose to launch a voluntary safety recall.

Subaru notified dealers of the impending recall Nov. 1.

The Solution

The car manufacturer has directed dealers to inspect the floor mat retention brackets in affected and replace them, free of charge, if necessary, according to an NHTSA recall acknowledgement document. Subaru began contacting owners Nov. 14. Those who need additional assistance can contact Subaru customer service at (800) 782-2783. Callers should use the internal recall reference code WTR-77. Owners can also connect with the NHTSA directly using its Vehicle Safety Hotline at (888) 327-4236.

Recall Masters  – November 1, 2017

Subaru recalls performance cars with defective audio equipmentgain

Subaru of America has recalled more than 9,100 vehicles possibly equipped with defective audio equipment, according to documentation filed with the National Highway Transportation Safety Administration. The campaign affects 2015 Subaru WRX performance sedans with production dates ranging from Jan. 17, 2014 to April 9, 2015. Subaru suspects 100 percent of the vehicles referenced in the action contain the defective equipment.

The Defect

The affected sedans likely feature factory-installed subwoofers positioned so that they abut luggage stowed in the trunk. This contact can loosen the subwoofer’s wiring, causing complete disconnection. Should these charged fixtures meet the metal frame of the subwoofer, an intermittent short may occur and damage to integrated circuit components. In some cases, the broken IC parts can generate constant electrical current, leading the subwoofer to overheat and increasing the likelihood of a fire. This poses an obvious safety threat to occupants…

Read the entire article on the Recall Masters website

Cherry Hill, N.J. – Nov. 1, 2017 – Subaru of America has recalled more than 9,100 vehicles possibly equipped with defective audio equipment, according to documentation filed with the National Highway Transportation Safety Administration. The campaign affects 2015 Subaru WRX performance sedans with production dates ranging from Jan. 17, 2014 to April 9, 2015. Subaru suspects 100 percent of the vehicles referenced in the action contain the defective equipment.

The Defect

The affected sedans likely feature factory-installed subwoofers positioned so that they abut luggage stowed in the trunk. This contact can loosen the subwoofer’s wiring, causing complete disconnection. Should these charged fixtures meet the metal frame of the subwoofer, an intermittent short may occur and damage to integrated circuit components. In some cases, the broken IC parts can generate constant electrical current, leading the subwoofer to overheat and increasing the likelihood of a fire. This poses an obvious safety threat to occupants.

Owners with vehicles containing the defective equipment have reported hearing crackling noises. Subaru suggested turning off the car audio system to silence these sounds.

Timeline of Events

In January 2017, Subaru received a field report detailing an instance of subwoofer overheating in a 2015 WRX performance sedan. Two months later, quality assurance personnel at the automaker took possession of the subwoofer and amplifier from the vehicle named in the report. In April, the Japanese automaker shipped the parts to the supplier, Harman International Industries, for analysis. On April 28, Harman submitted its findings. Engineers at the audio company had discovered that the IC features in the subwoofer sustained damage due to overstress. They also found that an electrical short had occurred when the subwoofer wire made contact with the metal support frame. However, Harman could not identify the root cause of the short. As a result, Subaru launched its own investigation to better understand the origin of this electrical disturbance.

In May 2017, Subaru received another field report from a dealer in Australia. Again, the company requested and received the parts involved for evaluation. Four months passed before engineers at the company uncovered the root cause: contact between the subwoofer and luggage. On Sept. 29, Subaru decided to conduct a safety recall. The organization notified dealers Oct. 9.

The Solution

The automaker has directed dealers to inspect the subwoofer wires and install wire retainer clips in affected vehicles free of charge, according to a recall acknowledgment document from the NHTSA. In some cases, dealers may replace the subwoofers altogether, a repair that Subaru has also pledged to subsidize. Owners should have received notification Oct. 31 via first-class mail. Those that did not can contact Subaru customer service personnel at (800) 782-2783. Callers should use the internal recall identification code WTQ-76. Owners in need of further assistance or information can also contact the NHTSA using its vehicle safety hotline at (888) 327-4236.