Drive Axles - Abuse Damage Inspection
NUMBER: 01-159-05DATE: 01-18-05
APPLICABILITY:
Impreza STI
WARRANTY BULLETIN
SUBJECT:
Axle Shaft Breakage and/or Damage from Abuse
INTRODUCTION
The purpose of this bulletin is to reinforce Subaru of America's (SOA) position regarding repairs to Subaru vehicles necessitated by racing or abusive driving habits. Axles can be damaged or broken from excessive torque transferred during acceleration from a complete stop (dumping the clutch) at high revolutions per minute (rpm) which puts an extreme load on the axles. Any damage that resists from racing or abusive driving is not covered under the vehicle warranty.
The will assist with identifying axles that have failed as the result of abuse:
If an extreme load is placed on rear axle shafts, one side could break and the opposite end could twist, both sides could twist or both sides could break. To inspect for a twisted axle shaft, inspect the crimp location on the axle boot bands. They should be aligned in a longitudinal direction as illustrated by the red dots (see Figure 1). However, this may not be necessarily true if the axle boots and/or bands have been replaced previously. It is recommended that you check prior repair history before concluding that misalignment is evidence of abuse. The example shows that the "B" Joint" (BJ) side and the "Double Offset Joint" (DOJ) side are twisted. The bands on the BJ, A & B, should be aligned with each other. The bands on the DOJ, C & D, should be aligned with each other. However, the bands on the BJ do not necessarily have to be inline with the bands on the DOJ.
BJ (wheel side) axle was twisted; A & B are not aligned (see Figure 2).
DOJ (rear differential side) axle was twisted; C & D are not aligned (see Figure 3).
The 3 photos (Figures 4, 5, and 6) show an axle shaft that was sheared off at the "Bell Joint" (BJ) as the result of abuse.
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