2004 Subaru Outback

Issue: 
This recall is for certain vehicles that had an airbag inflator replaced as a part of an earlier recall campaign. This recall provides a final repair. 

Long-term exposure to high absolute humidity and temperature, combined with high temperature cycling, may eventually degrade the propellant contained in the passenger-front airbag. This could cause the airbag to deploy with more force than normal. If the airbag inflator ruptures, fragments could be propelled toward vehicle occupants or cause damage to the airbag assembly, preventing its proper function. 

Safety Risk: 
If the vehicle is involved in a crash requiring an airbag deployment, the airbag inflator could rupture and create a risk of injury. 

Corrective Actions: 
Owners will be notified by mail and instructed to take their vehicle to a dealer to inspect the passenger-front airbag inflator. The passenger-front airbag module or inflator will be replaced as necessary. Note: The Canadian climate results in the propellant degrading slowly. This recall is being conducted as a precaution to address future risk. It is expected that all airbag inflators will be replaced before their function would be affected.

Issue: 
A problem with certain replacement ignition switches may allow the key turn out of the “ON” position while driving. This could cause the engine to turn off suddenly. It could also cause the airbag system not to work properly in a crash. 

Note: This is a voluntary service campaign that is not being conducted under the requirements of the Motor Vehicle Safety Act. This problem only affects certain parts used for replacement of original parts. 

Safety Risk: 
A sudden loss of engine power could increase the risk of a crash. An airbag system that does not work properly in a crash could cause an increased risk of injuries. 

Corrective Actions: 
The company will notify owners by mail and instruct them to take their vehicle to a dealer to inspect the ignition switch, and replace it as necessary.

On certain vehicles, long-term exposure to high absolute humidity and temperature, combined with high temperature cycling, could eventually degrade the propellant contained in the passenger frontal airbag. This could cause the airbag to deploy with more force than normal. As a result, if the vehicle were involved in a collision that warrants airbag deployment, fragments could be propelled toward vehicle occupants, and the airbag assembly could be damaged, preventing proper function. These issues could increase the risk of injury. Correction: Dealers will inspect, and replace the passenger frontal airbag inflator as necessary.  Note: Canadian climate results in the propellant degrading slowly. The recall is being conducted as a precaution to address future risk, and is expected to replace airbag inflators before their function would be affected.

On certain vehicles, the passenger (frontal) airbag inflator could produce excessive internal pressure during airbag deployment. Increased pressure may cause the inflator to rupture, which could allow fragments to be propelled toward vehicle occupants, increasing the risk of injury. This could also damage the airbag module, which could prevent proper deployment. Failure of the airbag to fully deploy during a crash (where deployment is warranted) could increase the risk of personal injury to the seat occupant. Correction: Dealers will replace the passenger airbag inflator.

On certain Legacy, Outback H-6 3.0L and Impreza WRX 2.0L Turbo, the cruise control cable could come out of its track on the cruise control lever and lodge on the control lever tab when the accelerator pedal is released.  If this condition occurs, the throttle will not return to the idle position which may cause the driver to lose control of the vehicle.  Correction:  Dealer will install a retaining clip to the cruise control lever tab.