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Discussion Starter #21
Re: 2008 STi - Broken welds on rear roof support...

The service manager just called to inform me that the regional rep sent the documentation 'up the chain' and is awaiting information in return. He said that he would call me back by the end of the week whether or not he has an update.
 

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Discussion Starter #22 (Edited)
Re: 2008 STi - Broken welds on rear roof support...

I received a call from Subaru of America today informing me that they are going to repair my vehicle under warranty.

Thumbs up? Not just yet... I suppose I can discuss what "interesting details" I previously mentioned.

Once they finally found the cause of the issue, the repair was initially approved and the dealer ordered a new cross-member for the roof. The body shop had all of this in their possession, but once they looked into actually doing the repair, they found that they would have to cut the roof to gain access to the welds or piece that they need to replace. They notified the dealer, who notified the regional rep. This is when the service manager informed me that the regional rep had to come see the car (see OP for 2011.05.18).

I went on the road the next week for work which gave them a week to contact me. I didn't hear anything so when I returned I called them and asked for an update as to when I should expect the regional rep to make an appointment. The service manager said he would call the regional rep to find out, and then get back to me. When the service manager called me back he informed me that the regional rep is no longer going to repair this under warranty and the warranty for this 'line item' was now void.

Anyways, while on the phone with Subaru, I requested details regarding the repair of the defect but the woman I spoke with didn't have the specifics. She said that she would contact the service manager at the dealer to discuss it with him and have him call me with that information. I expressed my concerns regarding what I already knew and how uneasy I felt about it all. Considering resale value and safety structure, I think these concerns are valid.
 

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Discussion Starter #24
Re: 2008 STi - Broken welds on rear roof support...

Not long after I posted last, the service manager called me saying that they wanted to get a second opinion regarding the repairs necessary. I'm going in there tomorrow to meet up with him and go to a shop to get it looked at.
 

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Re: 2008 STi - Broken welds on rear roof support...

I would have a product liability lawyer and be headed in the direction of a buy-back. Hands down no questions asked at this point in the process. Enough of the games. No way did any suspension change you made contribute to this "defect" and it is a "defect".

Post a incident report in the NHTSA's website so they can be notified. Potentially there may be others out there. Subaru didn't just build one.

GL.
 

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Re: 2008 STi - Broken welds on rear roof support...

When you say roof, do you mean the outer sheet metal panel or the actual roof bracing? There is absolutely no way in hell I would let them hack the bracing. The outer sheet metal skin though, might not care as much.

Are the welds accessible without hacking off the roof, if so see if they can get it welded and resprayed, by a third party if needed. Or even agree to have it done at a shop of your choosing at SOAs cost. I have a feeling the welds are accessible though, otherwise they'd have no way to know they've cracked. Car companies usually just like to replace parts that could be otherwise fixed, much simpler for them in terms of liability, ease, ensuring a one time fix or lack of ability / tools at a dealer. There's often times when this approach becomes silly and a repair can be properly done without replacing something and be far less hassle.
 

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Discussion Starter #28 (Edited)
Re: 2008 STi - Broken welds on rear roof support...

They brought the car to their 3rd party shop and they're the ones that said the they'd have to cut the roof to get to the welds to replace the piece. Sorry I can't provide details regarding what specific weld or piece needs repair or replacement right now, I'll hopefully get much more information tomorrow from my visit to the dealer and another 3rd party shop.
 

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Re: 2008 STi - Broken welds on rear roof support...

I hope everything works out for you. I have been reading all your updates and hope this issues gets resolved for you properly.
 

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Re: 2008 STi - Broken welds on rear roof support...

Man that sucks...what a PITA...best of luck. At this point they should be replacing the car in my mind but then Car companies are real mofo's about that.

A co-worker is in the midst of a lemon battle right now. They just bought a brand new chevy equinox in may and to make a long story short the car has disabled itself on the freeway, the car has started displaying stuff in turkish, the engine has been completely pulled apart twice due to knocking (currently still torn apart), and the ECU has been replaced all in 3months of ownership. The dealers have put more miles on it testing the car then they have and they still havent been able to solve the electrical problem. The car has been in the shop all but 1mth since they bought it. And Chevy still doesnt want to lemon it and have decided not to return their or their lawyers calls. I mean seriously why have lemon laws at that point...
 

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Re: 2008 STi - Broken welds on rear roof support...

Interesting... Definitely keep us updated :tup: I'd love to see some pics of what is going on. I've got some metal on metal squeaking that I can't quite tell where it's coming from. Hopefully not something like this...
 

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Discussion Starter #32
Re: 2008 STi - Broken welds on rear roof support...

Not that I want others to be experiencing this issue, but if anyone is... please get it checked out and let me know what is found via PM. If there is a similar issue with multiple cars, there might be something here to bite onto. Not really trying to sound malicious, but this is more than an annoyance, welds breaking could potentially turn into a pretty serious safety hazard.
 

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Discussion Starter #33 (Edited)
Re: 2008 STi - Broken welds on rear roof support...

Just returned from my trip to the dealer and 3rd party body shop. I'm a bit more optimistic and a little less concerned about the extent of the repairs, not quite out of the water yet though.

Click images for larger views.

This first picture shows the different layers of the roof and cross-member that is welded to it, this is what's rubbing together and squeaking;


This picture here shows the spot welds that could potentially be the culprit;


The manager of the body shop is someone who I've worked with before, and said this was an issue they'd have to "kind of throw things at the wall and see what stuck." I let him and the service manager (more-so the service manager) know that I understand they're caught in the middle of this whole ordeal, but if this turns into a situation where I'm without the car for extended periods of time, numerous times, that this issue would become a lot more complex. I think we're all on the same page.

The body shop owner is going to write up an estimate and get it to the service manager, who told me I should expect to hear from him mid next week because the documents and information have to be put through their appropriate processes.
 

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Discussion Starter #35 (Edited)
Re: 2008 STi - Broken welds on rear roof support (metal on metal squeak)...

I called the service manager today since I hadn't heard anything, he said that they should be ready for my car at the body shop next Tuesday (2011.08.02).

Based on a conversation I had within the past week with a fellow STi owner with fabrication experience, I'm going to make a call to the body shop to talk to the manager and potentially one of their fabricators to have them explain their approach to this repair step by step.
 

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Discussion Starter #36
Re: 2008 STi - Broken welds on rear roof support (metal on metal squeak)...

Well I missed the drop-off yesterday, I wasn't sure that it was a solid date. I rescheduled to drop the car off at the dealer next Monday (2011.08.08).
 

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Re: 2008 STi - Broken welds on rear roof support (metal on metal squeak)...

Damn man, that is an unfortunate problem to have. Good luck with everything. Should I still buy an STI?
 

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Re: 2008 STi - Broken welds on rear roof support (metal on metal squeak)...

Yes, buy an STi. I suspect other HB owners might have this issue too but with exhaust, suspension, and chassis mods they might not be able to hear the metal to metal noise above the other added in-cabin NVH. I suggested possibly riveting the rear seam instead of cutting, welding, and painting...not to mention the possible damage, loose interior panels, creating a NEW noise, or overspray. :eek:
 

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Discussion Starter #39
Re: 2008 STi - Broken welds on rear roof support (metal on metal squeak)...

I suggested possibly riveting the rear seam instead of cutting, welding, and painting...not to mention the possible damage, loose interior panels, creating a NEW noise, or overspray. :eek:
Hey T, you've unmasked yourself! :lol:

I definitely agree with the suggestion and would probably prefer that at this point. However, one of my concerns is that there is more going on back there than just those few spot welds. So I'm inclined to let Subaru fix this using their methods. This way if more surfaces either during the repair or later-on down the road, they're still 'on the hook' to either remedy it or take other measures to rectify the situation.
 

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Re: 2008 STi - Broken welds on rear roof support (metal on metal squeak)...

Mask is off, lol. :)

If it still squeaks after their repair just install a TBE and group N mounts, the noise will disappear. LOL. Struts on Sunday about noon?
 
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