NHTSA Complaint #11575233 — 2014 SUBARU OUTBACK

I am just the mechanic and this is my customer's vehicle, but whilst doing some regular maintenance on the vehicle and also replacing part number 383485200 which Subaru calls "HOLDER, AXLE BRG" due to a crack which ran thru one of the 5 fastener holes. Upon normal cleaning of the threads in the rear differential casting where the "holder, axle brg" is bolted up to the left output shaft side I noticed a massive cavity in the casting which was drilled into and tapped for a bolt. This cavity is so large it presents a huge risk of catastrophic rear differential failure resulting in potential loss of control and increasing the risk of a crash. When I called the dealership to obtain the answers to the questions I know my customer is going to ask me, they shrugged it off as no big deal and couldn't even get me a price on a new rear diff housing or complete assembly. Using my brake rotor thickness calipers I was able to measure what I believe is the closest part of the cavity to the hole where the "holder, axle brg" is fastened in place. This "holder, axle brg" is the output shaft seal housing, plus, the outer race for the differential carrier is pressed into this component. Making it quite a critical component of the delicate innerworkings of a differential. Just a few ten-thousandths out of tolerance and the ring and pinion gears will destroy one another, the cavity in the casting right in a bolt hole creates potential for the differential carrier to not receive the proper bearing preload greatly reducing the life of the bearings, and in the worst case, the cavity could cause the rear differential to crack under heavy load which could cause a catastrophic failure, locking up the rear differential causing the vehicle to skid uncontrollably.