Repair Process on This OEM Defect
 

My car was delivered with this part already wrinkled from the manufacturer. From the looks of it, the machine bent the part.

The dealer will fix it, but they want to pull the entire part and replace it with a new one using a local body shop. I am a little skeptical of most body shops, and would rather they just bent it back into position and re tack welded it. If they replace it, they will have to break the tack welds all the way into the top of the fender to remove this and replace it.

What are your thoughts?

http://sphotos-a.xx.fbcdn.net/hphoto...45749250_n.jpg

Edit: NEW PICS

Here's what it should look like:
http://i813.photobucket.com/albums/z...a/EN2C2441.jpg

Here's what it looks like:
http://i813.photobucket.com/albums/z...a/EN2C2444.jpg
http://i813.photobucket.com/albums/z...a/EN2C2444.jpg

If their plan is to have it taken to a body shop like that, I would probably just deal with it like it is. No sense in possibly making matters worse.
If you need to get it fixed, I would tell them I want to pick the body shop it's going to and do lots of research before hand. Not sure if this is even possible for you though.

I wish they could just write me an IOU for the repair and I could give it to whoever buys the car one day. The damage isn't really bothering me.

Where the heck is that part on the car?

what part is that?

It is the top of the inside of the trunk on the passenger side. It's a thin sheet. I will take a few more pictures later. Sorry for the poor quality

Here's what it should look like:
http://i813.photobucket.com/albums/z...a/EN2C2441.jpg

Here's what it looks like:
http://i813.photobucket.com/albums/z...a/EN2C2444.jpg
http://i813.photobucket.com/albums/z...a/EN2C2444.jpg

The bigger question is, how did it happen? I don't believe this actually passed the factory CQ. Maybe there is other damange?

I suspect a machine did it pre paint. The paint on the bent piece is not cracked.

Aside from that, everything else looks very straight.

deer hit your trunk didn't it?

and i think your right ^^^^

looks like a machine bent it

yea... for a car so new, I'd live with it since I wouldn't touch it. As long as it doesn't leak or affect anything, ask them to give you money instead so you can take it to any shop if you want....

I had a defect, but minor compared to yours. Front bumper was a lil dented, but on right lower lip area... a part of a car that would already get damaged from driveways/potholes/speed bumps. We came to agreement that they would repair/repaint or I'd take $$ to do myself. I would rather not get a new car painted as it would be a pain to match paint... no one even notices the damage unless I point it put it out and they kneel down to look.

I think I will try that. Honestly it doesn't bother me at all, but at the same time I think they need to make it right. I have a body guy I go to for everything, and wouldnt let them send the car to a random one if it go wrecked, so why would I for this.

i say new car

i don't know if you can even replace that part. it looks like it's part of the frame. i'm guessing a body shop will need to flatten that piece back out, but it will never be the same as factory.

good luck.

It is hard to say. The piece goes further back into the wheel well, so I could have them pull it all out and replace it that far, or leave it. I feel like leaving it is the better option, it is a new car, so why should I have to put up with it though?

Subaru needs to know about this not just the dealer. I have never seen or heard about an issue like this. It's as if the robotic machines that weld body had an incorrect motion or something, perhaps it was damaged prior to being installed but then where is the QC????? Any explanation as to how this happened? Makes me realize that I need to do a thorough inspection prior to purchase.

It has no real effect on the structural rigidity of the vehicle, but if you were to haul something big into or out of the trunk like that...I would hate for your hand to be there and cut yourself... Ouch...it hurts just thinking about it...it's like asking for stitches... Anyways, personally I would get that fixed; it's definitely a hazard. Just my $0.02

I wouldn't mind taking to a body shop to have the tab straightened since it is at the very end of it and really doesn't do anything for the structure, but I would also like to take the money for the repair, and give it to a body shop I trust. "Toyota Certified," or "Preferred" usually just means they give them a discount for continuing to use them. I really doubt that they do any quality checks on these body shops. All they care is that they are cheap and use Toyota oem parts.

I posted the picture in the feedback for SOA/Toyota thread.

Very interesting defect.

That is what I would do. Replacing that part will probably open a new can of worms IMO.

Replace car.......

^YES! haha

Bypass the dealers and call up TMC directly and say you aren't satisfied with your dealer's solution. Might not hurt to also PM @Moto-P who would probably relay it to the chief engineer who gladly takes action on issues like these since this car is his baby.

I used to work at a Toyota plant and seen them scrap completely built cars (Corollas) because they catch defects like these near the end of assembly line. They'd do a root cause analysis, fix the issue, queue up a new chassis, and build from scratch to replace it (or replace a bad batch).

To be honest, it is very annoying to feel like my car has already been in an accident even though it is brand new. I will send these messages and update here as I learn more.

Update:

Both the local scion sales manager as well as corporate Toyota called me yesterday. They needed the full story on the car and are going to be calling me again today with options. This whole situation is awkward though because I did not buy the car to be a race car or a daily driver. I bought it to save / collect it. So as any of us would know, lots of repairs are not really the best thing for a collectable vehicle.

Either way, Toyota has been really caring so far and I really hope they take care of me. They seem to have my satisfaction as their number one priority right now though. I am hoping this can turn into a testimonial of how awesome they are.

It's one of those rare questions, does the collectible value go up because of the "rare defect", or down because of damage. I'm guessing the latter.

I can't say that I have ever heard of damage making the car more desirable, but I am just excited to get things all figured out.

Not to sound like an unbeliever, but do you have any examples of cars with defects that increased value? I am just curious to see.

In cars, never to my knowledge, but as far as collectibles, sometimes defects are prizes. I had a few trading cards with misprints that upped their value considerably. In your case, it's most likely the opposite, but as with anything, if you find the right buyer...

Today's Update:

Scion/ Toyota Corporate called me and they still want me to take the car into their body shop to figure out how extensive the damage is. They told me on the phone that they really are hoping to just straighten the piece out and repaint it. I think this is a bit strange since I was told at the dealership that the metal should not be bent back as it will never have the same strength or be the same again, but I am willing to spend the time/ hassle and drive downtown to get it looked at. They wanted me to drop my car off at the dealership so they could arrange a loaner car, but I don't want anyone to drive my car around, so I told them I would just drive up to the body shop myself.

I will post more updates as I get them.

Hmmm, now I need to inspect mine when I go outside!

Yeah I would recommend to anyone purchasing a car that they need to run through ever nook and cranny on the vehicle. I have read a lot of great Subaru Testimonials and really hope that Toyota will treat me the same as what I have seen Subaru do for other people. It was a really tough to decide between the FRS and BRZ, so I am just going to hope and pray that I didn't lose the great customer service by purchasing the Scion over the Subaru.

I stopped by the body shop I take all of my vehicles to on my way home from work to get their perspective on the damage. He told me that to replace the part they want to cut out, the rear window would have to be removed along with the panel below it. It sounds like a total nightmare so far.

I am confident that I will be treated correctly, they haven't given me any real reason to doubt them yet.

Thanks for the post. I'm picking mine up this Friday and you can bet I'll be looking up under the rear deck lid at this piece.

Hope you get everything sorted out!

Yeah just be really thorough in your inspection. Knowing what I know now, I should have just waited for the next car to come instead of going through the hassle of this. You want to enjoy a new car when you get it, not worry about what the next step is.

I agree with this....call 1-800-SUBARU3 and get corporate involved...if that piece, weld, etc is part of the structure or crash worthiness of the car it could be a bigger issue than you think.

Oops, saw it was a Scion....and you already called, carry on.

I imagine if the OP were anal enough they could get a new car. Legally Scion cant sell a car with a known potential structural defect. A lawyer could have a field day with this (note: I hate lawyers) . Its a structural piece that's damaged, how can Scion prove the car meets crash test ratings or safety requirements since the test cars were not tested with this damaged piece in place. I think they are legally required to fix it, offer a new car, or put in writing that there is no loss of structural integrity.

I have spoken with Scion corporate and told them that I would like vehicle replacement. The car has too few miles (I have owned it for about 2 weeks now) to be getting parts cut out etc. The car will be inspected by a body shop this Friday. I believe I have contacted all of the involved parties and made them aware of the defect as well as the my concerns.

How this is handled will either create a life long customer with a great testimonial, or just the opposite. So far they are doing great, assuming they are really listening. They did tell me they saw the pictures of the damage on this forum, I am guessing they saw them in the feedback thread.

It is interesting they are monitoring this forum and admitted it.

I think it is good that they can admit they are actually looking for information where it matters. I think 99% of the "research" companies do, is so far off base that we end up with cars like the Veloster Turbo.

The defect seems to happen before paint, that is basically before anything is installed. It looks like the part is bent either before or while being put onto the car. And later it passed the eyes of those who assembled trunk area, and importantly of QC.

I hope you get a replacement. This is serious from manufacturing point of view. This is rare and TOYOTA should give you a replacement.

How did this get passed the final assembly inspection as well as the PDI!! :bs:

Sorry about to hear about the poor quality so let's see how they handle this situation and please keep us updated.

I guess the biggest disappointment for me, is that this is not just another car. I have been waiting on this car since I saw the early sketches/ rumors.

I remember the day this released, and making plans to get the car.
http://www.blog.automotiveaddicts.co...8/new-ae86.jpg

I entered the "First 86" competition, but did not win, but still this car is a lot more to me than just another car.

My corolla history runs pretty deep, and I sold my M3 to buy this car. So I really must say that this hasn't been the best experience in terms of getting what I want.

I have had this many ae86 corolla's leading up to this one, and am a very active member on a number of enthusiast forums.

My Corolla History:

http://i49.photobucket.com/albums/f2...t/Chola003.jpg

http://i49.photobucket.com/albums/f2.../IMAGE_035.jpg

http://i49.photobucket.com/albums/f2...ent/gts200.jpg

The Blue One
http://i623.photobucket.com/albums/t...tiltshift1.jpg

http://i623.photobucket.com/albums/t...a/P1000097.jpg

http://i813.photobucket.com/albums/z...a/DSC_0445.jpg

http://i813.photobucket.com/albums/z...a/DSC_0103.jpg