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Old 04-27-2015, 04:49 PM   #326
Speed Assault
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Return Follow up here. 2008 71k Stock, W/Cobb DP

To Reiterate- I removed the dash, because I knew I could make correct Repairs and add Proper Reinforcement to PREVENT THIS from Happening again!! and in less time it would take SOA and Dealer) I found failures, posted pictures above. Though I felt it was necessary to Have Subaru have Responsibility .

After a week with emails to SOA and 3days after dropping wrx off at dealer " Capitol Subaru" and I paid for Tow truck
Subaru is paying for repairs and a new clutch.

I decided to go with different further distance Dealer because of the poor service I get at my local Dealer. Who did nothing but adjust the clutch further to no more threads showing.
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Old 04-27-2015, 09:52 PM   #327
DeadGeneration
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I'm going to have to look at my firewall tomorrow. Maybe I'll go with a master cylinder brace just for prevention.
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Old 05-01-2015, 05:14 PM   #328
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I had mine fixed back in January, 2010 WRX with 103k miles on it at the time. Car is stock besides an exhaust and I have been the sole owner.

Clutch had been squeaking/creaking for as long as I could remember and I just lived with it. Steadily it got worse and by the time I dropped the car off I could no longer get the car into reverse on a cold start. After a few minutes of driving it would be difficult to get into but possible. I had resulted to reversing into every parking spot. First gear was also difficult on a cold start but with a little extra force would usually go in.

Opened a case with SOA and they paid for all repairs with a rental car included (dealership was out of loaners). Dealership had the welds fixed and replaced clutch pedal. Clutch felt like new when I got it back, it was a night and day difference.

Here we are about four months and 4k miles after the repairs were done and a small click has returned on the clutch. The brake master cylinder brace was installed previously, suppose I need to try the clutch brace now and hope it holds. Haven't brought it back to the dealership yet (1 hour and 15 minutes away) but I suppose I will to at least have it documented.
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Old 05-01-2015, 05:28 PM   #329
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Quote:
Originally Posted by fanatic View Post
I had mine fixed back in January, 2010 WRX with 103k miles on it at the time. Car is stock besides an exhaust and I have been the sole owner.

Clutch had been squeaking/creaking for as long as I could remember and I just lived with it. Steadily it got worse and by the time I dropped the car off I could no longer get the car into reverse on a cold start. After a few minutes of driving it would be difficult to get into but possible. I had resulted to reversing into every parking spot. First gear was also difficult on a cold start but with a little extra force would usually go in.

Opened a case with SOA and they paid for all repairs with a rental car included (dealership was out of loaners). Dealership had the welds fixed and replaced clutch pedal. Clutch felt like new when I got it back, it was a night and day difference.


Here we are about four months and 4k miles after the repairs were done and a small click has returned on the clutch. The brake master cylinder brace was installed previously, suppose I need to try the clutch brace now and hope it holds. Haven't brought it back to the dealership yet (1 hour and 15 minutes away) but I suppose I will to at least have it documented.
YA REASON it returned is they re welded the cracks not reinforced it like they should have. sorry to hear that.
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Old 05-01-2015, 11:23 PM   #330
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I bought my car ('09wrx) in Oct 2014…
I drove it with the remaining warranty and did not notice anything alarming. Couple of months in, I started noticing a crackling when I would go to clutch with my right foot already slightly resting on the brake pedal.
I decided to go with the Master clutch brace cylinder (by circuit MS) as a precaution… and all I can say is that the crackling is worst than ever!
I cringe every time i go to press on the clutch wondering if it will crack (more than 50% of the time it does)…
The squeaky pedal seems to only happen with very humid weather.
I had taken the wiper crowl off during warranty to make sure everything was A-ok… But I'm considering doing it again soon, and am scarred to see what lies beneath.
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Old 05-01-2015, 11:30 PM   #331
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Yeah I had my throwout bearing replaced recently and now therea a horrible squeak from the clutch fork but I guess its a common thing that is more of a nuisance
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Old 05-02-2015, 03:18 PM   #332
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Originally Posted by bmxhotsauce View Post
YA REASON it returned is they re welded the cracks not reinforced it like they should have. sorry to hear that.
It just seems like a bad design. When it was fixed the service adviser asked if my clutch was stock because it seemed heavier than normal. It's stock, but I'm not sure if it is heavier or not than others, who knows.
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Old 05-02-2015, 04:55 PM   #333
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Are you sure some of you guys are not confusing the crack with the sound the spring makes when you press the clutch in? I too thought my firewalls were cracked and found that my noise was only the spring.
I have the Perrin brace installed, so not sure if that is helping or not.
I will comment my clutch is very stiff, but I have since gotten used to it.
Most individuals they say, who have not driven a WRX comment on how stiff the clutch pedal is.
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Old 05-03-2015, 10:31 PM   #334
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Originally Posted by The Perfect Creature View Post
Are you sure some of you guys are not confusing the crack with the sound the spring makes when you press the clutch in? I too thought my firewalls were cracked and found that my noise was only the spring.
I have the Perrin brace installed, so not sure if that is helping or not.
I will comment my clutch is very stiff, but I have since gotten used to it.
Most individuals they say, who have not driven a WRX comment on how stiff the clutch pedal is.
slap me silly if this is the case.. but its not.

The cracking is not 100% of the time in my case. And also happens with a combination of brake & clutch pedal play. Which really makes it point towards pedal assembly movement.

Most of the time i hear the crack:
Getting ready for downshift or full stop; Let go of acceleration, and move right foot to the brake pedal.
As I go to clutch, and the right foot as begun engaging the brake pedal CRACK!

I can press the clutch 10x and not hear a sound. But it seems that playing with the brake pedal creates movement in the whole assembly that when I go to clutch the next time, it cracks.
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Old 05-04-2015, 07:12 AM   #335
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Well I went through the trouble of pulling the dash. Put two bolts through the upper part of the bracket. And it made zero difference.

I also sprayed white lithium grease on numerous parts of the clutch pedal assembly. On the return spring, on the "cam lobe" joint, and the plunger of the clutch master. Made no difference.

No I'm at a loss.
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Old 05-05-2015, 01:07 PM   #336
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I bit the bullet. Ordered the Circuit clutch brace. Since it seems like none of my welds are broken, and the noise is from flex.
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Old 05-08-2015, 12:44 AM   #337
Remz
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I've noticed a click last week while I was driving. The click comes and goes should I be concerned? This is my first Subaru and I take good care of my car. Please let me know what parts I needs to check first.

Thanks
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Old 05-08-2015, 08:28 AM   #338
yudangorgor
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just want to share a few clips as to what i'm experiencing..
i'll have to check my cowl again.. i checked on my own without removing the wiper motor and everything appears to check out..
i'll need to check again and remove the wiper motor and have someone press the clutch while i look from the engine bay.

These are the incidents in which i can capture.
There are other times where i'm riding the brakes to come to a stop and it would 'crack' or 'click'.
Even when my foot rests on the clutch, i can feel a pop.

https://drive.google.com/file/d/0Bz8...ew?usp=sharing
https://drive.google.com/file/d/0Bz8...ew?usp=sharing
https://drive.google.com/file/d/0Bz8...ew?usp=sharing
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Old 05-08-2015, 08:51 PM   #339
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Wow, I haven't been on NASIOC in a while, and I'm glad I decided to check it out today. I'm getting a new aftermarket clutch installed tomorrow. This will be my third clutch, with only 56k on the car. The OEM clutch went at 25k and I replaced it with an ACT heavy duty clutch which has just recently begun to slip.

I've also always had trouble getting the car into reverse and it's gotten a lot worse in the past 15k or so. And my clutch pedal started squeaking and clicking around 30k miles. I'll give all this info to the shop tomorrow (not the dealership), and hopefully they can fix the issue.

I drive my car hard, but not nearly hard enough to destroy a 420 ft/lbs clutch in 30k miles with only 300 whp.
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Old 05-09-2015, 10:01 AM   #340
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Quote:
Originally Posted by crowel57 View Post
Wow, I haven't been on NASIOC in a while, and I'm glad I decided to check it out today. I'm getting a new aftermarket clutch installed tomorrow. This will be my third clutch, with only 56k on the car. The OEM clutch went at 25k and I replaced it with an ACT heavy duty clutch which has just recently begun to slip.

I've also always had trouble getting the car into reverse and it's gotten a lot worse in the past 15k or so. And my clutch pedal started squeaking and clicking around 30k miles. I'll give all this info to the shop tomorrow (not the dealership), and hopefully they can fix the issue.

I drive my car hard, but not nearly hard enough to destroy a 420 ft/lbs clutch in 30k miles with only 300 whp.
i just changed my stock clutch with 71k miles on it. wnet stock again and a new stock flywheel. ive drag raced about 20 passes and am not easy on the car. i dont know how you guys tear up clutches esp, aftermarket units.
i installed the circuit motorsports clutch brace doing the clutch install.it firmed up the pedal area. i had 1 barely breaking spot weld under my wiper cowl.i had just started to get a little creaking noise members with noise, dont let it get worse.
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Old 05-10-2015, 02:08 AM   #341
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Default 08 WRX Clutch Noise Update

So, I just wanted to share my saga and what information I've gathered/learned/experienced over the years in the hopes it can help them with a very frustrating and dangerous problem. I purchased the car at the beginning of 09 and at this time it is approaching 120k miles. It started as clutch noise only when cold (Freezing~ish and below), that sounded just like gsrcrxsi's videos, right around 30k miles and two+ years on my car. It was a bad straining type squeak noise near the top of the pedal, then I got the 'click' not long after while the groaning progressed in volume. Over the last four years I've researched, researched, and spoken with 3 different body shops, 3 different dealerships' technicians, a handful of mechanics, and any gear head I could get to sit in my car. The body shops and Subaru mechanics themselves generally provided good information that has seemed relatively correct.

I had 3 welds broken, only 1 was visibly 'malformed' or broken beneath the cowl and 1 other that looked questionable, similar to the those Army identified in the other thread.

Having been sold how much like the factory bumper to bumper the Subaru classic was with a $100 deductible, I purchased the 100k/6 classic believing it was essentially extending my factory warranty minus a consumable or two(Offered/Supported directly by Subaru right???) and kept it stock. It has been my final lesson learned in aftermarket warranty, good luck figuring out what is actually covered if you don't want to throw a couple grand at 'consumables' first. I don't know if the Gold is substantially different, but, experience seems to differ greatly depending on the dealership too. I visited several dealerships multiple times and on every visit to I tried to get them to pay attention to the firewall once the issue first started surfacing and they said 'Only grease on internals, $600 please to pull the dash and perform.'. I asked about the health of the firewall welds on each visit (And calls to SOA trying to get something done) and was repeatedly told the firewall wasn't a problem with a stock clutch.

If you refer to the clutch pedal service manual diagram for your car it should show you every component on your clutch that should be greased. On the 08 it was 6/7 spots within the dash. Myself and the various dealerships were unable to grease beyond the pedal points without pulling parts of the dash, neither of us ever reduced or eliminated any noise at all on the lower linkage or trying to reach the points with only the bottom cover removed. (I wasn't willing to spray blindly upwards) Finally, the last dealership I brought it to had a technician who came out to identify the overwhelmingly loud 'haunted house' noise as probably a master cylinder bushing and the click as a switch. When we discussed the firewall concerns, he told me its possible, but he didn't believe it was causing the loudest noise or the problem and thought we would have to pull the dash to know for sure. They would be willing to inspect under the cowl for $x fee, (1.5 shop hours seemed standard), but again they recommended to pull the full dash to grease as they wouldn't do anything without obvious damage visible externally. I dealt with SOA Corporate several times to try and figure out if I paid the 5-8 hours to pull the dash if either power train or extended would pay for the repair and the answer was a definitive maybe as it was probably a clutch consumable failure, misuse, neglect, etc.

Around 96k, with only 1 weld looking questionable from the outside, I went ahead and pulled the dash to the airbags and using the clutch to reproduce the noises, agreed with the last technicians noise diagnosis. Behind the instrument panel, I was able to roughly hit every grease point in the service manual with White Lithium grease. The click was gone first, then steadily the 'groan' reduced until it/they were gone within two weeks. I drove it like this noise-free for two more years until clutch noises developed sensitivity to the weather.

As I prepped to grease the clutch switch again, I pulled the cowl first, just in case, and was finally able to fully identify a weld as damaged from outside by the rust and cracking. Again working with SOA that once I could point out the obvious firewall damage to a dealership and mentioned lawsuit, Subaru was finally willing to pay for an inspection with a shop able to complete the repair (Body Shop).

What ensued was what I would call a game of hot potato as the initial dealerships and/or body shops either couldn't do the welding, or didn't want to trouble of completely pulling the dash. One dealership with a body shop finally stepped up to the plate and after having the car for a day short of 3 weeks have repaired the problem for now. Even though the clutch pedal itself is a bit noisy now, they did not replace it or anything else from the information I could collect except the pedal clevis pin. I did insist they grease the internal dash components again while they had it completely apart.

It is unfortunate for me in all this time of jerking around with Subaru, the dealerships and body shops that my clutch engagement got substantially worse with too much force. During this time, after the most recent popping noise, if you used too much force pressing the clutch, it would grind.

Over the years and recently from talking with multiple dealerships, their body shop or affiliations, and own experience I believe that once the first weld breaks loose enough to change the engagement angles and pressure we 'force' those noises to surface. That is just my theory, but over this time of clutch noise identification I may be able to help a few people. Supposedly they 'reinforced' my firewall with additional welds, but, I still plan to purchase a brace and monitor. Is it a coincidence that many of the cases report stiff clutches for a long time too? I have had a leg-press machine from the factory, but have tried out the clutches on quite a few STIs, WRX, and NA Imprezas throughout this time and there is a huge variation. My friend's 09 WRX was heavy until he had one of their spun bearings, and at the two month point was still way lighter then originally set. The feather feeling of my clutch wore off 3 days after they re-greased everything and repaired the welds. If I have to repair the issue myself in the future I will find a buddy who knows how to properly rivet and correct it using that method.

Clutch Noises on the 08 WRX:
If you have a definitive 'click' it is probably the switch system, there are multiple threads across multiple forums identifying the culprit runs. For me and many others, it was the switch/rod/spring assembly on the pedal bracket. In 09+ it looks like they removed that offending rod/spring that used to call for grease on the switch system, so I don't know how that affected the system.

If you have a 'popping' sound, as I can best further describe it as a blue jean button ripping really forcefully, it is probably a weld starting to, or in the process of breaking. Reflecting back, I think I can identify each of the 3 popping phases, beginning with a short duration of popping around the time this loud clutch began and a body shop noticed the 3rd phase as well while it was occurring during this debacle.

If you have a metal 'crunching' sound, it may be the broken weld contacting and/or further breaking free.

Painful groans of the system(The general firewall blame noises out there in videos) were identified as master cylinder related.

If you have an orchestra of multiple, changing, noise, I would be very concerned about the firewall. Once the failure accelerates, I know a guy personally, and I think someone else reported in one of these threads it ruined their clutch fork as well.


All in all, I don't know how I feel about Subaru's response.I personally feel like if there wasn't the lawsuit they would have continued to scoff until some serious accidents finally start happening as a result. Pretty typical car company response for years. At this time it seems like aftermarket pressure plates are what they're focusing on denying any assistance over at this time. In this latest stage of dealing with Subaru and the dealerships, that is what they continued to insinuate until the 2nd dealer confirmed there was probably no way I'd ever had any aftermarket clutch components installed and if I hadn't replaced it by now and if the clutch behaves as well as it did at the start of this escapade, abuse is pretty out of the question. I've had 3 other MTs in my time and never had to replace a clutch component prior to 180k miles and it drives me nuts that I have a sensitive 2nd gear that developed over the last couple months when the engagement got really tricky.

If there is a single 08 WRX without a brace out there with more than 50k miles that hasn't broken at least 1 weld, I would really be surprised at this point.

Last edited by Stryx; 05-11-2015 at 01:10 AM. Reason: Added a little more info
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Old 05-10-2015, 10:40 PM   #342
wagonmeister
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Quote:
Originally Posted by yudangorgor View Post
just want to share a few clips as to what i'm experiencing..
i'll have to check my cowl again.. i checked on my own without removing the wiper motor and everything appears to check out..
i'll need to check again and remove the wiper motor and have someone press the clutch while i look from the engine bay.

These are the incidents in which i can capture.
There are other times where i'm riding the brakes to come to a stop and it would 'crack' or 'click'.
Even when my foot rests on the clutch, i can feel a pop.

https://drive.google.com/file/d/0Bz8...ew?usp=sharing
https://drive.google.com/file/d/0Bz8...ew?usp=sharing
https://drive.google.com/file/d/0Bz8...ew?usp=sharing
This is what I was trying to describe further up!
Although in the video, yours sounds like more of a pop. Mine really cracks. And I get it when I first lay my foot on the brake pedal. not when i apply force.
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Old 05-11-2015, 08:28 AM   #343
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Originally Posted by wagonmeister View Post
This is what I was trying to describe further up!
Although in the video, yours sounds like more of a pop. Mine really cracks. And I get it when I first lay my foot on the brake pedal. not when i apply force.
just yesterday before even starting the car, i press the brake first and it had the pop/crack noise.

At times it sounds like a crack and at times it sounds like a pop and the loudness varies..

the video probably doesn't do it justice as it doesn't capture the sound very well
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Old 05-11-2015, 09:26 PM   #344
gsrcrxsi
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Installed the clutch brace. Didn't make much difference.

Still squeals and squeaks. I'm starting to think its the pedal assembly itself.
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Old 05-12-2015, 10:53 AM   #345
kingsalami
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Quote:
Originally Posted by gsrcrxsi View Post
Installed the clutch brace. Didn't make much difference.

Still squeals and squeaks. I'm starting to think its the pedal assembly itself.
gsrcrxsi - Good luck tracking the source of that damn noise down.

I guess I've been relatively lucky - I've got just a faint groan and a bit of grittiness in my pedal linkage. I added a GS MC brace a couple years ago, and I think it made a noticeable difference in smoothing out clutch engagement, and it reduced the noise a bit. I think lubing up the pedal linkage and installing a brace may help some folks out there (who don't have a cracked firewall).
For everyone else with clutch engagement issues, especially if you're pushing 300+ hp, I would strongly suggest motor mounts and tranny mounts, if you haven't upgraded 'em already. Those, along with rear diff bushings, really tamed the nasty drivetrain lash I had initially. Group N mounts increased NVH a bit, but it's definitely worth it.
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Old 06-01-2015, 09:23 AM   #346
gsrcrxsi
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my issue seems to be linked to rain/humidity.

it squeals the worst after a rain, but after a few days, it quiets down and nearly goes away.
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Old 06-01-2015, 11:11 AM   #347
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Quote:
Originally Posted by gsrcrxsi View Post
my issue seems to be linked to rain/humidity.

it squeals the worst after a rain, but after a few days, it quiets down and nearly goes away.
I have exactly the same symptoms during what I have observed as the same type of environmental variables. However my issue (squeal) resolves itself within a few miles of driving as opposed to days.
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Old 06-02-2015, 01:29 PM   #348
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I took my car in last week for an annoying squeak that has been with the car since November of last year. I thought it was due to weather since it would get louder and quieter with temperature change. I had my car repaired back in October by a Subaru dealership in Kansas. I was PCSed (Military) to Colorado. I took my car to the local dealership here and they found that the repair that was made in Kansas was repaired wrong. They proceed to call the dealership in KS and Subaru of America. No one will warranty it. The dealership here said it will cost a lot to repair the messed up job that the other dealership did. Also they told me that my case was closed by Subaru of America I am not sure what that means. Is there any thing that I can do, or has anyone else ran into this problem. I already am talking to a Lawyer on Thursday.
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Old 06-10-2015, 07:42 AM   #349
Hitdatsit
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So I received this letter today. Does this mean they would still fix car under warranty or offer reimbursement of it happened during the warranty time? I have the creak but didn't see any welds broken. I ordered a gs brace and will see how it goes. I'm iffy about bringin it to subaru to fix since I have all my gauges installed and think they would mess things up.
http://i.imgur.com/aUD2b9x.jpg
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Old 06-10-2015, 09:25 AM   #350
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SOA & a dealership of your choosing should fix the issue regardless of warranty. They fixed mine with no issues.
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