2004 Subaru Forester Problems

leaking fuel lines under turbo in engine compartment when in cold weather

THERE IS A FUEL LEAK ON THE LOW AND HIGH PRESSURE FUEL RUBBER HOSES, AND THEY CAUSE FUEL ODOR TO ENTER THE CB VIA CLIMATE CONTROL. IT IS A VERY STRONG ODOR, THAT REQUIRES ME TO EITHER DRIVE WITH THE WINDOWS DOWN OR WAIT FOR THE CAR TO CLEAR OUT THE FUEL ODOR OUT OF THE CABIN. MOSTLY OCCURS DURING COLD WEATHER DAYS. ONCE ENGINE WARMS UP, ODOR FADES AWAY. MANY PEOPLE WITH SIMILAR CARS SAY IS A COMMON ISSUE WITH SUBARUS.

Bracket to the sway bar bushing fell off

TL* THE CONTACT OWNS A 2004 SUBARU FORESTER. THE CONTACT STATED THAT THERE WAS A LEAK IN THE HEAD GASKET. THE VEHICLE WAS TAKEN TO THE LOCAL DEALER HERB GORDON SUBARU (3161 AUTOMOBILE BLVD, SILVER SPRING, MD 20904, (866) 520-7894) WHERE IT WAS DIAGNOSED WITH THE HEAD COVER GASKET WITH NEEDING TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. UPON INVESTIGATION, THE CONTACT ASSOCIATED THE FAILURE WITH NHTSA CAMPAIGN NUMBER: 04V473000 (ENGINE AND ENGINE COOLING) HOWEVER, THE VIN WAS NOT INCLUDED. THE MANUFACTURER WAS INFORMED OF THE FAILURE. THE CONTACT WAS INFORMED THAT THE REPAIRS WERE NOT COVERED UNDER WARRANTY AND THE COSTS FOR THE REPAIR WOULD BE OUT OF POCKET. THE FAILURE MILEAGE WAS APPROXIMATELY 161,000.

My vehicle had a recall on the lower control arms that would rust and and break. That is exactly what happened while I was driving with my family. Control arm broke causing other parts to get destroyed. The fender breaks and other parts. The recall was performed before hand but it obviously wasn’t repaired correctly because it caused me to crash. Dave wright auto Subaru retailer in Iowa is refusing to repair my failed recall attempt. Consumer stated failed repair caused the consumer to crash and damaged more of my vehicle.

Bracket to the sway bar bushing fell off

HELLO, THIS IS THE SECOND 04 SUBARU FORESTER I HAVE OWNED THAT HAS A FAULTY SOLDER AIRBAG CONNECTION CAUSING THE AIRBAG LIGHT TO BE ON AND LIKELY DISABLING SOME OR ALL OF THE AIRBAG SYSTEM. THAT IS VERY HIGH LIKELIHOOD THAT MOST OF THESE 03-04 VEHICLES ARE AFFECTED. WHY IS THERE NOT A RECALL TO ADDRESS THIS SAFETY FAILURE? BELOW IS THE DOCUMENTATION FOR THE LACK OF RESPONSE FROM SUBARU OF AMERICA. ATTACHED IS A PDF OF THE TSB FOR THIS ISSUE. HI [XXX], THANK YOU FOR CONTACTING SUBARU OF AMERICA. I APPRECIATE THE OPPORTUNITY TO BE OF ASSISTANCE. I CAN CONFIRM THAT I HAVE DOCUMENTED THE CONCERNS YOU HAVE RELATED TO YOUR VEHICLE, INCLUDING YOUR REQUEST TO HAVE A RECALL ISSUED CONCERNING THE PROBLEM DESCRIBED IN TSB 17-07-04. SHOULD YOU HAVE ANY FURTHER QUESTIONS OR CONCERNS, FEEL FREE TO REACH OUT TO US BY REPLYING TO THIS EMAIL OR CALLING US AT 1-800-782-2783. SINCERELY, [XXX] SUBARU OF AMERICA, INC. CUSTOMER/RETAILER SERVICES DEPARTMENT 1-800-SUBARU3 (1-800-782-2783) SERVICE REQUEST NUMBER:[XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

TAKATA RECALL

FLOOR MAT DETACHED FROM FLOOR; RIDES UP UNDER AND TRAPS ACCELERATOR. *TR

ACCELERATOR TOOK OFF AT HIGH RPM AND CONTINUED AT HIGH RPM EVEN IN PARK. FORTUNATELY, I NOTICED THAT LIFTING MY FOOT OFF THE ACCELERATOR DID NOT SLOW THE CAR WHEN DRIVING IN LOW TRAFFIC CONDITIONS AT LESS THAN 40 MPH AND WAS ABLE TO OVERCOME ACCELERATION WITH BRAKING WITH SUFFICIENT CONTROL TO GET TO THE DEALERSHIP ABOUT 1 MILE AWAY. MOST DEFINITELY NOT THE ACCELERATOR PEDAL; THE MAT WAS NO WHERE NEAR THE PEDAL. HAD AN OIL CHANGE TWO DAYS PRIOR, BOTH OTHERWISE NOTHING TO REPORT CONCERNING THE CAR.

CAR WAS SHIFTED FROM DRIVE INTO NEUTRAL FOR OPERATOR TO USE A PARKING LOT GATE MACHINE. THE ENGINE SURGED A LITTLE WHILE IN NEUTRAL BUT SETTLED BACK DOWN. WHEN PARKING GATE OPENED THE OPERATOR SHIFTED INTO DRIVE AND LIGHTLY PRESSED THE GAS PEDAL. THE ENGINE IMMEDIATELY SURGED TO FULL THROTTLE AND RAPIDLY ACCELERATED ACROSS THE DRIVEWAY FOR A FEW SECONDS BEFORE BEING STOPPED BY COLLISION WITH A GRANITE POST. OPERATOR COULD NOT BRAKE HARD ENOUGH TO STOP THE VEHICLE IN TIME. DRIVER INJURED IN CRASH.

DRIVING HOME FROM GYM, I NOTICED THE CLUTCH PEDAL WAS NOT ENGAGING THE CLUTCH MAKING SHIFTING DIFFICULT. EVENTUALLY RETURNED HOME SAFELY AND UPON INSPECTION, I NOTICED A LARGE FIREWALL CRACK NEAR THE CLUTCH MASTER CYLINDER. THE LARGE FIREWALL CRACK COMPROMISED THE CLUTCH PEDAL FUNCTION. ALSO, FEAR OF POSSIBILITY OF BRAKE PEDAL FAILURE AND POSSIBLE EXPOSURE TO ENGINE BAY FUMES. I SPOKE TO A SUBARU SERVICE ADVISOR AND SUGGESTED TO "BRING-IN" FOR INSPECTION. ENROUTE TO THE DEALER WAITING FOR THE GREEN LIGHT ON THE MAIN STREET, DEPRESSED THE CLUTCH PEDAL AND FELT A SNAP THEN MY CLUTCH PEDAL PLAY IS NONE. LOOKED ON THE FLOOR OF MY CAR TO SEE WHAT FELL/DETACHED, AND IT LOOKED LIKE PART OF THE PEDAL BRACKET THAT ATTACHED TO THE CLUTCH MASTER CYLINDER. I EVENTUALLY TOWED MY CAR TO THE DEALER. ARE FIREWALL SUPPOSED TO CRACK?

The contact owns a 2004 Subaru Forester. The contact stated that while driving an undisclosed speed, the brake pedal was depressed and extended to the floor, causing the braking distance to be extended. The vehicle was towed to the local dealer who discovered that the brake hoses had failed due to rusting and corrosion of the brake lines. The contact was also informed that the entire subframe had sustained extensive rust and corrosion damage. The vehicle was not repaired. The failure mileage was 28,000.

My vehicle had a recall on the lower control arms that would rust and and break. That is exactly what happened while I was driving with my family. Control arm broke causing other parts to get destroyed. The fender breaks and other parts. The recall was performed before hand but it obviously wasn’t repaired correctly because it caused me to crash. Dave wright auto Subaru retailer in Iowa is refusing to repair my failed recall attempt. Consumer stated failed repair caused the consumer to crash and damaged more of my vehicle.

FAILED RECALL ON 2004 SUBARU FORESTER XT FRONT LOWER CONTROL ARMS. THE FRONT LOWER CONTROL ARM ON THE PASSENGER SIDE OF MY FORESTER RUSTED IN HALF. WHEN BACKING OUT OF A FLAT CONCRETE DRIVEWAY ONTO A CITY STREET, AS I BEGAN TO TURN THE WHEEL I HEARD/FELT A POP IN THE FRONT END. AS I BEGAN TO STRAIGHTEN THE WHEEL IT STARTED MAKING A GRINDING NOISE AND I NOTICED THE STEERING FELT FUNNY/LOOSE. BEFORE FOING ANY FURTHER I PULLED THE CAR STRAIT BACK INTO THE DRIVEWAY TO INSPECT THE PROBLEM. WHILE I WAS JACKING THE CAR UP I NOTICED IMMEDIATELY THE FRONT PASSENGER WHEEL APPEAR TO GO LIMP AND SLOPPY. AFTER CRAWLING UNDERNEATH TO CHECK I FOUND THAT THE CONTROL ARM HAD COMPLETELY BROKE/RUSTED IN HALF. A FEW WEEKS EARLIER I NOTICED THE FRONT CONTROL ARMS ON BOTH SIDES WERE QUITE RUSTED. AFTER A LITTLE RESEARCH I FOUND THAT SUBARU HAD A RECALL ON THE CONTROL ARMS AND WOULD EITHER REPLACE THEN OR RE COAT THEM. I THEN CONTACTED A LOCAL DEALER ABOUT THE RECALL. AFTER RUNNING MY VIN THE TOLD ME THAT MY VEHICLE HAD ALREADY BEEN SERVICED FOR THAT RECALL IN 2012 AND THAT MY CONTROL ARMS WERE UNDER COATED AND THEREFORE WERE NOT COVERED FOR REPLACEMENT. SO NOW AFTER MY CONTROL ARM IS COMPLETELY BROKEN I CONTACTED THE SAME DEALER AGAIN AND WAS TOLD TO TRY CONTACTING SUBARU OF AMERICA BUT THAT THEY COULD DO NOTHING. I THEN CONTACTED SUBARU OF AMERICA AND AFTER GIVING THEM ALL MY INFORMATION WAS TOLD AGAIN THAT MY VEHICLE HAD ALREADY BEEN SERVICED FOR THE RECALL AND WAS NOT COVERED, BUT IF I TOOK IT TO A DEALER THEY WOULD "LOOK AT IT". I THEN CONTACTED ANOTHER LOCAL DEALER AND I WAS ABLE TO TRAILER IT THERE MYSELF. I AM WAITING FOR A RESPONSE. THIS IS A DANGEROUS PROBLEM THAT NEEDS TO BE ADDRESSED IMMEDIATELY BEFORE SOMEONE IS HURT. HAD THE CONTROL ARM BROKE WHILE DRIVING DOEN THE ROAD AT ANY RATE OF SPEED THE RESULTS COULD BE CATASTROPHIC OR EVEN FATAL.

CSPC: THE WELD THAT CONNECTS THE MAIN PART OF THE RACK TO THE PORTION THAT ENTERS THE HITCH CRACKED, RESULTING IN THE BIKES DRAGGING IN THE ROAD UNTIL WE COULD PULL OVER. THE RACK THEN SNAPPED OFF COMPLETELY. AT THE TIME, WE HAD THREE BIKES WORTH ABOUT $2,500 EACH ON THE RACK, AND MORE SERIOUSLY, THIS COULD HAVE CAUSED A CATASTROPHIC ACCIDENT HAD THE RACK SNAPPED OFF WITH ANOTHER CAR DIRECTLY BEHIND US. *DT *JS *B F *CN *JS *TR

The contact owns a 2004 Subaru Forester. The contact stated that while driving an undisclosed speed, the brake pedal was depressed and extended to the floor, causing the braking distance to be extended. The vehicle was towed to the local dealer who discovered that the brake hoses had failed due to rusting and corrosion of the brake lines. The contact was also informed that the entire subframe had sustained extensive rust and corrosion damage. The vehicle was not repaired. The failure mileage was 28,000.

HAVING SEEN THE COMPLAINTS FROM OTHER USERS REGARDING THE RELIABILITY OF AIRBAG DEPLOYMENT IN THIS MODEL VEHICLE. RELEVANT TO LET THE PROPER AUTHORITIES KNOW OF A ROLLOVER ACCIDENT IN WHICH NO AIRBAGS (NOR FRONT NOR SIDE) DEPLOYED WITH A RESULTING FATALITY. *TR

WHILE RUNNING THE BLOWER MOTOR ON HIGH, THE CABIN BEGAN TO FILL WITH TOXIC SMOKE. THE BLOWER'S HOT WIRE CONNECTION HAD OVERHEATED, CHARRED/MELTED THE PLASTIC HOUSING AROUND THE TERMINAL, CHARRED/MELTED THE WIRES INSULATION AT THIS CONNECTION, AND MELTED THE COPPER UNTIL IT FELL LOOSE. THE BLOWER RESIDES EXPOSED UNDER THE GLOVE COMPARTMENT. NO EASILY COMBUSTIBLE MATERIALS WERE LOCATED UNDERNEATH THE BLOWER AT THAT TIME. *TR

IN VERY COLD WEATHER (LESS THAN 10 F) THE RUBBER GAS LINES LEAK VERY SIGNIFICANT AMOUNTS OF GAS ONTO THE ENGINE AND VERYNEAR THE HOT TURBOCHARGER. ANOTHER SUBARU JUST CAUGHT FIRE IN THE O'NEILL TUNNEL. HTTP://BOSTON.CBSLOCAL.COM/2014/01/27/CAR-FIRE-CAUSES-BACKUP-IN-ONEILL-TUNNEL/ *TR

OUR 2004 MODEL, MANUAL GEAR-BOX SUBARU FORESTER 2.5 X STALLS FAR TOO EASILY IN FIRST GEAR. RECENTLY, MY WIFE NARROWLY ESCAPED A HORRENDOUS ACCIDENT WHEN THE FORESTER'S ENGINE STALLED ON A BUSY HIGHWAY TRYING TO ACCELERATE ONTO THE HIGHWAY FROM THE SIDE ROAD WHICH SHE HAS TO USE TO ACCESS THE HIGHWAY FROM HER PLACE OF WORK. WE HAVE SPOKEN TO OTHER MANUAL GEAR-BOX SUBARU OWNERS, INCLUDING THE SUBARU WRX AND LIBERTY, WHO HAVE TOLD US THAT THEY EXPERIENCE THE SAME PROBLEM. WE BELIEVE THAT THIS MAY BE A FUNDAMENTAL DESIGN ISSUE AFFECTING MOST RECENTLY BUILT MANUAL GEAR BOX SUBARU PASSENGER VEHICLES, BUILT BY SUBARU AT THEIR MAIN FACTORY IN JAPAN, AND DISTRIBUTED GLOBALLY, INCLUDING BUT NOT LIMITED TO THE USA. *TR

THE VEHICLE GENERATED EXCESSIVE STATIC SHOCK. *NM THE ACCELERATOR BECAME STUCK. THERE WERE TIMES WHEN THE VEHICLE WOULD GO NO MORE THAN 15- 20 MPH. *JB

HOOD LATCH RELEASED WHILE DRIVING ON INTERSTATE AT 65 MPH. OCCURRED TWICE IN LESS THAN 30 MINUTES. THIS OCCURRED WHEN COMING OFF A BRIDGE AND THE ROAD BUMP CAUSED THE HOOD TO POP UP ONE INCH. THE SECONDARY LATCH CONTINUED TO OPERATE, BUT THIS COULD CAUSE A CATASTROPHIC FAILURE OF THE HOOD.*AK

1. NO FAILURE YET. CENTER, REAR PASSENGER, ROOF MOUNTED, SEATBELT IS CURRENTLY NOT BEING USED ON A 2004 SUBARU FORESTER X. 2. 10LB TUG ON THE CENTER, REAR PASSENGER, ROOF MOUNTED, SEATBELT ON A 2004 SUBARU FORESTER X WILL CAUSE THE HEADLINER TO CAVE. FURTHER INSPECTION OF THE SEATBELT RETRACTOR UNIT FOUND THAT IT'S MOUNTED ON A THIN GAUGE METAL (BENDABLE) FLAP BOLTED TO THE ROOF WITH ONE BOLT. 3. NOTHING HAS BEEN YET. IT'S A NEW ITEM PROBLEM.

DT: CONTACT STATES HE HAS HAD TO CHANGE THE TIRES ON HIS VEHICLE ON 1-22-05. THE MILES ON THE VEHICLE WERE 14,394. THERE ARE NOW 21,000 MILES ON THE CAR AND HE HAS HAD TO CHANGE THE REAR CYLINDER ON THE CAR. THIS WAS COVERED BY THE EXTENDED WARRANTY. HE HAS CONTACTED THE DEALER. HE HAS ALSO TALKED TO THE MANUFACTURER. ON 4-7-05 HE HAD TO CHANGE THE TIRES AGAIN AT 17,151. THE MANUFACTURER WAS RUDE TO HIM AND SAID HE HAD WAITED A LONG TIME TO COMPLAIN ABOUT THE TIRES. *NM

THERE IS TEAR BETWEEN THE TREAD AND SIDEWALL ON THE RIGHT REAR SIDE TIRE, WHICH IS CAUSING THE CONSUMER TO NOT MAINTAIN EASY CONTROL WHEN BEING DRIVEN. MANUFACTURER WAS CONTACTED BY OWNER. *JB *NM

MY 2004 FORESTER 2.5XT SUSTAINED A SIGNIFICANT MOTOR VEHICLE ACCIDENT ON 10/25/11 DAMAGING THE FRONT & REAR END AT A REPAIR COST APPROACHING 9K. MY SEAT BELT FAILED TO HOLD ME IN PLACE -- NO OTHER VEHICLE OCCUPANTS. SUBARU CORP IN NJ, USA WAS NOTIFIED. I BELIEVE THE 'EMERGENCY LOCKING RETRACTOR' (ELR) FAILED TO OPERATE AS INTENDED; MY CHEST SLAMMED AGAINST THE STEERING WHEEL TWICE WHEN I WAS HIT IN THE REAR AND WHEN I SUBSEQUENTLY HIT THE VEHICLE IN FRONT. THIS HAPPENED AT A TRAFFIC LIGHT AND 10MPH WAS ESTIMATED WHEN TRAVELING FROM A STOPPED POSITION INTO THE VAN IN FRONT. I WAS INJURED WITH A BLACK & BLUE MARK ON MY CHEST WITH SOME DISCOMFORT FOR 2 WEEKS. MY BODY BENT AT THE WAIST AND MY NECK WAS NOT EFFECTED. A POLICE REPORT WAS FILED. THE CABIN AREA WHERE THE SEAT BELT ASSEMBLIES ARE LOCATED WERE NOT DAMAGED BY THE CRASH. WITHIN 1 WEEK SUBARU REQUESTED INFORMATION FROM ME AND RESOLVED THE CASE. I APPRECIATE THE COMPANY'S QUICK RESPONSE, BUT I AM NOT SATISFIED WITH THE RESOLUTION. I REQUESTED THAT THE SEAT BELTS BE EVALUATED BY SUBARU EXPERTS ALONG WITH OTHER ASSOCIATED SAFETY COMPONENTS, AND TO HAVE MY SEAT BELT (AT A MINIMUM) REPLACED BY MY LOCAL DEALERSHIP AT NO COST TO ME. MANUAL STATES TO REPLACE THE SEAT BELT IF IN AN ACCIDENT. THE COMPANY RESPONDED BY SAYING THAT BECAUSE THE VEHICLE WAS IN AN ACCIDENT, THAT SUBARU CORPORATION WILL NOT DO ANYTHING, WILL NOT INSPECT THE VEHICLE AND WILL NOT PAY FOR NEW SEAT BELTS. THE COMPANY ALSO DID NOT REQUEST ANY PHOTOS FROM THE COLLISION REPAIR FACILITY TO VALIDATE THAT THE SEAT BELTS WERE NOT PHYSICALLY ALTERED BY THE IMPACT. IT WAS THE CRASH THAT REVEALED THAT THE SEAT BELTS DID NOT OPERATE AS THEY WERE SUPPOSED TO, TO HOLD ME BACK IN MY SEAT. BECAUSE I CONTACTED SUBARU CORP WITH NO VISUAL DAMAGE TO MY SEAT BELT, THE INSURANCE COMPANY WILL NOT REPLACE THE SEAT BELT. MY COST IS OVER $500. *TR

FAILED RECALL ON 2004 SUBARU FORESTER XT FRONT LOWER CONTROL ARMS. THE FRONT LOWER CONTROL ARM ON THE PASSENGER SIDE OF MY FORESTER RUSTED IN HALF. WHEN BACKING OUT OF A FLAT CONCRETE DRIVEWAY ONTO A CITY STREET, AS I BEGAN TO TURN THE WHEEL I HEARD/FELT A POP IN THE FRONT END. AS I BEGAN TO STRAIGHTEN THE WHEEL IT STARTED MAKING A GRINDING NOISE AND I NOTICED THE STEERING FELT FUNNY/LOOSE. BEFORE FOING ANY FURTHER I PULLED THE CAR STRAIT BACK INTO THE DRIVEWAY TO INSPECT THE PROBLEM. WHILE I WAS JACKING THE CAR UP I NOTICED IMMEDIATELY THE FRONT PASSENGER WHEEL APPEAR TO GO LIMP AND SLOPPY. AFTER CRAWLING UNDERNEATH TO CHECK I FOUND THAT THE CONTROL ARM HAD COMPLETELY BROKE/RUSTED IN HALF. A FEW WEEKS EARLIER I NOTICED THE FRONT CONTROL ARMS ON BOTH SIDES WERE QUITE RUSTED. AFTER A LITTLE RESEARCH I FOUND THAT SUBARU HAD A RECALL ON THE CONTROL ARMS AND WOULD EITHER REPLACE THEN OR RE COAT THEM. I THEN CONTACTED A LOCAL DEALER ABOUT THE RECALL. AFTER RUNNING MY VIN THE TOLD ME THAT MY VEHICLE HAD ALREADY BEEN SERVICED FOR THAT RECALL IN 2012 AND THAT MY CONTROL ARMS WERE UNDER COATED AND THEREFORE WERE NOT COVERED FOR REPLACEMENT. SO NOW AFTER MY CONTROL ARM IS COMPLETELY BROKEN I CONTACTED THE SAME DEALER AGAIN AND WAS TOLD TO TRY CONTACTING SUBARU OF AMERICA BUT THAT THEY COULD DO NOTHING. I THEN CONTACTED SUBARU OF AMERICA AND AFTER GIVING THEM ALL MY INFORMATION WAS TOLD AGAIN THAT MY VEHICLE HAD ALREADY BEEN SERVICED FOR THE RECALL AND WAS NOT COVERED, BUT IF I TOOK IT TO A DEALER THEY WOULD "LOOK AT IT". I THEN CONTACTED ANOTHER LOCAL DEALER AND I WAS ABLE TO TRAILER IT THERE MYSELF. I AM WAITING FOR A RESPONSE. THIS IS A DANGEROUS PROBLEM THAT NEEDS TO BE ADDRESSED IMMEDIATELY BEFORE SOMEONE IS HURT. HAD THE CONTROL ARM BROKE WHILE DRIVING DOEN THE ROAD AT ANY RATE OF SPEED THE RESULTS COULD BE CATASTROPHIC OR EVEN FATAL.

SUBARU REFUSES TO MAKE WINTER BLADES FOR THE REAR WIPER BLADE ON 2004-2008 SUBARU FORESTERS. THIS RESULTS IN REAR WIPER BLADES THAT ICE UP AND CANNOT EFFECTIVELY WIPE THE REAR WINDOW IN ICE OR SNOW. REAR VISION IS BLOCKED. THIS SUMMER BLADE FAILURE HAS OCCURRED MORE TIMES THAN I CAN COUNT. STOPPING ALONG SIDE A HIGHWAY TO CLEAN THEM OFF CAN BE A SAFETY HAZARD. I HAVE CONTACTED SUBARU SEVERAL TIMES ON THIS SINCE 2004. ALL THEY SAY IS THAT THEY WILL TALK ABOUT IT. CAN YOU MAKE THEM MANUFACTURE A WINTER BLADE? *TR