2002 Subaru Outback Brakes Problems

I BOUGHT CAR OCT 6; FIRST INSPECTION APPOINTMENT AT MY USUAL GARAGE MON OCT 12- FAILED DUE TO RUSTY SUSPECT BRAKE CONNECTION. SELLER HAD ME TAKE TO HIS DEALER- MASTRIA SUBARU IN RAYNHAM. THEY PUT A PAINT/COATING OVER RUSTY AREA. I WAS PRETTY SKEPTICAL BUT BROUGHT CAR TO MY GARAGE IN VT MONDAY OCT 19 AND THE LEAKY BRAKE FLUID MUCH MORE CLEARLY VISIBLE- DUE TO SMOOTHER (THOUGH BUMPY FROM OXIDATION BELOW) PAINT SURFACE. I ALSO SAW LEAKING COOLANT, LEAKS IN OIL PAN, AND A CRACK IN MUFFLER PIPE JUST ENGINE SIDE OF MUFFLER (IT HAD BEEN GETTING NOISIER AND NOISIER) MY MECHANIC POINTED OUT THE TIMING BELT GASKET WAS MISSING AND ONE BOLT 'MISSING' ; IT WAS STICKING OUT OF ANOTHER 'HOLE' THAT WAS FOR A FULLY THREADED BOLT. THE SELLER HAS SENT LONG-WINDED INSULTING E-MAILS AND STATES I MUST RETURN CAR TO HIM TO HAVE THE SAME DEALER SERVICE IT. I AM TAKING IT TO A&M, 400 MYSTIC AVE, SOMERVILLE THIS MORNING NEAR ME! FOR ESTIMATE TODAY. THERE'S A REJECT STICKER FROM READING PETROLEUM ON IT- I DIDN'T KNOW MA & VT HAD RECIPROCAL STATUS- BUT I THINK THE VT INSPECTION IS MORE STRINGENT, SAFER AND COMPREHENSIVE

NHTSA ID

10783939

Incident

Oct 6, 2015

Mileage

141,682 mi

TL* THE CONTACT OWNS A 2002 SUBARU OUTBACK. THE CONTACT STATED THAT THE BRAKES WOULD NOT RELEASE AFTER BEING APPLIED, EVEN WHEN THE CONTACT'S FOOT WAS NO LONGER ON THE BRAKE PEDAL. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 120,000. THE CURRENT MILEAGE WAS 135,000.

NHTSA ID

10564798

Incident

Feb 17, 2013

Mileage

120,000 mi

DATES ARE APPROXIMATE, PROBLEM IS ONGOING. UPON INITIAL START-UP, IN COOL/COLD WEATHER THE BRAKE PEDAL WILL BE VERY HARD AND BRAKES ARE VERY WEAK REQUIRING TREMENDOUS FOOT PRESSURE WITH STILL REDUCED BRAKING EFFECTIVENESS. AFTER A PERIOD OF TIME AND MULTIPLE STOPS BRAKE ASSIST SEEMS TO INCREASE AND THE BRAKES GET STRONGER OR NORMAL. I HAVE RESEARCHED THAT THIS IS NOT AN UNCOMMON PROBLEM WITH SUBARU CARS AT HIGHER MILEAGE. IT IS SAID TO BE WATER IN THE BRAKE BOOSTER HOSE ONE WAY VALVE. CHANGING THE HOSE, I AM TOLD, WILL NOT SOLVE THIS PROBLEM AS MORE WATER WILL ENTER THE SYSTEM AND FREEZE OR GUM PU THE WORKS. VERY DANGEROUS ESPECIALLY FOR DRIVERS WHO DO NOT HAVE THE STRENGTH TO PRESS SO HARD ON THE PEDAL. *TR

NHTSA ID

10564698

Incident

Feb 1, 2012

Mileage

150,000 mi

BRAKES BRIEFLY FAIL IN FREEZING COLD WEATHER CONDITIONS. 5 OR 10 HARD PUMPS HAVE USUALLY BROUGHT THEM BACK. VERY DANGEROUS IF YOU ARE NOT EXPECTING IT. I NEVER LEAVE MY DRIVEWAY OR PARKING SPACE WITHOUT REPEATED PUMPING TO GET THEM WORKING AGAIN. WE ARE SKI INSTRUCTORS (AND THIS CAR IS MARKETED FOR THAT) BUT ITS QUITE DANGEROUS IN FREEZING WEATHER. *TR

NHTSA ID

10327072

Incident

Nov 25, 2009

Mileage

77,000 mi

REPETITIVE FAILURE OF BOTH FRONT BRAKE ROTORS. ROTORS HAVE THICKNESS VARIATION WHICH CAUSES HEAVY BRAKE PULSATION AND STEERING WHEEL JUDDER FROM SIDE TO SIDE WHEN BRAKING FROM GREATER THAN 45 MPH. FIRST COMPLAINT 6/18/03 9971 MILES FRONT ROTORS WERE RESURFACED. SECOND COMPLAINT 5/3/04 16180 MILES RESURFACE FRONT ROTORS. THIRD COMPLAINT 4/7/05 23013 MILES RESURFACE FRONT ROTORS REPLACE FRONT BRAKE PADS. FOURTH COMPLAINT 5/20/08 42147 MILES REPLACE FRONT ROTORS AND FRONT BRAKE PADS. FIFTH COMPLAINT 3/17/09 49719 MILES RESURFACE FRONT ROTORS. SUBRAU DOES HAVE A CUSTOMER PAY UPGRADE IN THEIR TSB #: 06-33-04 DATE: 01/15/04 FOR 2001-2003 SUBARU VEHICLES TO MODIFY THE DISC BRAKE PAD. *TR

NHTSA ID

10269832

Incident

Mar 17, 2009

Mileage

9,971 mi

MY 2002 SUBARU OUTBACK HAD FRONT ROTOR FAILURE IN 2007-----THE FINS THAT HOLD THE ROTORS TOGETHER RUSTED AND BROKE. WHEN YOU CHECKED THE ROTOR THICKNESS WITH A MICROMETER IT WAS FINE BUT WHEN YOU APPLIED BRAKES THE PRESSURE SQUEEZED THE SURFACES TOGETHER AND MADE IT FEEL LIKE THE ROTORS WERE WARPED---ALSO UNDETECTABLE BY RUNOUT GAGE. *TR

NHTSA ID

10254934

Incident

Jun 28, 2007

Mileage

65,000 mi

IN COLD WEATHER THE BRAKES DO NOT FUNCTION WHEN THE CAR IS FIRST TURNED ON. THIS IS TERRIFYING. THIS HAS HAPPENED SEVERAL TIMES AND BEEN CONFIRMED BY A SECOND DRIVER. AFTER ABOUT A MINUTE THE BRAKES SEEM TO BE NORMAL. WE ARE NOW AFRAID TO USE THE CAR. *JB

NHTSA ID

10184128

Incident

Feb 25, 2007

Mileage

42,500 mi

OUR 2002 SUBARU OUTBACK EDDIE BAUER EDITION HAS EXPERIENCED A CONSISTENT BRAKE FAILURE THE FIRST THING IN THE MORNING ON DAYS WHERE THE OUTSIDE TEMPERATURE IS AT OR BELOW 45 DEG F. THE FAILURE IS REPEATABLE AS FOLLOWS: AFTER STARTING THE VEHICLE WITH FOOT ON THE BRAKE, THE CAR INITIALLY SEEMS OKAY WITH NORMAL BRAKE PEDAL FEEL (SOFT BUT NOT STIFF) - IN ABOUT THE TIME IT TAKES TO PUT THE CAR INTO REVERSE THE BRAKE PETAL STOPS RESPONDING AND BECOMES VERY STIFF. ALSO, BRAKE ASSIST DISAPPEARS AND IT BECOMES VERY DIFFICULT (ALMOST IMPOSSIBLE) TO STOP THE VEHICLE, EVEN ON THE SLIGHT DOWNGRADE OF OUR DRIVEWAY. - UNDER THE FORCE OF GRAVITY, IT IS POSSIBLE FOR THE CAR TO DRIFT BACKWARD INTO ONCOMING TRAFFIC, OR ANYTHING ELSE THAT HAPPENS TO BE LOCATED BEHIND THE CAR SUCH AS PEDESTRIANS AND TRASHCANS, FOR EXAMPLE. NO ACCIDENTS OR NEAR-MISSES HAVE OCCURRED AS OF THE TIME OF THIS WRITING, BUT THIS IS NOT TO SAY THAT THEY COULD NOT HAVE OCCURRED UNDER NORMAL VEHICLE USE AND TRAFFIC CONDITIONS IN OUR AREA. THE CAR USUALLY COMES TO REST WITHIN 2 TO 3 SECONDS AFTER WHICH THE BRAKES SEEMS TO RECOVER TO NORMAL FUNCTION. - GOOD FUNCTIONALITY SEEMS TO CONTINUE AS LONG AS THE CAR HAS NOT BEEN SITTING IN THE COLD AND/OR AS LONG AS THE ENGINE COMPARTMENT IS WARM. THIS PROBLEM HAS BEEN BROUGHT UP TO TWO LOCAL SUBARU DEALERS WHO BOTH INDICATED THEY HAVE NEVER SEE THIS PROBLEM BEFORE. ALSO, ONE WAS ABLE TO REPLICATE THE PROBLEM. GIVEN THEIR EXPERT COMMENTARY AND PHYSICAL EVIDENCE IT IS SUSPECTED THAT THE CAR'S BEHAVIOR MIGHT CONSTITUTE AN EMERGING SAFETY FLAW TO THE VEHICLE'S BRAKING SYSTEM. SYSTEM WILL BE REPAIRED BY CONSUMER. CONSUMER HAS CONTACTED SUBARU CUSTOMER SUPPORT REGARDING THIS MATTER. THEY INDICATED THAT THIS WAS NOT AN OFFICIALLY KNOWN ISSUE PER THE LIST OF NHTSA RECALL ACTIONS; HENCE, THEY TOOK NO ACTION TO REMEDY/INVESTIGATE THE PROBLEM. SEE SUBARU CASE #: 936244 FOR DETAILS. SEE ALSO NHTSB COMPLAINT #: 10106583. *NM

NHTSA ID

10172846

Incident

Nov 7, 2006

Mileage

55,000 mi

FRONT BRAKE ROTORS ON MY 2002 OUTBACK 3.0 WAGON HAVE WARPED CAUSING SEVERE SHIMMY WHEN BRAKING AT HIGH SPEED. THEY WERE REPLACED AT ABOUT 30,000, AND THIS HAS HAPPENED AGAIN. MY OPINION AS A SCIENTIST IS THAT THE ROTORS ARE UNDER-ENGINEERED FOR THE SIZE/WEIGHT OF THE VEHICLE, AND THAT THIS IS A SAFETY ISSUE IN THAT CONTROL OF THE VEHICLE IS COMPRISED AT HIGH SPEED. MORE SPECIFICALLY, THE ROTORS DISTORT WITH A NORMAL AMOUNT OF BRAKING HEAT, AND THEN RETURN FLAT WHEN COMPLETELY COOLED, INDICATING DEFECTIVE METALLURGY IN THEIR COMPOSITION. *JB

NHTSA ID

10135429

Incident

Sep 6, 2005

2002 SUBARU OUTBACK, LL BEAN EDITION. BRAKES HAVE FAILED TO WORK ON SEVERAL DIFFERENT OCCASIONS WHEN OUTSIDE TEMPERATURE IS LESS THAN APPROX. 28 DEG F. THIS IS USUALLY FIRST THING IN THE MORNING WHEN LEAVING FOR WORK. CAR IS PARKED ON DRIVEWAY WITH A SLIGHT DOWNGRADE TO THE STREET, AND CAR HAS DRIFTED INTO DRIVEWAY ACROSS THE STREET BEFORE COMING TO A STOP. BRAKES ARE USUALLY FINE AFTER SEVERAL MINUTES OF DRIVING. *NM

NHTSA ID

10106583

Incident

Jan 18, 2005

Mileage

45,000 mi

MY 2002 SUBARU OUTBACK SPORT (BASED ON THE IMPREZZA) DISPLAYS THE SAME PROBLEM WITH THE ABS SYSTEM BEING INEFFECTIVE WHEN BRAKING OVER BUMPS AS THE 2002, 2003 WRXS CURRENTLY BEING INVESTIGATED BY ODI (PE03-029). THIS PROBLEM IS NOT JUST LIMITED TO THE WRX VEHICLE. THE PROBLEM IS CLEARLY DEMONSTRATED UNDER LIGHT TO MODERATE BRAKING EFFORT, IF THE VEHICLE ENCOUNTERS A SHARP BUMP (E.G. A RAISED PAVEMENT SECTION AT AN EXPANSION JOINT) WHILE THE BRAKES ARE APPLIED. NORMAL ABS FUNCTION WOULD MOMENTARILY EASE UP THE BRAKING PRESSURE ON THE FRONT WHEELS AS THEY BECOME UN-WEIGHTED ON THE BACK SIDE OF THE BUMP, SO THAT THEY DO NOT LOCK-UP. AFTER THE FRONT WHEELS ARE FULLY WEIGHTED AGAIN THE ABS SYSTEM WOULD ALLOW THE PREVIOUS BRAKING EFFORT TO BE RE-ESTABLISHED ALLOWING THE CAR TO STOP ALMOST NORMALLY. THUS THE BRAKING DISTANCE OF THE VEHICLE MIGHT BE EXTENDED BY THE LENGTH OF THE BUMP (PERHAPS 6 INCHES). THIS CORRECT BEHAVIOR IS EXHIBITED BY MY 1994 PROBE GT. IF I DRIVE MY SUBARU OVER THE SAME ROAD CONDITIONS, WHEN THE VEHICLE HITS A SHARP BUMP, THE ABS SYSTEM START FUNCTIONING AND CONTINUES FOR A SIGNIFICANT PERIOD OF TIME, EVEN AFTER PASSING OVER THE BUMP. THIS, IN ITSELF, SHOULD NOT BE A PROBLEM, BUT DURING THIS TIME THE BRAKING EFFICIENCY IS DRASTICALLY REDUCED. THIS TYPICALLY EXTENDS THE STOPPING DISTANCE OF THE SUBARU BY 10-30 FEET (WHEN STOPPING FROM 30MPH) OVER WHAT WOULD HAVE BEEN ACHIEVED IF THE BUMP HAD NOT OCCURRED. IF I IMMEDIATELY RELEASE THE BRAKE PEDDLE, AND THEN FULLY APPLY THE BRAKES THE CAR DOES STOP. SO THIS PROBLEM IS NOT ASSOCIATED WITH THE TIRES ABILITY TO GRIP THE ROAD, OR THE BRAKES ABILITY TO STOP THE ROTOR/DRUM. I BELIEVE IT TO BE A PROGRAMMING ERROR IN THE ECU. THIS PROBLEM IS REPEATABLE AND FULLY DEMONSTRABLE. I WOULD BE HAPPY TO SUPPLY FURTHER DETAILS TO HELP GET THIS ISSUE RESOLVED. *JB

NHTSA ID

10088344

Incident

Jan 31, 2002

Mileage

10 mi

THE DEALERSHIP REPLACED AT THE FRONT ROTORS AND PADS AT 9000 MILES. AT 17,000 MILES THE FRONT ROTORS AND PADS WERE REPLACED AGAIN, DUE TO CORROSION. *JB

NHTSA ID

10082039

Incident

Jul 15, 2004

BRAKES, COMPLETE BRAKE JOBS (ROTORS AND PADS REPLACEMENT) AT LOW MILEAGE. *JB

NHTSA ID

10062737

Incident

Nov 28, 2002

Mileage

14,000 mi

IN COLD SEVERE WEATHER BRAKES SHUTTER. RECALL 02V079000 WAS ISSUED; HOWEVER, THIS VEHICLE WAS NOT INCLUDED IN THE RECALL DUE TO VIN. *AK

NHTSA ID

10048173

Incident

Oct 20, 2003

Mileage

46,000 mi

2002 LLBEAN OUTBACK ROTOR & BRAKE PROBLEMS. 8/29/02 7,681 MILES--VIBRATION WHEN APPLIED BRAKES--DEALER RESURFACED FRONT ROTORS. 12/30/02 12,464 MILES---VIBRATION WHEN APPLIED BRAKES & SCRATCHY NOISE WHEN APPLIED BRAKES.---DEALER RESURFACED FRONT ROTORS AND REPLACED FRONT BRAKES (NO PAD LEFT). 6/4/03 20,309--VIBRATION WHEN APPLIED BRAKES. DEALER REPLACED FRONT ROTORS & FRONT BRAKES. 10/4/03 25,460--BROUGHT CAR IN FOR OIL CHANGE & DEALER INSPECTED BRAKES. FRONT ROTORS AND BRAKES NEEDED TO BE RESURFACED. DEALER RESURFACED. *JB

NHTSA ID

10041270

Incident

Aug 29, 2002

Mileage

7,681 mi

2002 SUBARU OUTBACK H6 AWD AUTOMATIC TRANSMISSION -- WARPED AND GLAZED FRONT ROTORS AT RELATIVELY LOW MILES (25,600), REQUIRING REPLACEMENT OF PADS AND TURNING OF ROTORS. -- DEALER INITIALLY CLAIMED WEAR AND TEAR ITEM, BUT AFTER REVIEWING SERVICE RECORD WITH SUBARU, OFFERED WARRANTY REPAIR. I HAD FREQUENTLY COMPLAINED OF A SHIMMY WHILE DRIVING AND RECENTLY BEGAN EXPERIENCING A STEERING WHEEL SHIMMY WHILE BRAKING (SINCE LAST TIRE ROTATION). THIS IS THE FIRST INDICATION FROM DEALER THAT THERE WAS ANY PROBLEM WITH THE BRAKES. CAR MOSTLY DRIVEN ON HIGHWAY WITH INFREQUENT BRAKING. *JB

NHTSA ID

10039099

Incident

Sep 18, 2003

EXPERIENCED VIBRATION WHEN APPLYING BRAKES. DEALER RECUT ROTORS FRONT & REAR AT APPROXIMATELY 13,000 MI. PROBLEM RECURRED AT APPROX 17,000 MILES. DEALER RECUT FRONT ROTORS.*AK

NHTSA ID

10032732

Incident

Aug 12, 2003

Mileage

13,000 mi

NHTSA# ON CERTAIN PASSENGER VEHICLES, THE BRAKE MASTER CYLINDERS MAY NOT FUNCTION PROPERLY IN AMBIENT TEMPERATURES BELOW FREEZING 32 DEGREES FAHRENHEIT AND LOWER. CONSUMER HAS THE SAME PROBLEM. HOWEVER THIS VEHICLE WAS NOT RECALLED DUE TO THE VIN. *AK

NHTSA ID

10026849

Incident

Jul 9, 2003

WHEN THE BRAKES WERE APPLIED, THERE WAS A VIBRATION. THE DEALER REPLACED THE DISC BRAKE. *JB

NHTSA ID

10020350

Mileage

3,000 mi

WHILE DRIVING 25 MPH ON A DIRT ROAD THE CONSUMERS VEHICLE BEGAN TO FISHTAIL. WHEN THE CONSUMER APPLIED THE BRAKES THEY DID NOT STOP THE VEHICLE AND THE STEERING FAILED. THE CONSUMER LOST CONTROL OF THE VEHICLE AND COLLIDED HEAD ON WITH A TREE. NEITHER THE FRONT DRIVER NOR PASSENGER AIR BAGS DEPLOYED. *NLM

NHTSA ID

10012508

Incident

Jan 21, 2003

WHILE DRIVING 25 MPH ON A DIRT ROAD THE CONSUMERS VEHICLE BEGAN TO FISHTAIL. WHEN THE CONSUMER APPLIED THE BRAKES THEY DID NOT STOP THE VEHICLE AND THE STEERING FAILED. THE CONSUMER LOST CONTROL OF THE VEHICLE AND COLLIDED HEAD ON WITH A TREE. NEITHER THE FRONT DRIVER NOR PASSENGER AIR BAGS DEPLOYED. *NLM

NHTSA ID

10012506

Incident

Jan 21, 2003

WHILE DRIVING 25 MPH ON A DIRT ROAD THE CONSUMERS VEHICLE BEGAN TO FISHTAIL. WHEN THE CONSUMER APPLIED THE BRAKES THEY DID NOT STOP THE VEHICLE AND THE STEERING FAILED. THE CONSUMER LOST CONTROL OF THE VEHICLE AND COLLIDED HEAD ON WITH A TREE. NEITHER THE FRONT DRIVER NOR PASSENGER AIR BAGS DEPLOYED. *NLM

NHTSA ID

10012503

Incident

Jan 21, 2003

THE VEHICLE STARTED TO FISH-TAIL, THE CONSUMER DEPRESSED THE BRAKES WITH FORCE AND DISCOVERED THE VEHICLE HAD NO BRAKES. *JB *TS

NHTSA ID

10012066

Incident

Jan 21, 2003

Mileage

8,094 mi

THE DEALER TOOK TOO LONG TO PEFORM RECALL #02V079000 REGARDING THE MASTER CYLINDER.*JB

NHTSA ID

10009124

Incident

Feb 18, 2003

WHEN THE BRAKE WAS APPLIED, THE VEHICLE EXPERIENCED EXTENDED STOPPING DISTANCE.*JB *TS

NHTSA ID

10008998

Mileage

10,000 mi