2004 Subaru Forester
Problems, recalls and owner-reported issues
Fuel/propulsion system is the leading concern among 219 owner complaints filed for this model year. This is the 9th highest complaint count among 26 Forester model years with reports.
Of the 2004 reports, 13 involved a crash and 4 involved a fire. 8 people were injured.
What owners report most often
Recalls and investigations
Suspension, front, control arm, lower armSep 6, 2011
SUBARU IS RECALLING CERTAIN MODEL YEAR 2002-2007 IMPREZA, MODEL YEAR 2003-2008 FORESTER, AND MODEL YEAR 2005-2006 SAAB 9-2X VEHICLES MANUFACTURED FROM SEPTEMBER 5, 2000 THROUGH NOVEMBER 26, 2007 ORIGINALLY SOLD, OR CURRENTLY REGISTERED IN, MASSACHUSETTS, MARYLAND, MICHIGAN, NEW HAMPSHIRE, NEW YORK, PENNSYLVANIA, VERMONT, WISCONSIN, CONNECTICUT, DELAWARE, IOWA, ILLINOIS, INDIANA, MAINE, MINNESOTA, MISSOURI, NEW JERSEY, OHIO, RHODE ISLAND, WEST VIRGINIA AND THE DISTRICT OF COLUMBIA. THE FRONT LOWER CONTROL ARMS MAY BREAK AT THE HANGER BRACKETS DUE TO CORROSION IF THE HANGER BRACKET IS EXPOSED TO SALTY AND HUMID ENVIRONMENTS SUCH AS ROADS CONTAINING SNOW MELTING AGENT.
A BROKEN CONTROL ARM CAN RESULT IN THE LOSS OF CONTROL OF THE VEHICLE, INCREASING THE RISK OF A CRASH.
SUBARU WILL HANDLE THEIR VEHICLES AND SAAB WILL HANDLE THEIRS. DEALERS WILL INSPECT THE DEGREE OF CORROSION OF THE FRONT LOWER CONTROL ARMS, AND WILL EITHER RUSTPROOF OR REPLACE THEM. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL IS EXPECTED TO BEGIN DURING DECEMBER 2011. OWNERS MAY CONTACT SUBARU AT 1-800-782-2783. OWNERS MAY CONTACT SAAB AT 1-800-955-9007.
Campaign 11V464000 on NHTSA.gov
Engine and engine coolingOct 1, 2004
ON CERTAIN PASSENGER AND SPORT UTILITY VEHICLES, THE COVER BOLTS FOR THE ENGINE OIL CONTROL VALVE MAY NOT BE SUFFICIENTLY TIGHTENED, ALLOWING OIL TO LEAK FROM AROUND THE COVER GASKET.
IF LEAKING OIL CONTACTS COMPONENTS OPERATING AT HIGH TEMPERATURES, A FIRE COULD RESULT IN THE ENGINE COMPARTMENT.
DEALERS WILL INSPECT AND RETIGHTEN THE OIL-FLOW CONTROL VALVE COVER BOLTS. THE RECALL BEGAN ON OCTOBER 8, 2004. OWNERS SHOULD CONTACT SUBARU AT 1-800-782-2783.
Campaign 04V473000 on NHTSA.gov
Representative owner complaints: fuel/propulsion system
63 reports, newest first. Show all
Fuel/propulsion system, Dec 13, 2013
I'VE OWNED MY 2004 SUBARU FOR 5 YEARS WITHOUT INCIDENT, BUT AS OF DECEMBER 2013, I'VE EXPERIENCED A STRONG FUEL SMELL BOTH INSIDE AND OUTSIDE OF THE CAR. THE SMELL IS OVERPOWERING WHILE CAR IS PARKED, BUT LESSENS WHILE MOVING. IT BEGAN AFTER THE FIRST BIG DROP IN TEMPERATURE (40 DEGREES TO 10 DEGREES), AND HAS PERSISTED FOR OVER A WEEK NOW. *TR
Fuel/propulsion system, Dec 10, 2013
DURING THE COLD WEATHER THERE IS AN VERY STRONG GAS SMELL IN THE CAR. I STARTED THE CAR AND LOOKED UNDER THE HOOD AND CAN SEE WHERE GAS IS LEAKING FROM THE FUEL SYSTEM. I BELIEVE IT LEAKS IN THE SAME SPOT THAT MANY OTHER PEOPLE HAVE REPORTED. *TR
Fuel/propulsion system, Nov 6, 2013
IT WAS SUMMER WHEN I FIRST NOTICE THE SMELL OF FUEL THROUGH MY VENTS AND I WAS DRIVING PASS AN GAS STATION (SHELL) SO I DIDN'T THINK MUCH NOT TILL THE NEXT MORNING AS I WARMED UP THE CAR I SMELLED PURE GASOLINE NEXT TO THE PASSENGER FENDER I THEN POP THE HOOD AND TRACED IT AND I WAS LEAD TO THE TURBO SIDE OF THE ENGINE SEEMS TO BE COMING FROM THE FUEL RAIL AREA UNSURE AS THE ENGINE WARMED UP THE SMELL FADED AWAY BUT NOW IT'S WINTER AND IT'S BAD I CAN SEE A BIG LOST IN FUEL CONSUMPTION FULL TANK DOESN'T LAST A WEEK IT'S DRIVEN TO AND FROM WORK AROUND 4 TO 12 MILES A DAY NEED HELP! *TR
Fuel/propulsion system, May 13, 2013
FOR A PERIOD OF APPROXIMATELY THREE WEEKS IN EARLY JANUARY 2013 MY WIFE, DAUGHTER AND I COULD SMELL WHAT CAN ONLY BE DESCRIBED AS RAW GASOLINE WHEN WE DROVE OUR 2004 SUBARU FORESTER XT. IT WOULD TYPICALLY TAKE LESS THAN 5 MINUTES AFTER WE STARTED THE ENGINE FOR THE SMELL OF GAS TO BECOME VERY STRONG, EVEN OVERWHELMING. ALTHOUGH IT COULD STILL BE SICKENING, THE PROBLEM WOULD IMPROVE SOMEWHAT AFTER WE DROVE THE CAR FOR A FEW MINUTES. AFTER WE CAREFULLY REFUELED THE CAR ON TWO OR THREE OCCASIONS WE CONCLUDED THAT THE ISSUE DEFINITELY HAD NOTHING TO DO WITH SPILLED FUEL OR THE FUEL CAP. WE WERE VERY CONCERNED THAT WHETHER OR NOT THE SITUATION LED TO A FIRE, WE WERE ALL BEING MADE VERY SICK BY THE PROBLEM. WE CONTACTED THE SUBARU DEALER WHERE WE HAVE OUR FORESTER SERVICED AND DROPPED OFF THE CAR FOR THEM TO TROUBLESHOOT. WE WERE QUICKLY CONTACTED AND TOLD THAT THE ISSUE WAS WITH THE FUEL SYSTEM AND THAT BECAUSE THE FUEL LINES RAN UNDER THE TURBOCHARGER THE REPAIR WOULD BE VERY EXPENSIVE (AND IT WAS). AFTER RESEARCHING THE ISSUE IT QUICKLY BECAME APPARENT THAT THIS IS A COMMON PROBLEM WITH NOT ONLY FORESTERS, BUT FOR OTHER SUBARU MODELS AS WELL. BEING THAT THIS IS (BY ANY STANDARD) A COMMON PROBLEM ARISING FROM THE DESIGN OF THE VEHICLE, THAT THERE IS NO OPTION BUT TO REPAIR THESE VEHICLES ON THREAT OF FIRE OR ILLNESS, THAT THE PROBLEM DOES NOT OCCUR DUE TO ANY KIND OF MISUSE OR NEGLECT, THERE SHOULD BE A RECALL MADE FOR ALL SUBARUS THAT EXPERIENCE LEAKING FUEL SYSTEMS (NOT JUST THE WRX). BECAUSE THE REPAIR IS SO EXPENSIVE, AND SO MANY OF THE AFFECTED VEHICLES LACK ANY WARRANTY COVERAGE TO PAY FOR THE REPAIR, I AM CONCERNED THERE ARE MANY OWNERS WHO WILL ATTEMPT THE REPAIR THEMSELVES OR HAVE THE WORK DONE BY TECHNICIANS WHO ARE NOT FAMILIAR WITH THE PROBLEM. IT IS MY SINCERE HOPE THAT A SAFETY RECALL IS MADE AND OWNERS ARE NOTIFIED BEFORE ANYONE IS HARMED. *TR
Fuel/propulsion system, Mar 15, 2013
NOTICED A STRONG SMELL OF GAS WHILE DRIVING MY 2004 FORESTER XS, CAUSING HEADACHES TO MYSELF AND PASSENGERS. I BROUGHT IT TO MY MECHANIC WHO SAID THAT THERE WAS RAW GAS POOLING ON THE MANIFOLD. HE SAID THAT HE HAS SEEN THIS MANY TIMES BEFORE - LEAKING FUEL LINES DUE TO THE COLD (IT WAS 12 DEGREES WHEN I FIRST NOTICED IT). HE NOTED THAT THIS WAS THE WORST LEAK HE HAS SEEN. LOOKING AT A $700 BILL. I HAVE SINCE READ MANY OTHER COMPLAINTS ON THIS ISSUE. WONDERING WHY THERE HAS NOT BEEN A RECALL FOR THIS OBVIOUS SAFETY ISSUE. *TR
Fuel/propulsion system, Feb 19, 2013
TL* THE CONTACT OWNS A 2004 SUBARU FORESTER. THE CONTACT STATED THAT THERE WAS AN OVERPOWERING GASOLINE FUEL SMELL INSIDE AND OUTSIDE OF THE VEHICLE. THE ODOR WOULD BECOME STRONGER WHEN THE CONTACT WAS OPERATING THE VEHICLE AT VARIOUS SPEEDS. THE VEHICLE HAD NOT BEEN DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 116,000.
Fuel/propulsion system, Feb 8, 2013
THIS IS IN A 2004 SUBARU FORESTER XT (TURBO). STRONG SMELL OF UNBURNED FUEL COMING FROM ENGINE COMPARTMENT AND FILLING PASSENGER COMPARTMENT UPON STARTUP. *TR
Engine, Fuel/propulsion system, Jan 28, 2013
THERE WAS A VERY STRONG GASOLINE SMELL INSIDE THE CAR (2004 SUBARU FORESTER XS) THAT HAPPENED IN COLD WEATHER DURING JANUARY 2012. IT HAPPENED AGAIN JUST RECENTLY IN JANUARY 2013. IT WAS SO STRONG IT MADE THE DRIVER AND PASSENGER HAVE A HEADACHE AND BECOME NAUSEOUS. MANY OTHER OWNERS HAVE REPORTED THE VERY SAME THING AND HAVE NOT BEEN SUCCESSFUL IN GETTING SUBARU TO AT LEAST INVESTIGATE. SUBARU HAS ISSUED A RECALL FOR THE WRX MODEL, BUT NOT FOR THE FORESTER. THIS IS A HEALTH AND SAFETY RISK THAT SHOULD BE TAKEN CARE OF BY SUBARU. *TR
Fuel/propulsion system, Jan 25, 2013
IN COLD TEMPERATURES, THERE IS A STRONG SMELL OF GASOLINE IN THE CABIN AND IN THE ENGINE COMPARTMENT. FUEL LEAKS IN COLD TEMPERATURES IS A RECURRENT PROBLEM WITH THIS MAKE/MODEL/YEAR AS EVIDENCE BY: SIMILAR COMPLAINTS IN SUBARU FORUMS. SIMILAR PROBLEMS IN RELATED MODELS. *TR
Fuel/propulsion system, Jan 20, 2013
IN COLD TEMPERATURES, THERE IS A STRONG SMELL OF GASOLINE IN THE CABIN AND IN THE ENGINE COMPARTMENT. FUEL IS LEAKING BUT THE DEALER WAS UNABLE TO LOCATE IT WHEN BROUGHT IN ON A WARMER DAY. FUEL LEAKS IN COLD TEMPERATURES IS A RECURRENT PROBLEM WITH THIS MAKE/MODEL/YEAR AS EVIDENCE BY: SIMILAR COMPLAINTS IN SUBARU FORUMS. SIMILAR PROBLEMS IN RELATED MODELS (SUBARU WRX) THIS IS A DANGER TO HEALTH AND SAFETY AND A RECALL SHOULD BE ISSUED. *TR
Fuel/propulsion system, Jan 15, 2013
TL* THE CONTACT OWNS A 2004 SUBARU FORESTER. THE CONTACT STATED THAT WHEN THE TEMPERATURE WAS BELOW 30 DEGREES, THERE WAS A STRONG GASOLINE SMELL INSIDE THE VEHICLE. THE CONTACT HAD NOT NOTICED A FUEL LEAK. THE VEHICLE WAS NOT TAKEN TO THE DEALER. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 101,000 AND THE CURRENT MILEAGE WAS 125,000
Fuel/propulsion system, Dec 20, 2012
TL* THE CONTACT OWNS A 2004 SUBARU FORESTER. THE CONTACT STATED THAT HE COULD SMELL GASOLINE INSIDE THE CABIN OF THE VEHICLE WHEN DRIVING AT VARIOUS SPEEDS. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR INSPECTION AND WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED BUT PROVIDED NO ASSISTANCE. THE FAILURE MILEAGE WAS 107,000.
Engine, Fuel/propulsion system, Dec 20, 2012
STRONG FUEL ODOR INSIDE CABIN DEVELOPED WHEN OPERATING ON COLD MORNINGS; FUEL ODOR TYPICALLY WENT AWAY WITHIN 15 MINUTES OF STARTING THE CAR. INSPECTION OF FUEL LINES, FILTER, ETC. REVEALED NO OBVIOUS LEAKS ABOVE THE INTAKE MANIFOLD. DEALER QUOTED APPROXIMATELY $800 TO REMOVE INTAKE MANIFOLD AND INSPECT. I HAVE HAD TWO INDEPENDENT SHOPS ATTEMPT TO FIX THIS ISSUE OVER THE PAST 3 YEARS WITH VARYING DEGREES OF SUCCESS; THE MOST RECENT (2011) REMOVED THE INTAKE MANIFOLD AND REPLACED ALL RUBBER FUEL LINES UNDER THE MANIFOLD, BUT THE PROBLEM HAS RECURRED THIS FALL AND WINTER AND AT INCREASINGLY WARM TEMPERATURES. NOW, THERE IS A VISIBLE AND OBVIOUS LEAK FROM A FUEL LINE JUST AS IT GOES UNDER THE MANIFOLD--INACCESSIBLE WITHOUT REMOVING THE MANIFOLD. CLEARLY, THE PROBLEM IS WITH THE DESIGN OF THE METAL FUEL RAIL TO RUBBER LINE INTERFACE, SINCE THIS IS A COMMON PROBLEM IN FORESTER XTS ACROSS SEVERAL MODEL YEARS. SUBARU OF AMERICA ISSUED A RECALL FOR THIS PROBLEM ON THE WRX, BUT SO FAR HAS NOT ACKNOWLEDGED THE PROBLEM FOR THE FORESTER OR FORESTER XT. THIS IS A COSTLY REPAIR AND A HUGE SAFETY ISSUE: THE LEAKING FUEL DRIPS DIRECTLY ONTO THE ENGINE CYLINDER HEADS AND IN SOME CASES (ON PASSENGER-SIDE FUEL LINE LEAKS) IS IN CLOSE PROXIMITY TO THE TURBOCHARGER--REPRESENTING A SIGNIFICANT RISK OF ENGINE FIRE. THE FUEL FUMES IN THE CABIN ARE ALSO A HEALTH AND SAFETY RISK WHICH SHOULD BE DEALT WITH BY SUBARU. *TR