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
219 reports, newest first.
Steering, Suspension, Wheels, Mar 14, 2018
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.
Equipment, Other or unspecified, Feb 21, 2018
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
Fuel/propulsion system, Feb 8, 2018
LEAKING FUEL LINE UNDER MANIFOLD, FUEL SMELL VERY STRONG AND LEAKS INTO ENGINE BAY.
Fuel/propulsion system, Jan 4, 2018
GOT UP TO AND STARTED MY CAR TO GET IT WARMED UP SINCE IT WAS 8 F OUTSIDE. 20 MINUTES LATER WHEN I GOT INTO THE CAR THERE WAS A STRONG SMELL OF GAS. UPON INSPECTION OF THE ENGINE COMPARTMENT I FOUND THAT THERE WAS A FUEL LINE ON THE DRIVERS SIDE DRIPPING GASOLINE ONTO THE ENGINE BLOCK, WHERE IT WAS POOLING. WHILE SEARCHING ONLINE FOR INFO ON THIS, I FOUND THAT THIS IS A COMMON ISSUE WITH EARLY 2000'S SUBARUS, EVEN TO THE EXTENT THAT THEY RECALLED THE WRX MODELS FOR THIS EXACT REASON, BUT MADE NO MENTION OF THEIR OTHER MODELS.
Fuel/propulsion system, Dec 30, 2017
GAS SMELL COLD WEATHER CAR IDOLING
Fuel/propulsion system, Dec 12, 2017
JUST LIKE 60 OR SO OTHER 03-05 FORESTER XT OWNERS, I'M EXPERIENCING THE FUEL LEAK FROM THE RUBBER FUEL LINE WHERE IT CLAMPS ON TO THE METAL LINE TO THE FRONT DRIVERS SIDE INJECTOR. JUST LIKE EVERYONE ELSE, THE ISSUE ONLY OCCURRED WHEN TEMPERATURES DROPPED BELOW ABOUT 20F - UNCOINCIDENTALLY, IN MY OPINION, THIS WAS THE FIRST NEW ENGLAND WINTER THIS CAR HAD EVER SEEN. SUBARU HAS ISSUED A RECALL FOR WRX WITH THE SAME EXACT ISSUE INVOLVING THE SAME EXACT HARDWARE. GET ON IT SUBARU, THIS IS COMPLETELY UNACCEPTABLE AND AN EXTREMELY DANGEROUS DESIGN FLAW. YOU'VE ALREADY FESSED UP TO THE ISSUE WITH OTHER VEHICLES USING THE EJ255 NOW DON'T FORGET ABOUT US FOZZY OWNERS.
Fuel system, Gasoline, Engine, Nov 24, 2017
TL* THE CONTACT OWNS A 2004 SUBARU FORESTER. WHETHER THE VEHICLE WAS PARKED OR BEING DRIVEN, A FUEL ODOR WAS DETECTED IN AND OUTSIDE THE VEHICLE. THE FUEL ODOR WAS MOST NOTICEABLE WHILE OPERATING THE HEATER. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS TAKEN TO MID-HUDSON SUBARU (1715 U.S. 9, WAPPINGERS FALLS, NY 12590 (866) 678-2048) SEVERAL TIMES, BUT NO LEAKS OR FAILURES WERE DETECTED. THE CONTACT STATED THAT THE DEALER FINALLY DETECTED A FUEL ODOR AND DIAGNOSED THE FAILURE AS A MALFUNCTION WITH TUBING OR PIPING WITHIN THE ENGINE. THE PARTS NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED DUE TO THE COST. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND STATED THAT THEY WOULD CONTACT THE LOCAL DEALER. THE FAILURE MILEAGE WAS APPROXIMATELY 120,000. *TT *TR
Fuel/propulsion system, Sep 25, 2017
CAR HAS A STRONG GAS ODOR IN THE CAB WHEN TEMPERATURE DROPS TO 20 DEGREES AND BELOW. OCCURING ON COLD START AND CONTINUING IN MOTION ON LOCAL AND HIGHWAY DRIVING. AFTER A FEW UNSUCCESSFUL FIXES BY AUTHORIZED SUBARU SERVICE PROBLEM STILL EXISTS FOR THREE YEARS SOA NEEDS TO RECOGNISE THIS GAS LEAK FOR THIS MODEL AND YEAR AS A RECALL AND PERMINENT FIX PLEASE HELP
Other or unspecified, Aug 4, 2017
WHEN TEMPS DROP THERE IS A STRONG SMELL OF GAS IN THE CABIN, DOESN'T GO AWAY AND PEOPLE GET VERY SICK. IT DOESN'T MATTER IF IT'S IN MOTION, STOPPED, ANYWHERE, AND NOTHING CAUSES IT TO GO AWAY UNTIL WELL INTO SPRING TIME OR WARMER WEATHER.
Suspension, Jul 11, 2017
DRIVING APPR. 35MPH ON STATE HIGHWAY 6 IN EASTHAM, MA WHEN STEERING WHEEL WAS JERKED OUT OF MY HANDS, CAR ABRUPTLY MOVED TO THE RIGHT AND INTO GRANITE CURB BEFORE COMING TO A STOP. UPON EXITING CAR I FOUND RIGHT FRONT TIRE TURNED TO THE RIGHT WHILE OTHER TIRES WERE FACING FORWARD. RIGHT LOWER CONTROL ARM WAS BROKEN CAUSING CV AXLE TO BREAK AT INNER JOINT. THIS WAS A CROWDED HIGHWAY ON A SUMMER WEEKEND IN A RESORT AREA. I AM EXTREMELY FORTUNATE TO NOT HAVE BEEN INJURED OR CAUSED INJURY TO OTHERS. REPAIRS TOTALED $929.95
Power train, Other or unspecified, Service brakes, May 21, 2017
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?
Fuel/propulsion system, Mar 15, 2017
THERE IS A RAW GAS SMELL INSIDE THE CAR WHEN PARKED, OR STOPPED WHILE THE CAR IS RUNNING IN COLD WEATHER.
Engine, Fuel/propulsion system, Feb 3, 2017
FUEL LEAK IN LINES ABOVE ENGINE BUT BELOW INTAKE DURING COLDER WEATHER. FUEL FUMES PULLED INTO VEHICLE BY HEATING SYSTEM.
Fuel/propulsion system, Dec 28, 2016
THERE IS A TERRIBLE GAS SMELL DURING COLD WEATHER FROM SOME LEAK IN THE FUEL LINE. OTHER SUBARU MODELS HAVE BEEN RECALLED FOR THIS SAME PROBLEM, BUT NOT THE FORESTER. THE SMELL IS SO BAD THAT IT HAS GIVEN ME HEADACHES AND NAUSEA. THE SMELL IS PARTICULARLY AWFUL WHEN THE HEAT IS TURNED ON, WHICH IS PROBLEMATIC SINCE ONE WANTS THE HEAT ON WHEN IT'S THAT COLD OUT. SMELL PERSISTS AROUND THE CAR EVEN WHEN IT ISN'T RUNNING AND IS SO BAD I CAN'T PARK IT INSIDE MY ATTACHED GARAGE BECAUSE IT COMES INTO THE HOUSE. SUBARU REALLY NEEDS TO ADDRESS THIS. I HAVE MENTIONED IT TO MY MECHANIC SEVERAL TIMES AND THEY HAVE TRIED TO CORRECT IT BY TIGHTENING FUEL LINE CONNECTIONS, WHICH HAS NOT SOLVED THE ISSUE. THEY TOLD ME ABOUT THE OTHER MODELS BEING RECALLED, AND WHEN I RESEARCHED IT MYSELF I DISCOVERED THAT THERE ARE HUNDREDS (AT LEAST) OF SUBARU FORESTER OWNERS WHO HAVE COMPLAINED ABOUT THE SAME PROBLEM. THIS IS A HEALTH HAZARD. I DON'T THINK ANYONE SHOULD BE BREATHING THESE CONCENTRATED FUMES. SUBARU NEEDS TO DO A RECALL AND REPLACE THESE FAULTY LINES. THIS PROBLEM HAS BEEN ONGOING FOR AT LEAST THE PAST 2 YEARS/WINTERS. MY MOST RECENT VISIT TO THE MECHANIC (TO ADDRESS THE FUEL SMELL AGAIN) WAS DECEMBER 23, 2016.
Fuel/propulsion system, Dec 19, 2016
CAR LEAKS FUEL PROFUSELY FROM FUEL LINE NEAR ENGINE BLOCK WHEN RUNNING DURING COLD WEATHER TEMPERATURES BELOW 20 DEGREES FAHRENHEIT.
Other or unspecified, Fuel/propulsion system, Dec 19, 2016
IN VERY COLD WEATHER, THERE IS A STRONG GASOLINE SMELL INSIDE THE CAR THAT REMAINS AS THE CAR WARMS UP. THIS ONLY OCCURS WHEN TEMPERATURES ARE WELL BELOW FREEZING.
Fuel/propulsion system, Dec 16, 2016
FORESTERS HAVE A COMMON PROBLEM OF A VERY COMMON PROBLEM OF THE FUEL LINE LEAKING. THE COLD CAUSES SHRINK TO THE FUEL LINES CAUSING A LEAK INTO THE ENGINE AND FUEL VAPORS TO ENTER THE CABIN. THIS ISSUE OCCURS WHETHER IT'S STATIONARY OR IN MOTION AS WELL AS ALL OTHER CONCEIVABLE STATES THAT THE VEHICLE CAN BE IN. A RECALL WAS ISSUED FOR THE WRX, THE SAME SHOULD OCCUR WITH THE FORESTER. THIS ISSUE OCCURS EVERY WINTER WHEN THE TEMP DROPS BELOW 20 DEGREES.
Fuel/propulsion system, Dec 8, 2016
STRONG FUEL ODOR HAS BEEN ENTERING THE CABIN DURING STARTUP ON COLD MORNINGS. THIS IS CAUSED BY A FUEL LINE LEAKING ONTO THE ENGINE. THE LEAK CAN BE SEEN BUT IS INACCESSIBLE WITHOUT REMOVING THE INTAKE MANIFOLD. ONCE THE VEHICLE HEATS UP AND THE LINE EXPANDS THE LEAK STOPS. I AM VERY CONCERNED ABOUT THE POTENTIAL FOR A VEHICLE FIRE AND THE DANGER OF INHALING GASOLINE FLAMES. *TR
Engine, Fuel/propulsion system, Dec 7, 2016
TL* THE CONTACT OWNS A 2004 SUBARU FORESTER. WHEN THE VEHICLE WAS STARTED, A VERY STRONG FUEL ODOR EMERGED FROM THE ENGINE COMPARTMENT. THE FUEL TANK LEAKED FUEL ONTO THE MANIFOLD. THE FAILURE WAS DIAGNOSED BY AN INDEPENDENT MECHANIC AS A FUEL TANK LEAK. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 149,966.
Power train, Nov 16, 2016, fire
THE TURBOCHARGER BROKE TWICE IN THE 2D QUARTER 2015. SHORTLY AFTER THE SECOND TIME IT WAS FIXED, THE CAR CAUGHT FIRE OVER THE TURBOCHARGER UNIT (WHILE BEING DRIVEN 9/18/15), UNDER THE HOOD. NEW SUBARUS HAVE BEEN RECALLED FOR THIS REASON, BUT I THINK THE REPLACEMENT TURBOCHARGER WAS DEFECTIVE. THE SUBARU TURBO FP # WAS 14411AA5329L.
Engine, Oct 14, 2016, fire
TL* THE CONTACT OWNED A 2004 SUBARU FORESTER. WHILE DRIVING VARIOUS SPEEDS, THE RPMS BEGAN TO INCREASE AND THE VEHICLE OVERHEATED. THE VEHICLE WAS PULLED OVER TO THE SIDE OF THE ROAD AND CAUGHT FIRE FROM THE ENGINE COMPARTMENT. THE FIRE WAS EXTINGUISHED BY THE FIRE DEPARTMENT. THERE WERE NO INJURIES AND A POLICE REPORT WAS NOT FILED. THE VEHICLE WAS TOWED AND LATER DEEMED DESTROYED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 110,000.
Suspension, Aug 1, 2016
TL* THE CONTACT OWNS A 2004 SUBARU FORESTER. WHILE DRIVING 5 MPH MAKING A LEFT TURN, THE FRONT PASSENGER WHEEL TURNED IN THE OPPOSITE POSITION AND CAUSED THE VEHICLE TO STOP. THE VEHICLE WAS TOWED TO AN INDEPENDENT GARAGE LOT WHERE IT WAS DIAGNOSED THAT THE CONTROL ARM WAS CORRODED AND CAUSED BOTH LOWER CONTROL ARMS AND AXLE TO DETACH. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 11V464000 (SUSPENSION). THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 190,000.
Suspension, Jul 28, 2016
TL* THE CONTACT OWNS A 2004 SUBARU FORESTER. WHILE DRIVING APPROXIMATELY 40 MPH, AN UNUSUALLY LOUD NOISE EMITTED FROM THE FRONT END OF THE VEHICLE. THE FAILURE OCCURRED WHEN DRIVING VARIOUS SPEEDS. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT BOTH FRONT LOWER CONTROL ARMS EXHIBITED EXCESSIVE CORROSION; HOWEVER, THE REAR LOWER CONTROL ARMS WERE NOT AS SEVERELY DAMAGED. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 11V464000 (SUSPENSION). THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 75,000.
Air bags, May 7, 2016
TAKATA RECALL
Fuel/propulsion system, Jan 20, 2016
FUEL LINES SEEP FUEL ONTO THE TOP OF ENGINE BLOCK AND NEAR TURBO INLET AREA WHEN TEMPERATURES ARE BELOW ~20 DEGREES FAHRENHEIT. THE SEEPAGE OCCURS AT THE CLAMPS BETWEEN THE METAL AND GAS LINES BELOW THE INTAKE MANIFOLD. THESE CLAMPS ARE NOT ACCESSIBLE WITHOUT REMOVAL OF MANY PARTS BY A PROFESSIONAL MECHANIC. GAS FUMES FILL THE CABIN WHEN THIS OCCURS AS WELL. FUMES ARE NOT BAD WHEN MOVING BUT IF STOPPED AT A STOP SIGN OR AFTER STARTING THE VEHICLE THE FUMES ARE VERY STRONG. THIS HAS BEEN A KNOWN ISSUE WITH OTHER MODEL SUBARUS (2002 - 2003 SUBARU IMPREZA & IMPREZA WRX) THAT HAVE A VERY SIMILAR ENGINE CONFIGURATION BUT HAS NEVER BEEN ADDRESSED WITH THE SUBARU FORESTER. THE CONCERNS I HAVE ARE 1) FIRE HAZARD OF GAS POOLING ON TOP OF ENGINE BLOCK NEAR TURBO AND OTHER COMPONENTS 2) FUMES BUILDING UP IN THE PASSENGER CABIN.