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.
Fuel/propulsion system, Nov 5, 2014
FOR AS LONG AS I CAN REMEMBER, EVERY TIME THE WEATHER GETS BELOW 40 DEGREES OR SO, THE INTERIOR CABIN SMELLS LIKE RAW GASOLINE UPON STARTING THE CAR AND CONTINUING THROUGH SEVERAL MINUTES OF RUN TIME. *TR
Air bags, Aug 26, 2014
SINCE 2009 THE DRIVER SIDE AIRBAG LIGHT WILL STAY ON AFTER I HAVE STARTED THE CAR. IT WILL STAY ON FOR DAYS, WHETHER IT IS HOT SUMMER TIME OR COLD WINTER DAYS. IT MAY STAY ON FOR A FEW DAYS OR FOR MONTHS. THE LAST TIME WAS FROM JULY 19, 2014 TO AUGUST 25, 2014. THIS IS THE FIRST TIME THAT I HAVE REVIEWED THE LIST OF VEHICLE SAFETY COMPLAINTS. SEEING THE OTHER COMPLAINTS ABOUT THE AIRBAG LIGHT REMAINING ON ENCOURAGES ME TO SUBMIT MY HISTORY ALSO. WHEN IT HAS BEEN ON, I THINK I SHOULD TAKE IT TO THE DEALER BUT THEN IT GOES OFF BEFORE I CAN TAKE THE CAR IN TO THE DEALER. SEEING ALL THE COMPLAINTS I ALSO THINK SUBARU SHOULD BE RESPONSIVE TO THIS PROBLEM. *TR
Suspension, Aug 26, 2014
TL* THE CONTACT OWNS A 2004 SUBARU FORESTER. THE CONTACT STATED THAT WHILE REVERSING INTO A RESIDENTIAL THE DRIVEWAY, THE FRONT PASSENGERS SIDE LOWER CONTROL ARM FRACTURED. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC. THE TECHNICIAN DIAGNOSED THAT THE CONTROL ARM NEEDED TO BE REPLACED. THE CONTACT WAS MADE AWARE THAT THE VEHICLE WAS NOT INCLUDED IN RECALL NHTSA CAMPAIGN ID NUMBER: 11V464000 (SUSPENSION). THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 120,000.
Power train, Aug 11, 2014
I STARTED THE CAR, PUT MY FOOT ON THE BRAKE, AND ATTEMPTED TO MOVE IT INTO GEAR. IT WOULD NOT MOVE OUT OF PARK. THE RELEASE WAS BROKEN. EVENTUALLY I HAD TO CALL A TOW TRUCK BECAUSE I COULD NOT GET IT INTO GEAR. IT HAS BEEN TO JACK WILLIAMS TIRE IN CAMP HILL, PA 17011 3-4 TIMES SINCE THEN FOR THE SAME ISSUE. *TR
Air bags, Aug 1, 2014
THE AIRBAG LIGHT STAYS ILLUMINATED FOR WEEKS AT A TIME AND THEN WILL RANDOMLY TURN OFF. I HAVE TAKEN IT TO THE DEALER TWICE AND THEY COULD NOT IDENTIFY THE PROBLEM. I HAVE CONTINUOUSLY HAD THE PROBLEM OFF AND ON FOR THE PAST YEAR. I SEE SEVERAL PEOPLE HAVE HAD THE SAME PROBLEM WITH THIS MODEL AND YEAR SUBARU, THIS SHOULD BE TAKEN CARE OF BY SUBARU- [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
Electrical system, Jul 16, 2014
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
Air bags, Jul 8, 2014
THE DRIVER SIDE FRONT AIR BAG LIGHT HAS LIT UP ON THE DASHBOARD. IT STAYS ON EVERY TIME I START THE CAR AND DRIVE IT. I HAVE TAKEN IT TO THE LOCAL SUBARU DEALER IN ROCHESTER, MN (CLEMENTS). THEY SAY IT WILL COST $3000 TO INSTALL A BRAND NEW AIR BAG SYSTEM. I DISAGREE. THIS IS AN INHERENT , SERIOUS SAFETY FLAW IN THE CAR. IN MY OPINION, SUBARU SHOULD FIX IT FREE OF CHARGE. I HAVE NOT RECEIVED ANY SAFETY ADVISORY FROM SUBARU OF AMERICA. YOUR GUIDANCE WOULD BE APPRECIATED. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6) *JS
Engine, May 20, 2014
2004 SUBARU FORESTER XT HAD CATASTROPHIC ENGINE AND TURBO FAILURE WHILE DRIVING ON HIGHWAY. IT IS CLEAR THAT MY VEHICLE SUFFERED FROM SUBARU SERVICE CENTER NEGLIGENCE AND A DESIGN FLAW OF A BANJO BOLT THAT FILTERS OIL TO THE TURBO BUT EASILY GETS CLOGGED, SHUTTING OFF OIL TO THE TURBO, CAUSING OIL DEPRIVATION TO THE TURBO, BURNING OUT THE TURBO, AND CAUSING FRAGMENTS TO GET INTO THE ENGINE, BLOWING OUT THE ENGINE AS WELL. WHILE I WAS SPARED AN ACCIDENT AND INJURY, IT WAS A CLOSE CALL AS WHILE I WAS DRIVING I SUDDENLY HAD A FAILURE TO ACCELERATE, AND VERY NEARLY WAS PLOWED IN FROM BEHIND BY A LARGE TRACTOR TRAILER TRUCK. MY CAR NOW REQUIRES A COMPLETE REPLACEMENT OF ENGINE AND TURBO, COSTING IN EXCESS OF $7,000. I HAVE DECIDED TO SELL THE VEHICLE RATHER THAN BEARING THE HUGE EXPENSE REQUIRED TO REPAIR. THE ISSUE WITH THIS BANJO BOLT AND SUBARU TURBO / ENGINES OF THIS ERA ARE WELL DOCUMENTED ON THE INTERNET AUTOMOBILE FORUMS AND IN SOCIAL MEDIA. SUBARU SHOULD COMPENSATE OWNERS FOR DEVALUING THEIR CARS, AND SHOULD HAVE A RECALL BEFORE MORE DRIVERS ARE HARMED OR KILLED. *TR
Fuel system, Gasoline, May 9, 2014
VERY STRONG SMELL OF GAS IN CABIN. I HAVE 2 KIDS THAT I TAKE TO SCHOOL, AND IN THE MORNING I HAVE TO START MY CAR 20 MIN BEFORE WE LEAVE AND OPEN THE WINDOWS TO AIR IT OUT. THE GAS SMELL IS TOXIC, AND DANGEROUS. THIS IS THE A DESIGN FLAW THAT POSES SERIOUS RISK, AS IT IS BOTH A HEALTH AND A FIRE HAZARD. IT SEEMS JUST ABOUT EVERY FORESTER OWNER HAS THE SAME PROBLEMS AS WELL. SUBARU NEEDS TO EXPAND THE EXISTING IMPREZA / WRX RECALLS TO THE FORESTER, AS THE RELEVANT PARTS ARE THE SAME AND THE ISSUE IS VIRTUALLY IDENTICAL. PLEASE FIX THIS. *TR
Fuel system, Gasoline, Mar 24, 2014
EXTREMELY STRONG SMELL OF GAS IN CABIN IN COLD WEATHER. I DRIVE MY SMALL DAUGHTER TO DAYCARE EVERY DAY IN THAT CAR. THE GAS SMELL IS HORRIFIC, TOXIC, AND DANGEROUS. ALSO, THE CAUSE OF THAT GAS SMELL IS THE GAS LEAKAGE FROM THE RUBBER HOSE OF THE FUEL LINE ONTO HOT COMPONENST IN THE ENGINE COMPARTMENT. THIS IS A DESIGN FLAW THAT POSES SERIOUS RISK, AS IT IS BOTH A HEALTH AND A FIRE HAZARD. SUBARU NEEDS TO EXPAND THE EXISTING IMPREZA / WRX RECALLS TO FORESTER, AS THE RELEVANT PARTS ARE THE SAME AND THE ISSUE IS VIRTUALLY IDENTICAL. *TR
Air bags, Mar 19, 2014
MY CAR WAS PARKED. WHEN I GOT IN CAR AND TURNED KEY, THE PASSENGER SIDE AIRBAG DEPLOYED. CAR WAS NOT HIT OR IN ACCIDENT. *TR
Fuel system, Gasoline, Mar 13, 2014
WHEN WEATHER GOT COLDER THIS FALL AND WINTER SUDDENLY INTENSE SMELL OF FUEL IN CABIN. LOOKED UNDER HOOD, TIGHTENED WHATEVER FUEL CLAMPS I COULD REACH BUT MADE NO DIFFERENCE. EVERY DAY BELOW 40DEGREES POWERFUL SMELL OF RAW FUEL THROUGHOUT VEHICLE. THEN HAD TO TAKE TRIP INTO NEIGHBORING CITY, IN STOP AND GO TRAFFIC EVEN WITH WINDOWS FULL OPEN IN 15 DEGREE WEATHER FUMES GOT SO OVERWHELMING I HAD TO PULL OVER IN A PARKING LOT, ESCAPE THE CAR AND VOMIT. BACK HOME CALLED DEALER, THEY SAID THEY KNEW EXACTLY WHAT IT WAS. THEY TOLD ME IT WAS LEAKY FUEL HOSES AND CLAMPS UNDER INTAKE MANIFOLD AND QUOTED OVER $800 TO FIX AS THEY TOLD ME OTHER MODELS WERE COVERED BY RECALL BUT FORESTERS HAD "DODGED THE RECALL PROCESS" SO FAR. *TR
Fuel system, Gasoline, Feb 25, 2014
LEAKING FUEL WHEN COLD OUTSIDE, I CAN SEE FUEL DRIPPING FROM A FUEL LINE UNDER INTAKE MANIFOLD EVERY TIME I START MY CAR IN THE MORNING WHEN THE CAR IS COLD IN THE COLD WEATHER IN WINTER. *TR
Engine and engine cooling, Fuel system, Gasoline, Feb 16, 2014
I AM EXPERIENCING AN EXTREMELY STRONG SMELL OF GAS. THIS BEGAN WINTER OF 2013, WHICH I HAD REPAIRED AT MY EXPENSE OF $700+, THOUGH MY MECHANIC INFORMED ME SUBARU WAS RECALLING THIS AND REPAIRING FOR FREE ON OTHER MODELS. I AM ABSOLUTELY DISGUSTED THAT THIS PROBLEM IS RECURRING NOW WINTER OF 2014, IN A VEHICLE WHICH I DRIVE MY SMALL CHILDREN IN. THE GAS SMELL IS HORRIFIC, TOXIC, AND DANGEROUS. *TR
Fuel/propulsion system, Feb 13, 2014
THERE IS A PRONOUNCED, UNMISTAKABLE SMELL OF UNCOMBUSTED GASOLINE EMANATING FROM THE ENGINE COMPARTMENT AS SOON AS THE CAR IS STARTED ON COOL OR COLD MORNINGS. THE FUMES ENTER THE PASSENGER CABIN THROUGH THE VENTILATION SYSTEM. IT IS STRONG ENOUGH TO CAUSE HEADACHES AND REQUIRE LOWERING THE WINDOWS UNTIL IT DISSIPATES MINUTES LATER. THIS IS A WELL KNOWN, WELL DOCUMENTED PROBLEM ON THE INTERNET CAUSED BY DEFECTIVE FUEL LINES UNDER THE INTAKE MANIFOLD. GASOLINE IS LEAKING ONTO HOT ENGINE COMPONENTS. *TR
Fuel system, Gasoline, Feb 13, 2014
I'VE OWNED MY 2004 FORESTER FOR 4 YEARS NOW AND NEVER EXPERIENCED THIS PROBLEM. HOWEVER, THIS WINTER SEEMINGLY HAVING LONGER COLD SPELLS SEEMED TO INDUCE THE PROBLEM. THERE IS A STRONG FUEL SMELL IN THE VEHICLE, ESPECIALLY WHEN I TURN ON THE HEAT, WHICH IS A MAJOR ISSUE IN THE WINTER. I'VE READ A LITTLE ABOUT IT AND IT SEEMS MANY OTHER SUBARU OWNERS ARE HAVING THE SAME ISSUE. *TR
Fuel system, Gasoline, Engine, Feb 10, 2014
FUEL LINES CRACK IN COLD WEATHER (APPROX UNDER 25 AND UNDER). STRONG FUEL SMELL IN CABIN WAS ENOUGH TO MAKE PASSENGERS ILL, CAR WAS NOT DRIVABLE. FUEL WAS POOLING IN THE ENGINE BAY NEAR THE HOT TURBO AND EXHAUST SYSTEM. CONTACTED DEALERSHIP, SERVICE WRITER KNEW WHAT THE ISSUE WAS AS SOON AS I TOLD HIM MAKE, MODEL AND YEAR - SAID IT'S VERY COMMON. FOUND PAGES OF COMPLAINTS ON NHTSA SITE AND HUNDREDS IN FORUMS. SUBARU ISSUED A RECALL FOR THE SAME ISSUE ON THE 2003 GENERATION WRX VEHICLES, BUT NOT THE FORESTERS. THIS IS A MAJOR PROBLEMS. SUBARU'S ARE PURCHASED AS IDEAL SNOW VEHICLE, AND REPAIRS COST UPWARD OF $600. THIS IS A DIRECT SAFETY ISSUE. *TR
Fuel/propulsion system, Feb 8, 2014
UPON START UP IN COLD WEATHER (BELOW FREEZING), THERE IS A STRONG SMELL OF RAW FUEL IN THE CABIN. AT TIMES IT IS UNBEARABLE NECESSITATING ROLLING DOWN THE WINDOWS, EVEN IN SUB-FREEZING TEMPERATURES. IT LOOKS LIKE FUEL IS LEAKING FROM SOMEWHERE IN THE ENGINE BAY. IT HAS HAPPENED REPEATEDLY AND I WORRY THE FUMES ARE DANGEROUS FOR NOT ONLY PASSENGERS' HEALTH, BUT ALSO IN CASE OF AN ACCIDENT. *TR
Fuel system, Gasoline, Feb 4, 2014
UPON STARTING CAR IN COLD WEATHER (APPROX. 25 DEGREES F OR COLDER), THERE IS A STRONG FUEL SMELL. CANNOT TURN HEAT ON AS FUEL SMELL FILLS CABIN AND MAKES PASSENGERS NAUSEOUS. HEADACHES HAVE ALSO OCCURRED. WHEN VEHICLE IS PARKED IN GARAGE AFTER DRIVING IN COLD WEATHER, FUMES ACCUMULATE IN GARBAGE AND LEAK INTO HOUSE AS WELL. APPARENTLY FUEL LINES SHRINK IN COLD AND LEAK FUEL DIRECTLY ONTO ENGINE. THIS IS BOTH HEALTH AND FIRE HAZARD. *TR
Fuel system, Gasoline, Engine, Jan 31, 2014
VERY STRONG FUEL SMELL IN THE CAR WITH HEATER ON SO STRONG HAVE TO ROLL WINDOW DOWN. HAPPENS 2 TO 3 TIMES A WEEK ON COLD DAYS. STRONGEST WHEN ITS A COLD START. *TR
Power train, Electrical system, Engine, Jan 30, 2014
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
Engine and engine cooling, Fuel system, Gasoline, Jan 30, 2014
IN COLD WEATHER (BELOW 20 DEGREES OR SO) THE FUEL LINES IN THE ENGINE COMPARTMENT COME LOOSE AND LEAK RAW GASOLINE ONTO THE HOT ENGINE. OBVIOUSLY THERE IS A GOOD CHANCE OF AN ENGINE FIRE WITH POSSIBLE LOSS OF LIFE. THIS HAS BEEN REPORTED IN SEVERAL FORUMS, THERE IS A TSB OUT ON THIS FOR THE WRX (SAME ENGINE, SAME PART NUMBERS), AND MOST DEALERS (IN COLD STATES) KNOW OF THIS PROBLEM. *TR
Fuel system, Gasoline, Engine, Jan 28, 2014
ON VERY COLD DAYS WHILE CAR IS WARMING UP, A STRONG SMELL OF FUEL IS COMING FROM UNDER THE INTAKE MANIFOLD. A CLOSER INSPECTION REVEALS A SMALL FUEL LEAK FROM THE FUEL SUPPLY LINES NEAR THE TURBO. A SUBARU IMPREZA ENTHUSIAST FORUM HAS A "RAW FUEL SMELL" LOG OF MORE THAN 131 PAGES AND 3,000 POSTS (HTTP://FORUMS.NASIOC.COM/FORUMS/SHOWTHREAD.PHP?T=131755). SUBARU ISSUED A TECHNICAL SERVICE BULLETIN (TSB) FOR CERTAIN SUBARU IMPREZAS, BUT THEY HAVE NOT INITIATED ANY TSBS FOR ANY OTHER CARS ALL USING THE SAME OR SIMILAR ENGINES. SEE TSB 01-170-09. AS LEAKING FUEL ONTO YOUR ENGINE IS A SAFETY HAZARD, I WOULD LIKE TO SEE SUBARU INITIATE SOME KIND OF TSB OR RECALL FOR ALL ENGINES EXPERIENCING THIS PROBLEM. I UNDERSTAND MANY SUBARU OWNERS HAVE COMPLAINED TO SUBARU AND NHTSA WITH NO RESULTS. *TR
Engine and engine cooling, Fuel system, Gasoline, Jan 24, 2014
FUEL AND EXHAUST LINE LEAKS IN COLD WEATHER. OVER THE INITIAL THREE DAY PERIOD - DAY ONE CHILDREN COMPLAINED OF HEADACHES, DAY TWO DRIVER EXPERIENCED SEVERE HEADACHE AND NAUSEA BUT DID NOT REALIZE IT WAS DUE TO FUEL LEAK. DAY THREE CABIN FILLED WITH OVERPOWERING FUMES COMING FROM HEATING VENT. HAD TO DRIVE WITH HEAT OFF AND ALL WINDOWS OPEN IN ORDER TO BRING CAR IN FOR SERVICE. HAVE HAD TO BRING CAR IN TWICE THIS MONTH TO REPAIR ALL OF THE LEAKS AND RENT A CAR IN ORDER TO GET TO WORK APPOINTMENTS. CERTIFIED SUBARU SPECIALIST REPORTED THAT HE HAS SEEN QUITE A FEW INCIDENCES OF SAME ISSUE RECENTLY DUE TO EXTREME COLD WEATHER. THIS IS A DANGEROUS SAFETY ISSUE AND IS NOT ACCEPTABLE. 2002-2003 IMPREZA RECALLED DEC 2009 FOR SAME ISSUE. *TR
Fuel system, Gasoline, Jan 24, 2014
A STRONG FUEL SMELL WHEN I STARTED MY CAR. *TR