2004 SUBARU FORESTER Engine Problems

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.

Mileage: 161,000

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.

Mileage: 57,000

ANYTIME THE TEMPERATURE DROPS BELOW 60 DEGREES FAHRENHEIT THERE'S A STRONG SMELL OF GASOLINE INSIDE THE CAB OF THE VEHICLE. WHEN LOOKING UNDER THE HOOD I CAN SEE IT DRIPPING OUT OF SOMETHING UNDERNEATH THE INTAKE MANIFOLD. SEVERE GAS LEAK. NAUSEOUS AND DANGEROUS FUMES.

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

Mileage: 120,000

FUEL LEAK IN LINES ABOVE ENGINE BUT BELOW INTAKE DURING COLDER WEATHER. FUEL FUMES PULLED INTO VEHICLE BY HEATING SYSTEM.

Mileage: 76,000

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.

Mileage: 149,966

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.

Mileage: 110,000

TO WHOM IT MAY CONCERN, HELLO, I AM THE OWNER OF A 2004 FORESTER XT WHICH I LOVE. I'VE OWNED THE CAR FOR ALMOST A YEAR AND ITS BEEN NOTHING BUT RELIABLE UP TO THIS POINT. THE WEATHER OUTSIDE IS FRIGHTFUL, AND WITH THAT COMES A COMMON PROBLEM FOR MANY SUBARU OWNERS. DURING THE COLD SNAPS, SAY BELOW 20F, THERE IS STRONG FUEL SMELLS WHICH FILLS THE CABIN. IT ONLY HAPPENS DURING START-UP, AND LASTS ABOUT 15 MINS BEFORE THE CAR WARMS UP. FROM SEARCHING MANY FORUMS AND INTERNET THREADS IT SEEMS THIS PROBLEM HAS BEEN OCCURRING SINCE EARLY 2001. THERE WAS A RECALL NOTICE (WVK-21)FOR THE 2002 -2003 WRX'S WHICH HAD A SAME PROBLEM I AM EXPERIENCING NOW. UNFORTUNATELY A RECALL WAS NEVER ISSUED FOR LATER MODEL SUBARUS WHICH SUFFER THE SAME PROBLEM. THE PROBLEM IS FUEL LEAKING FROM 5 MAIN FUEL LINES GOING INTO THE INTAKE MANIFOLD. IT SEEMS THAT WHEN IT IS COLD OUTSIDE, THE LINES ARE SHRINKING AND IS ALLOWING FUEL TO SPEW OUT EVERYWHERE. JUST FROM SEARCHING FOR 3 DAYS I'VE SEEN 125 CASES OF THIS HAPPENING TO OTHER OWNERS. WILL YOU PLEASE PUT OUT A BULLETIN BEFORE SOMEONE DIES FROM THERE CAR EXPLODING BECAUSE OF EXTRA FUEL LEAKING OUT OF THE FUEL HOSES. PLEASE I BEG OF YOU, PLEASE ISSUE A RECALL!!! *TR

Mileage: 130,000

THE SMELL OF FUEL BECAME OBVIOUS AFTER A 10-15 MINUTE DRIVE. UPON EXAMINATION, THERE WAS FUEL DRIPPING FROM A FUEL LINE. THIS OCCURRED AFTER THE FIRST FREEZE OF THE YEAR, FITTING OTHER DESCRIPTIONS OF THIS ISSUE I FOUND FOR THIS MODEL. *TR

Mileage: 96,000

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

Mileage: 76,485

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

Mileage: 126,000

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

Mileage: 120,000

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

Mileage: 68,000

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

Mileage: 87,000

TL* THE CONTACT OWNS A 2004 SUBARU FORESTER. THE CONTACT STATED WHEN THE TEMPERATURE DROPPED, FUEL FUMES WERE EMITTED IN AND AROUND THE VEHICLE. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR INSPECTION. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 117,000. THE INTAKE MANIFOLD WAS REPLACED. UPDATED 03/12/14 UPDATED 3/12/14*CN THE FUEL LINES, CLAMPS AND UPPER INTAKE GASKETS WERE REPLACED. THE FUEL LINES WERE CRACKED. UPDATED 04/01/14

Mileage: 117,000

STRONG SMELL OF GASOLINE UPON STARTING THE CAR IN VERY COLD WEATHER. INSIDE AND OUTSIDE THE VEHICLE. ONLY HAPPENS WHEN IT IS COLD OUTSIDE. REALLY GIVES ME A HEADACHE AND MAKES ME NERVOUS ABOUT IGNITING. *TR

Mileage: 129,000

DURING THE RECENT COLD SNAP HERE IN TENNESSEE I GOT A REPORT FROM A FRIEND THAT HIS 2004 FORESTER XT WAS LEAKING FUEL INTO HIS ENGINE BAY. I WENT OUT TO START MY CAR THE NEXT DAY AND MINE IS DOING THE SAME THING. THE FUEL IS SLOWLY LEAKING ONTO THE ENGINE BLOCK. THIS IS AN EXTREMELY DANGEROUS SITUATION. I DID SOME RESEARCHING AND IT SEEMS THAT ALMOST ALL FORESTER MODELS FROM 2002-2006 HAVE THIS EXACT SAME ISSUE! SOME HAVE BEEN RECALLED, BUT THE FORESTER XT HASN'T. THE ENGINES ARE THE SAME...I DON'T UNDERSTAND WHY THIS DANGEROUS PROBLEM HASN'T BEEN RESOLVED BY SUBARU. *TR

Mileage: 87,000

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

Mileage: 118,148

THERE HAS BEEN A CONTINUOUS OIL LEAK FROM MY 2004 SUBARU FORESTER XS. MY MECHANIC DIAGNOSED THE PROBLEM AS A LEAK IN THE MAIN SEAL BETWEEN THE TRANSMISSION AND THE ENGINE. THIS IS NOT NORMAL AND IT WILL COST ME $1,000 TO FIX BECAUSE THE TRANSMISSION WILL HAVE TO BE REMOVED. THERE ARE OTHER COMPLAINTS REGISTERED ABOUT SIMILAR OIL LEAKS IN THIS MODEL YEAR. SUBARU SHOULD INVESTIGATE. *TR

Mileage: 119,000

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

Mileage: 75,000

THE ENGINE OVERHEATED AND SEIZED WHILE ON A FREEWAY WITHOUT A SINGLE WARNING LIGHT REGARDING HIGH TEMP OR CHECK ENGINE. NO COOLANT WAS VISIBLE IN THE RADIATOR DURING INSPECTION AFTER THE INCIDENT. SHOULDN'T A 21ST CENTURY DRIVER/OWNER BE NOTIFIED BY SOME INDICATOR THAT THEY ARE ON THE VERGE OF HEATING AN ENGINE TO THE POINT OF FAILURE? AND WHERE DID THE COOLANT GO? DOES THIS VEHICLE HAVE A HISTORY OF BAD THERMOSTATS I'M NOT AWARE OF? IT WOULD HAVE BEEN A LOT SAFER IF THERE WERE SOME WARNING LIGHT FOR HIGH TEMP SO WE CAN PULL OVER TO ALLOW THE CAR TO COOL DOWN IN ORDER TO PREVENT AN ACCIDENT AND SAVE THE ENGINE. *TR

Mileage: 84,572

TL* THE CONTACT OWNS A 2004 SUBARU FORESTER. THE CONTACT STATED THERE WAS A SLIGHT LEAK OF OIL COMING FROM THE ENGINE THAT WAS DRIPPING INTO THE CATYLITIC CONVERTER. THE VEHICLE WAS TAKEN TO DEALER AFTER LEARNING OF NHTSA RECALL CAMPAIGN ID NUMBER: 04V473000 (ENGINE AND ENGINE COOLING). THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFER ANY ASSISTANCE SINCE THE VEHICLE WAS NOT INCLUDED IN ANY RECALLS. THE FAILURE MILEAGE WAS 78,000 AND THE CURRENT MILEAGE WAS 80,000.

Mileage: 78,000