2004 Subaru Forester Problems

What owners report

Owners of this model year most often report a gasoline smell in and around the cabin, typically on cold starts in cold weather, which complaints attribute to fuel lines and hoses under the intake manifold. The remaining reports cover rusted front lower control arms, warning-light and non-deployment air bag concerns, and engine oil seepage and overheating. Mileage at report varies widely, with many fuel-smell reports filed between roughly 50,000 and 180,000 miles.

1. 1
   Fuel system

   Fuel smell in cabin on cold starts

   • 122 complaints (56%)
   • median 107,000 mi at 10.2 yrs old (111 state mileage)
   • 1 mention a crash, fire or injury
   • owner-quoted repair $750 (median of 10 quotes)
   • filed 2008–2024

   Complaints describe a strong raw gasoline odor inside the cabin and around the engine bay, most often at startup on cold mornings and sometimes while idling or driving. Owners say the fumes enter through the vents and are strong enough to cause headaches or nausea, and several report seeing fuel seeping onto the engine near the intake manifold or turbo area. Some were told by the dealer that fuel lines and clamps under the manifold were leaking or loose; others say the dealer described it as normal for the engine or tied to cold weather. Mostly reported in temperatures at or below freezing, from roughly 16,000 to 200,000 miles.

   What to check: On a cold morning, start the car with the hood open and check for a fuel smell and any dampness around the fuel lines and clamps under the intake manifold. Ask whether the lines or clamps have been replaced and keep the receipt.

   2 excerpts from owner complaints in NHTSA records

   “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.”

   NHTSA complaint #10556013, filed 2013-12, 179,000 miles

   “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.”

   NHTSA complaint #10555430, filed 2013-12, 70,000 miles
2. 2
   Suspension

   Front lower control arm rust and failure

   • 20 complaints (9%)
   • median 157,900 mi at 14.2 yrs old (17 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2011–2022

   Complaints describe front lower control arms that corrode and in some cases break, sometimes producing a loud noise or a sudden pull to one side while driving. Several owners say they later learned of a related recall campaign but that their vehicle was not covered, often because of where it was registered. Dealers reportedly replaced arms in some cases, with owners sometimes paying labor. Reported from about 75,000 to over 240,000 miles, most often on vehicles in areas that use road salt.

   Recall 11V4640002 related service bulletins

   What to check: Have the front lower control arms inspected for rust, especially at the hanger bracket area, and check by VIN whether the vehicle was ever covered or repaired under recall 11V464000.

   2 excerpts from owner complaints in NHTSA records

   “Having recently bought my 2004 Subaru Forester xt, it ran great for the first few months. Then, while on the highway, it would shake uncontrollably, almost like an earthquake. Having taken it to Subaru a month before, I mentioned that it was doing this a little, but not to the extent that it did on the highway. He said it would be $150 to look at it. Taking it in to a different mechanic, they had to replace the lower control arm. …”

   NHTSA complaint #10808646, filed 2015-12, 175,000 miles

   “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. …”

   NHTSA complaint #11079474, filed 2018-03, 244,123 miles
3. 3
   Engine

   Engine oil seepage and oil on hot parts

   • 31 complaints (14%)
   • median 102,323 mi at 10.3 yrs old (27 state mileage)
   • 5 mention a crash, fire or injury
   • filed 2004–2021

   Complaints describe oil seeping from the engine and collecting on the exhaust or catalytic converter, and in some cases smoke or fire from the engine compartment after overheating. Others report a failed head gasket or a blown turbo after timing belt service. Owners often mention that their vehicle was not included in the related oil control valve recall or that no assistance was offered. Reported from roughly 78,000 to 170,000 miles, sometimes after other engine work.

   Recall 04V4730002 related service bulletins

   What to check: Look for oil residue around the rocker cover, oil filler tube and under the engine, and ask whether the oil control valve cover bolts were checked under recall 04V473000.

   2 excerpts from owner complaints in NHTSA records

   “Had timing belt replaced on 2004 Forester turbo as recommended on maintenance,schedule, next day on highway, loud screeching noise and lose of power. Stopped driving towed to mechanic. Said it was blown turbo. Never notified of banjo bolt issue, Subaru should recall or remedy situation at their cost.”

   NHTSA complaint #10383171, filed 2011-02, 106,000 miles

   “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.”

   NHTSA complaint #10916164, filed 2016-10, 110,000 miles
4. 4
   Vehicle speed control

   Unexpected acceleration from a stop

   • 19 complaints (9%)
   • median 56,000 mi at 7.2 yrs old (16 state mileage)
   • 9 mention a crash, fire or injury
   • filed 2004–2020

   Complaints describe the engine revving or the car accelerating on its own, sometimes right after starting or when shifting from park or reverse into drive, with braking described as insufficient in some cases. Some owners say the condition did not repeat, and one notes no floor mat involvement. Most report no dealer diagnosis. Reported from about 38,000 to 57,000 miles, typically at low speed or from a standstill.

   What to check: Check that the floor mat is properly secured and ask whether the throttle body and pedal sensor have ever been inspected or cleaned.

   2 excerpts from owner complaints in NHTSA records

   “While parking my car in a museum parking area on a slope, I shifted the automatic gear shift from reverse to drive and the car suddenly accelerated and took off down a crowded parking lot driveway at very high speed. The car was at a standstill at the time of the gear shifting. I could not slow or stop the rapidly accelerating car by braking. I was focused on not hitting people and other entering cars and didn't think to try the emergency brake or shifting into neutral. …”

   NHTSA complaint #10318150, filed 2010-03, 52,000 miles

   “Accelerator took off at high RPM and continued at high RPM even in park. Fortunately, I noticed that lifting my foot off the accelerator did not slow the car when driving in low traffic conditions at less than 40 MPH and was able to overcome acceleration with braking with sufficient control to get to the dealership about 1 mile away. Most definitely not the accelerator pedal; the mat was no where near the pedal. Had an oil change two days prior, both otherwise nothing to report concerning the car.”

   NHTSA complaint #10399045, filed 2011-05, 74,110 miles
5. 5
   Air bags

   Air bag warning light on or bag not deploying

   • 20 complaints (9%)
   • median 63,191 mi at 6.7 yrs old (12 state mileage)
   • 4 mention a crash, fire or injury
   • filed 2004–2019

   Complaints describe the air bag warning light staying on for one or both front positions, with owners saying the system may then be disabled. One owner links it to a connector solder joint and mentions an existing service bulletin for the issue; another reports a passenger bag deploying while the car was parked and unoccupied, and another reports bags that did not deploy in a collision. Some owners say they were not offered a repair. Reported from about 43,000 to over 80,000 miles, across a wide range of vehicle ages.

   2 related service bulletins

   What to check: Turn the key and confirm the air bag light goes out after the self-check. Ask for any prior air bag diagnostics or repairs under the Takata-related bulletins.

   2 excerpts from owner complaints in NHTSA records

   “The contact owns a 2004 Subaru Forester. The contact stated that the air bag warning light illuminated for both the passenger and driver side air bags. The vehicle was not taken to the dealer. The manufacturer was not contacted. The failure mileage was 50,000 and the current mileage was 100,000.”

   NHTSA complaint #10470657, filed 2012-08, 50,000 miles

   “The contact stated while driving on the highway at 55mph the vehicle was involved in an accident. The air bags did not deploy. Although seatbelts were worn the two occupants sustained injuries. A police report was filed. As a result of the accident the vehicle was totaled.”

   NHTSA complaint #10149296, filed 2006-02, 43,500 miles

Buying note. On this model year, pay most attention to a cold-start fuel smell and to rust on the front lower control arms, since both come up repeatedly in owner reports. A cold-morning test drive, a look underneath for corrosion, and a VIN check for recall coverage tell you most of what you need before buying.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.