2005 Subaru Forester Problems

What owners report

Owners of this model year most often describe two long-running themes: a fuel smell or leak from the lines under the intake manifold in cold weather, and corrosion of the front lower control arms that can lead to fracture. A third frequent theme is unexpected accelerator behaviour — either surging or a delayed/no response. Many of these reports come from vehicles above 80,000 miles, though the control-arm and cold-weather fuel reports also appear on lower-mileage examples.

1. 1
   Suspension

   Front lower control arm corrosion and fracture

   • 17 complaints (18%)
   • median 130,000 mi at 12.7 yrs old (15 state mileage)
   • 2 mention a crash, fire or injury
   • filed 2013–2023

   Complaints describe rust-through of the front lower control arms (transverse links), sometimes found during routine inspection and sometimes only after the arm fractures — with reports of the wheel tilting or the tire detaching from the vehicle at low speed. Several owners say the corrosion was first noted by an independent mechanic while the dealer considered the parts acceptable, and some state they were told the vehicle had already been serviced under the control-arm campaign. Subaru issued a recall for this area, and a service bulletin sets inspection criteria for the transverse link bushings. Reported from roughly 25,000 miles upward, with many at 60,000-130,000 miles; complaints associate the corrosion with road salt exposure and, in one case, air-conditioner condensation.

   Recall 11V4640002 related service bulletins

   What to check: Have the front control arms inspected from below for rust at the bracket and hanger area before buying, and ask for documentation of whether the control-arm recall (11V464000) service was performed and what it involved.

   2 excerpts from owner complaints in NHTSA records

   “This vehicle is only 14 years old and I've had it for 2 years. I had it taken to my family mechanic for minor issues and found out that the suspension is completely rusted out. If I had been hit by someone or had hit a large hole, he said the vehicle would have completely collapsed.”

   NHTSA complaint #11217730, filed 2019-06, 130,000 miles

   “My car was at my mechanics getting looked at. He noticed the lower front control arm brackets were corroded (the passenger side is severely corroded), told me about it and stressed that I needed to take it to a dealership asap to have it replaced. When I contacted the dealership, they confirmed the recall for my car, mentioned the service had already been performed (by the previous owner) and scheduled an appointment. …”

   NHTSA complaint #10691164, filed 2015-02, 80,230 miles
2. 2
   Fuel system

   Cold-weather fuel smell or leak under the intake

   • 20 complaints (22%)
   • median 94,000 mi at 9.3 yrs old (16 state mileage)
   • filed 2009–2022

   Owners describe a strong raw gasoline smell inside and outside the vehicle, most often when temperatures drop below roughly 20-30 degrees F, with the smell fading once the engine reaches operating temperature. Some report visible fuel seepage or dripping on the engine block near the passenger side, and one dealer inspection found fuel seeping past hose clamps on lines under the intake manifold. Dealers quoted repairs ranging from a few hundred dollars to more, and some owners asked the manufacturer about reimbursement. Mostly reported in cold weather below about 30 degrees F, across a wide mileage range from roughly 40,000 to over 200,000 miles.

   2 related service bulletins

   What to check: Ask whether the fuel lines under the intake manifold have been replaced or re-clamped, and check for a fuel smell at cold start on a chilly morning. Look for damp or discolored hose sections near the passenger side of the engine bay.

   2 excerpts from owner complaints in NHTSA records

   “I can see gas running down my engine block. The leak is on passenger side under the intake manifold of my ej255. Smells of gas very strongly. I am worried a fire might start because it is very near the turbocharger. It happens when the vehicle is in motion and stationary. Both on a city street and highway. And also when turning”

   NHTSA complaint #11041352, filed 2017-10, 186,000 miles

   “It had been cold, below freezing in the mid west, most of the time I would recirculate the cabin air, but every time when I bring in fresh air from outside to clear the moisture, I experienced a strong odor of raw gas coming in through the air vents. Then I noticed fuel was actually leaking in the engine compartment, one section of the rubber hose was damp as a result of fuel dripping over it.”

   NHTSA complaint #10561506, filed 2014-01, 93,000 miles
3. 3
   Vehicle speed control

   Unexpected acceleration or accelerator non-response

   • 22 complaints (24%)
   • median 58,000 mi at 8.6 yrs old (17 state mileage)
   • 8 mention a crash, fire or injury
   • filed 2005–2023

   Owners describe two patterns: the vehicle surging or accelerating on its own at low speed or while reversing, and the opposite — pressing the accelerator and getting no response until the engine is shut off and restarted. Some complaints also mention a sticking accelerator that does not decelerate in cold weather with the heater on, or erratic idle that rises and falls. In several cases no trouble codes were stored or the dealer could not duplicate the behaviour; a few owners had a throttle or accelerator sensor code noted. Spread broadly from very low mileage (under 1,000 miles) to over 200,000 miles, with no single mileage band; a few reports tie the sticking pedal to temperatures below about 30 degrees F.

   1 related service bulletin

   What to check: On a test drive, try light throttle from a stop and low-speed reversing, and check the idle for surging or hunting. Ask whether any throttle-body or accelerator-pedal sensor work has been done and whether stored codes were ever read.

   2 excerpts from owner complaints in NHTSA records

   “On several occasions while using the cruise control the vehicle deceleration lever, which Subaru labels coast was depressed. The vehicle slowed to the desired rate of travel and the lever was released. The cruise control system was supposed to maintain the same speed as when released, but the vehicle accelerated apparently back to the previous set point. I contacted Subaru of america by e-mail and they stated that I should take the vehicle into my local Subaru dealer. …”

   NHTSA complaint #10159214, filed 2006-06, 500 miles

   “My 2005 Subaru Forester suddenly accelerated as I approached a stoplight. The car was in neutral, the clutch was not engaged and my foot was on the brake. The acceleration subsided after I placed the car in first gear and slightly pressed on the gas pedal moving the car forward about a foot. This sudden acceleration occurred over a dozen times in the course of 24hrs. The car was taken to the local Subaru dealer where several test runs were performed as well as a monitor test. …”

   NHTSA complaint #10119786, filed 2005-05, 85 miles
4. 4
   Brakes

   Brake pedal fading to the floor / brake line corrosion

   • 5 complaints (5%)
   • median 42,000 mi at 9.8 yrs old (5 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2006–2017

   Complaints describe the brake pedal slowly sinking or going to the floor with little warning, sometimes preceded by a low-fluid light. One owner had the master cylinder replaced after fluid was found bleeding back into the reservoir; others found rusted-through rear brake lines, and one reported an intermittent ABS light with longer stopping distance that the dealer could not reproduce. Subaru service bulletins address brake caliper fluid leaks and pad-clip corrosion. Reported from about 34,000 to 127,000 miles, on vehicles used in salt-road regions where line corrosion was found.

   2 related service bulletins

   What to check: Inspect the brake lines along the underbody for rust, especially on cars from salt-road states, and check the fluid level and pedal feel. Ask when the brake fluid was last changed and whether the calipers have been serviced.

   2 excerpts from owner complaints in NHTSA records

   “The rear brake lines rusted through and failed without notice. One several model of Subaru, brakes lines were replaced for corrosion due to a recall. When ordering the replacement part I noticed it applied to some of the cars covered under the recall and some that were not. It seems to my that my forrester had precisely the same lines that were recalled on other models and should have been included in you original settlement with Subaru. …”

   NHTSA complaint #11003422, filed 2017-07, 127,000 miles

   “The brake light came on two days prior. Checked fluid and was a bit low. I hadn't noticed and fluids under car so did not give it a second thought. I was driving on sunday and had loss of pedal and the brake light came on and I nursed it home. I added fluid and pumped pedal in driveway. The pedal went to floor. I pulled it up on the internet and found some Subaru vehicles same age had brake line issues that were involved in a recall. I to a local shop and the service manger told me it would be very expensive. …”

   NHTSA complaint #10667849, filed 2014-12, 77,000 miles

Buying note. Given these reports, a pre-purchase inspection that puts the car on a lift is worth doing — the front control arm corrosion and brake line condition are things a mechanic can see directly. Also check the service history for the control-arm recall work and try a cold start on a cool morning to check for a fuel smell.

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.