2004 Subaru Impreza Problems

What owners report

Owners of the 2004 Impreza most often describe a strong gasoline smell in and around the car when starting in cold weather, which many trace to a short rubber fuel hose under the intake manifold. Suspension complaints are the second theme: rear strut clunking at low mileage and, on older cars, corroded front lower control arms. Air bag recall parts availability and unanswered Takata notifications also come up repeatedly.

1. 1
   Fuel system

   Fuel smell / leak from hose under intake manifold in cold

   • 28 complaints (29%)
   • median 89,107 mi at 9.2 yrs old (23 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2004–2022

   Owners describe a strong raw gasoline smell in the cabin and engine bay after cold starts, usually fading once the engine warms. Several say they traced it to a short rubber hose joining the metal fuel lines under the intake manifold, which they believe shrinks enough in low temperatures to weep fuel onto the engine. Complaints describe dealers quoting several hundred dollars for the repair because the intake manifold must be removed, and owners note recalls covered earlier model years but not this one. Most often reported on cold starts below roughly freezing, sometimes in the 20s F or lower, from low mileage up to well past 100,000 miles.

   What to check: Start the car from cold on a cool morning and smell around the engine bay and vents; ask whether the fuel hose under the intake manifold has been replaced, and look for fuel residue or a gasoline odor on the manifold.

   2 excerpts from owner complaints in NHTSA records

   “Strong fuel smell when temperatures are below freezing that does not disipate. 2002-2003 models have been recalled for same design flaw in fuel line. Since I own a 2004, repair may cost upwards of $400 due to extensive labor involved. Found many others with same issue when researching situation online. I am concerned about potential fire hazard.”

   NHTSA complaint #10820568, filed 2016-01, 120,000 miles

   “During cold weather my 2004 Subaru wrx smells of fuel both inside and outside of the vehicle. Using the heat causes the odor to increase and turning off the heat to dissipate the odor causes all of the windows to fog up and/or ice-over. The fumes have caused my eyes to water and have also given me headaches.”

   NHTSA complaint #10144713, filed 2005-12, 40,800 miles
2. 2
   Suspension

   Front lower control arm corrosion and fracture

   Mentioned in 8 of 60 sampled complaints

   Complaints describe front lower control arms rusted through at the hanger bracket, in some cases breaking and causing loss of steering or a collapsed front end. Several owners say rustproofing done under an earlier recall did not stop the corrosion, and others report the dealer declined the recall repair because of excessive rust. Typically reported on older, higher-mileage cars in the 55,000 to 235,000 mile range, mostly in regions that use road salt.

   Recall 11V4640001 related service bulletin

   What to check: Have the car inspected on a lift with attention to the front lower control arms and their mounting brackets, ask whether the 11V464000 remedy was performed, and be wary of cars with heavy underside rust.

   2 excerpts from owner complaints in NHTSA records

   “I was driving on i190 in worchester ma merging into i290 when the lower control arm broke and the front end collapsed causing loss of control of the vehicle. At the Subaru dealer's the control arm and sub frame were found to be rusted clear through. There was a factory recall issued in 2011, which we were not informed of. The vehicle has been serviced by Subaru only since we purchased it.”

   NHTSA complaint #10585733, filed 2014-04, 56,307 miles

   “Lower control arm failed causing a complete loss of steering due to rust.car was starting out just after traffic light turned green so a very slow speed.this would have been much worse if I was traveling at a faster speed. Car was previously recalled for this same issue and the repair was to inspect and spray rust proofing on lower control arms. This was not an acceptable repair as it failed anyway. I have a 2006 same make and model with the same recall and it was sprayed with rust proofing. …”

   NHTSA complaint #10903274, filed 2016-09, 127,842 miles
3. 3
   Air bags

   Front passenger air bag inflator recall not completed

   • 13 complaints (14%)
   • median 105,000 mi at 9.7 yrs old (6 state mileage, few)
   • 4 mention a crash, fire or injury
   • filed 2005–2024

   Many complaints are about the Takata front passenger inflator recall rather than a failure: owners say they were notified but parts were unavailable, dealers could not give a date, or calls were not returned. A smaller number report the air bag warning light on without a known cause, and others describe the bags not deploying in a crash. Reported across a wide mileage range, mostly between about 65,000 and 190,000 miles, years after the recalls were announced.

   Recall 15V323000Recall 20V001000Recall 20V002000Recall 20V003000Recall 23V0760003 related service bulletins

   What to check: Check the VIN against open recalls and ask for documentation that the passenger inflator replacement and any follow-up reinstallation recall were completed.

   2 excerpts from owner complaints in NHTSA records

   “Takata recall - I received a recall letter dated july 2015. Having received no update I called the dealership, duteau Subaru, in lincoln, ne this fall. They said they had no parts. On Subaru's website today I read instructions to call the dealership and make an appointment for repair. Calling the dealership I was unable to make an appointment. They did offer to put my name on a waiting list should parts arrive.”

   NHTSA complaint #10840316, filed 2016-03, 65,000 miles

   “Solo car spin out....hit a brick wall no airbag deployment in the front end crash. Recieved two head wounds/knee injury/memory loss. Othing done to correct damage or situation.”

   NHTSA complaint #10114449, filed 2005-03, 5,000 miles
4. 4
   Suspension

   Rear strut clunking and binding

   • 6 complaints (6%)
   • median 14,000 mi at 1.4 yrs old (6 state mileage, few)
   • filed 2005–2010

   Owners report a knocking or clunking from the rear suspension over bumps, braking and low-speed driving, with some saying the strut binds or sticks in a compressed position and the car feels loose or wanders. Several complaints mention repeated strut replacement, often at very low mileage, and some say the dealer needed multiple attempts before identifying the strut as the cause. Often reported from roughly 10,000 to 35,000 miles, with some appearing later in life.

   2 related service bulletins

   What to check: Drive over bumps and listen for rear clunking, then push down on each rear corner to check for sticking or sagging; ask whether struts have been replaced and keep records.

   2 excerpts from owner complaints in NHTSA records

   “For some time both rear struts in my car have been making a loud clunking noise. It has gotten worse to the point where they will now get stuck in a certain position. This can be very dangerous when driving at highway speeds as it makes the car wander all over the road. I have complained to the dealership and to Subaru of america with no resolution. This is a very common problem with many of these particular cars. They have been like this since the car had about 25,000 miles on it.”

   NHTSA complaint #10116047, filed 2005-03, 25,000 miles

   “2004 Impreza sti - rear clunking noise from right rear suspension. Occasional strut lockup in compressed position. Dealer attempted to fix this problem three times before realizing it was a faulty rear strut. Many other owners of the same car have reported the same problem. I was fortunate as my dealer properly diagnosed and repaired the problem. After the repair, the strut issue went away. Subaru of america should be required to recall this model to check for this strut problem. …”

   NHTSA complaint #10141697, filed 2005-11, 15,000 miles
5. 5
   Brakes

   Brake pedal going to the floor / brake line rust-through

   • 6 complaints (6%)
   • median 20,800 mi at 2.4 yrs old (5 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2004–2020

   Owners describe the brake pedal sinking to the floor, sometimes after hitting a bump, with normal braking returning after releasing and reapplying. Several complaints attribute it to a corroded hard brake line or connector near the fuel tank that leaked fluid, and a few describe unexpected ABS activation on ice or rough pavement. Reported from about 7,000 miles on nearly new cars up to roughly 165,000 miles, with the rust-related cases on older vehicles.

   2 related service bulletins

   What to check: Inspect the brake lines and connectors along the underside for rust and wet spots, check fluid level and pedal feel, and ask about any prior brake line or caliper work.

   2 excerpts from owner complaints in NHTSA records

   “Similar to recall campaign #wqk-47 the hard brake line near my gas tank has corroded and leaked all of my brake fluid. Had I been on the highway this could have been catastrophic. The vehicle was in motion, I noticed the brake pedal was traveling farther than normal. When I got home, there was almost no braking ability left in the car, pedal went to the floor. Checked master cylinder, it was empty, added fluid, pressed on brakes, could hear the fluid leaking out. Checked around car to find fluid. …”

   NHTSA complaint #11322968, filed 2020-05, 165,000 miles

   “Driving south on south dixie highway traveling at 45 MPH. Upon noticing the red light the brakes were applied. When the brakes were applied there was no response from them at all. I had to redirect the course of the car to avoid hitting other cars at a red light. As I turned to the right I came upon a curb and the front left tire as well as the left rear tire hit the curb. The front suspension of the car was damaged. The car was not driveable after the accident. It was towed to bird road Subaru in miami. …”

   NHTSA complaint #10100223, filed 2004-11, 7,000 miles

Buying note. Smell the car from a cold start and check for fuel residue under the intake manifold, have the underside inspected for control arm and brake line corrosion, and confirm every open air bag recall has been completed with paperwork before agreeing on a price.

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.