2004 Subaru Outback Problems

What owners report

Owners of this model year most often describe unintended or erratic acceleration — surging while braking, high idle, stuck throttle or cruise control engagement — plus a large group of airbag complaints that center on the Takata passenger-side inflator recalls and parts availability. Engine issues appear as coolant loss and head gasket replacement around 60,000-100,000 miles, and a smaller cluster describes a strong fuel smell in cold weather.

1. 1
   Vehicle speed control

   Unintended or erratic acceleration / high idle

   • 23 complaints (26%)
   • median 53,800 mi at 5.6 yrs old (20 state mileage)
   • 4 mention a crash, fire or injury
   • filed 2004–2017

   Complaints describe the engine surging or racing at stops, lurching forward when shifting into gear, and speed continuing after the accelerator is released. Several report the throttle staying open with cruise control off, and some say the pedal had no effect while the engine held a fast idle. Owners describe repeated dealer visits where the problem could not be duplicated, with repairs including throttle body cleaning, throttle position sensor, accelerator pedal position switch and ECM replacement. Reported from a few thousand miles up to well past 100,000 miles, at both low speeds and highway cruising speeds.

   Recall 04V128000

   What to check: Ask whether the cruise control cable and throttle body have been inspected or serviced, and whether any throttle position sensor or pedal switch work was done. A test drive that includes stops, reverse and steady-speed cruising can help confirm smooth throttle response.

   2 excerpts from owner complaints in NHTSA records

   “The vehicle tends to have poor acceleration performance during first 1 minute of operation causing a sudden surge of power during the first few minutes of operation climbing our 15% grade driveway. Initially the car would not even go up the driveway. The dealer found some of the problem, but it still continues to surge if the car is left setting for a few day. Very difficult to duplicate so the dealer says it is not a problem if we cannot duplicate. Prolbem has occurred starting in about april 2004 and continued thru today. …”

   NHTSA complaint #10116577, filed 2005-04, 3,000 miles

   “On two separate occasions, with two different drivers, my Subaru Outback 2004 vehicle experienced dangerous sudden acceleration. In both cases, we were stopped in traffic for a few minutes, foot on the brake, when suddenly, the car began to surge forward. Even exerting strong pressure on the brake, the car continued to surge forward, the engine racing. On one occasion, we were behind other stopped cars and almost rear-ended the car in front of us. On another, we were stopped at a cross walk and almost lurched forward into pedestrians. …”

   NHTSA complaint #10108341, filed 2005-02, 2,500 miles
2. 2
   Air bags

   Take no Takata passenger airbag inflator recall completed

   • 21 complaints (23%)
   • median 87,500 mi at 11.3 yrs old (8 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2003–2018

   Many complaints in this sample are about the passenger-side front airbag inflator recalls rather than a failure. Owners describe receiving notices but being told parts were unavailable, being asked to keep passengers out of the front seat, and receiving conflicting information between the dealer and recall lookup tools about whether their vehicle was included. A few describe the airbag warning light staying on. Mostly filed between 2014 and 2019, often at higher mileages and on vehicles long out of warranty.

   Recall 20V001000Recall 20V003000Recall 20V002000Recall 16V359000Recall 16V361000Recall 16V358000Recall 15V323000Recall 14V763000

   What to check: Check the vehicle identification number with a dealer or the recall lookup tool for open airbag inflator campaigns, and ask for written confirmation that any open remedy has been completed.

   2 excerpts from owner complaints in NHTSA records

   “I received a recall notice on passenger side airbag in july 2016..I was told I would be informed by mail when parts were available for repair by my local Subaru dealer. It's 14 months later and I have not received any further notice. I do not believe this has been handled in a timely manner and still cannot have passengers in front seat.”

   NHTSA complaint #11030656, filed 2017-09, 184,000 miles

   “I cannot determine if my vehicle is on the tikata airbag recall list. The dealer says it isn't. The NHTSA site says it is, the VIN shows it isn't specifically. My question is if the 2004 outbacks are included in the recall or if the NHTSA info is wrong....please advise.....updated 10/02/15 updated 12/28/15”

   NHTSA complaint #10743586, filed 2015-07, 115,000 miles
3. 3
   Transmission and drivetrain

   Rough or abrupt transmission shifting and lurching

   • 13 complaints (14%)
   • median 45,819 mi at 3.8 yrs old (10 state mileage)
   • 4 mention a crash, fire or injury
   • filed 2004–2014

   Complaints describe harsh shifting on acceleration and deceleration, lurching forward while stopped with the brake applied, and in one case the transmission dropping out of gear while parked. Owners report dealer diagnoses pointing to a torque converter or transmission control issue, and some describe the car stalling or shifting unexpectedly at highway speed with cruise control engaged. Reported from around 16,000 miles up to about 100,000 miles.

   What to check: Drive the car through several upshifts and downshifts, including from a stop and at highway speed, and ask whether the transmission fluid has been serviced or any transmission work has been done.

   2 excerpts from owner complaints in NHTSA records

   “Auto started running rough. Transmission shifting abruptly. Throttle would remain open after foot taken off accelerator. Car would maintain last speed before foot off accelerator. This would continue on level ground and even uphill to a large extent speed would be maintained with no input from driver. Cruise control was off. No codes generated and no check enging light. Dealer notified. Could not duplicate. This occurred on three separate occasions before dealer replace throttle positon sensor.”

   NHTSA complaint #10098126, filed 2004-11, 7,700 miles

   “Blown headgasket at only 40k. Car has been maintained on a regular schedule with extra care car when needed. Took to dealer and complained of smell of coolant in the interior of car when driving and after shutting vehicle down or at a traffic light stop. Took to dealer complaining of a noise coming from the bottom of engine. After the dealer examined vehicle nothing was found as per report. I took the car for brake repair and the mechanic noted a coolant leak from the left bank of the engine block. …”

   NHTSA complaint #10261399, filed 2009-03, 40,000 miles
4. 4
   Engine cooling

   Coolant loss and head gasket replacement

   • 6 complaints (7%)
   • median 76,207 mi at 6.0 yrs old (4 state mileage, few)
   • filed 2007–2014

   Complaints describe coolant smell inside the cabin, coolant leaking from the engine, and unexplained overheating. Owners report being told the head gasket needed replacement, sometimes together with the water pump and timing belt, and some describe the repair being needed again later. One owner links a leaking head gasket to contaminated catalytic converters and a catalyst efficiency code. Most commonly reported between roughly 40,000 and 120,000 miles, and in some cases recurring after an earlier repair.

   What to check: Look for coolant residue or seepage at the head gasket area and check the coolant level and condition; ask whether the head gasket, water pump or timing belt have been replaced and at what mileage.

   2 excerpts from owner complaints in NHTSA records

   “Multiple head gasket failure at 60,000 mile intervals since the car was new. It seems like the manufacturer is covering up a very bad engine design after looking online of very same reports. I am surprised with all of the complaints it is not been recalled or corrected. Unfortunately, due to costs of repair I am forced to scrap the car and find a different car company.”

   NHTSA complaint #10542004, filed 2013-09, 174,000 miles

   “Diagnostic code p0420 (catalyst sys). Vehicle would not pass emissions test due to code. 85000 miles on vehicle. Was told there was a computer upgrade for this complaint put out by Subaru. Dealer performed upgrade then informed me headgasket was leaking. Dealer replaced head gasket goodwill . Dat after repair code 0420 came back and now need converters replaced to the tune of $1800.00 to $2200.00 due to contaminated converters. Fuel, oil leaking into exhaust from failed head gasket.”

   NHTSA complaint #10321730, filed 2010-03, 85,035 miles
5. 5
   Fuel system

   Fuel smell in the cabin in cold weather

   • 5 complaints (6%)
   • median 79,250 mi at 8.8 yrs old (4 state mileage, few)
   • filed 2009–2014

   Owners describe a strong gasoline smell inside the cabin, most often when starting the car in cold weather, sometimes strong enough that they avoid driving with the heater on. One complaint traces it to a leaking pulsation damper on the fuel rail on the six-cylinder engine. Complaints note the smell returns in cold snaps after short-term fixes. Reported mainly in cold weather, from very low mileage up to about 135,000 miles.

   Recall 03V303000

   What to check: On a cold start, check for a fuel odor around the engine bay and inside the cabin, and ask whether fuel lines, clamps or the pulsation damper have been inspected or replaced.

   2 excerpts from owner complaints in NHTSA records

   “2004 Subaru Outback: strong fuel odor inside vehicle when cold out. Research shows this is a common issue with Outback and impreza wrx. Subaru recalled the wrx, why not the outbacks! This defect poses an extreme risk for fire and a recall is needed.”

   NHTSA complaint #10662661, filed 2014-12, 5 miles

   “2004 Subaru Outback, h6 (6-cylinder) with a faulty pulsation dumper/damper valve. Part of the fuel injection system, the valve assembly sits above the intake manifolds on both sides of the engine. The passenger side valve (metal construction) was literally weeping gasoline (strong smell inside cabin was the tip off). I removed the assembly and replaced the hoses first, but the valve was leaking through the top surface walls (not a seam). Awaiting replacement parts now. …”

   NHTSA complaint #10317786, filed 2010-03, 92,000 miles

Buying note. Have a pre-purchase inspection focus on throttle and cruise control operation, coolant and head gasket condition, and transmission behavior, since these are the areas owners describe most. Confirm with a dealer which airbag inflator campaigns apply and whether they have been completed.

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.