The 2015 FR-S is a lightweight sports coupe built on the Subaru/Toyota 86 platform with a naturally-aspirated FA20 boxer engine. While generally reliable for spirited driving, it suffers from a few critical drivetrain and lubrication issues that can result in catastrophic engine failure if ignored.
Valve Spring Failure Leading to Catastrophic Engine Damage
Occasional · high severityTypical onset: 60,000-100,000 mi
Symptoms: Sudden loss of power and misfire, often accompanied by check engine light, Metallic rattling or ticking noise from engine bay, Pieces of valve spring found in oil during changes, Complete engine failure if spring breaks and valve drops into cylinder
Fix: Valve spring recall was issued but didn't cover all affected engines. If springs fail and damage occurs, you're looking at head gasket replacement minimum (8-12 hours labor), but broken valves often require full engine rebuild or short block replacement (20-30 hours labor). Many owners proactively replace valve springs around 60k miles as insurance.
Estimated cost: $3,500-8,000
Piston Ring Land Cracking and Ringland Failure
Occasional · high severityTypical onset: 80,000-120,000 mi
Symptoms: Excessive oil consumption (more than 1 quart per 1,000 miles), Blue smoke from exhaust on cold starts or hard acceleration, Loss of compression in one or more cylinders, Rough idle and misfires that worsen over time
Fix: The FA20 is known for thin piston ring lands that crack under detonation or sustained high RPM. Once cracked, you need new pistons at minimum. Most shops recommend full short block replacement to avoid repeat failures (22-28 hours labor). This is especially common on modified or track-driven cars, but stock examples fail too.
Estimated cost: $5,000-9,000
Connecting Rod and Main Bearing Wear (Oil Starvation)
Occasional · high severityTypical onset: 70,000-110,000 mi
Symptoms: Knocking or tapping noise from lower engine, especially when cold, Low oil pressure warning light during hard cornering or spirited driving, Metallic debris in oil filter during changes, Sudden bearing seizure leading to engine lock-up in worst cases
Fix: The horizontally-opposed engine design allows oil to drain away from pickup during aggressive cornering, starving bearings. Combined with the stock oil pan design, this causes premature bearing wear. Requires crankshaft removal, bearing replacement, and often crank polishing or replacement (24-32 hours labor). Many enthusiasts install baffled oil pans as preventive measure.
Estimated cost: $4,500-7,500
Transmission Mount Failure (Manual Transmission)
Common · low severityTypical onset: 50,000-90,000 mi
Symptoms: Excessive shifter vibration, especially in 1st and 2nd gear, Clunking noise when letting off throttle or shifting, Notchy or vague shifter feel, Visible tearing or separation of rubber mount during inspection
Fix: The front transmission mount tears from engine torque and spirited shifting. Straightforward replacement job requiring transmission support (2-3 hours labor). Upgraded polyurethane mounts last longer but increase NVH. Consider replacing both front and rear mounts simultaneously.
Estimated cost: $250-450
Throwout Bearing Chatter and Failure
Common · medium severityTypical onset: 40,000-80,000 mi
Symptoms: Chirping, squealing, or grinding noise when clutch pedal is depressed, Noise disappears when pedal is released, Difficulty shifting into gear from neutral, Eventually leads to clutch not disengaging fully
Fix: The throwout bearing on manual transmission models develops chatter and eventual failure. Requires transmission removal to replace (6-8 hours labor). Always replace clutch assembly, pressure plate, and pilot bearing while transmission is out to avoid repeat labor costs.
Estimated cost: $1,200-2,000
Cricket Chirp (Fuel Pump Resonance)
Common · low severitySymptoms: High-pitched chirping or buzzing noise from rear of car around 3,000-4,000 RPM, Sound comes from fuel tank area under rear seats, No performance issues, purely audible annoyance, More noticeable with windows down or in parking structures
Fix: Known issue where fuel pump resonates against the tank at specific frequencies. Some dealers installed foam isolation pads under TSB, but it's not a recall. Most owners live with it. DIY foam installation takes 1-2 hours. No functional impact on vehicle.
Estimated cost: $100-300
Transmission Oil Cooler Line Leaks (Automatic Models)
Occasional · medium severityTypical onset: 60,000-100,000 mi
Symptoms: Red transmission fluid puddles under vehicle, Low transmission fluid warning or slipping during shifts, Fluid visible on oil cooler lines near radiator, Burnt smell if fluid level drops significantly
Fix: Automatic transmission models develop leaks at oil cooler line fittings and connections. Lines need replacement and system refill (2-3 hours labor). Check fluid level frequently if leak is detected to prevent transmission damage from low fluid operation.
Estimated cost: $400-700
Buy one if you're handy and diligent about oil checks, but budget $5k-8k for eventual engine work — the FA20 has great character but real longevity issues past 80k miles.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.