The 2016 FR-S is mechanically solid for a sports car, but the FA20 boxer engine has a well-documented weakness: valve spring failure and the catastrophic piston/ringland damage that follows. Otherwise, it's a simple, reliable platform with minimal electronics to fail.
Valve Spring Failure Leading to Engine Damage
Occasional · high severityTypical onset: 60,000-100,000 mi
Symptoms: sudden misfire with CEL, metallic rattling from engine, loss of power in one cylinder, metal debris in oil, catastrophic failure can occur without warning
Fix: Valve spring breaks, drops into cylinder, destroys piston and ringlands. Often requires complete engine rebuild or short block replacement. 20-30 hours labor for rebuild, 12-16 hours for short block swap. This is THE known failure mode for the FA20.
Estimated cost: $4,500-8,000
Cricket Chirping Noise from Throw-Out Bearing
Common · low severityTypical onset: 30,000-80,000 mi
Symptoms: chirping or squeaking when clutch pedal is at rest, noise disappears when clutch is depressed, gets louder in cold weather, does not affect drivability
Fix: Throw-out bearing develops a characteristic chirp. Requires transmission removal to replace. Many owners live with it for years. 6-8 hours labor if you're already doing clutch work, but not worth pulling the trans just for this noise alone.
Estimated cost: $800-1,200
Transmission Mount Failure
Occasional · medium severityTypical onset: 70,000-110,000 mi
Symptoms: clunking when shifting or engaging clutch, excessive drivetrain movement, vibration during acceleration, visible tearing of rubber mount
Fix: Rear transmission mount tears or separates, especially on cars driven hard. Straightforward replacement, 1.5-2 hours labor. OEM or upgraded polyurethane mounts available.
Estimated cost: $200-400
Fuel Pump Failure
Occasional · high severityTypical onset: 80,000-120,000 mi
Symptoms: rough idle or stalling, hesitation under acceleration, no-start condition, fuel pump whine from rear of car, intermittent loss of power
Fix: Fuel pump can fail without warning, leaving you stranded. Requires dropping the fuel tank. 3-4 hours labor. Not a recall item despite being common enough to see regularly.
Estimated cost: $600-900
Ignition Coil Failure
Occasional · medium severityTypical onset: 60,000-100,000 mi
Symptoms: cylinder misfire code (P0300-P0304), rough idle, loss of power, check engine light flashing
Fix: Direct ignition coils fail individually. Easy diagnosis with code scanner. Replace all four while you're in there. 1 hour labor for all four on a boxer engine (much easier access than most).
Estimated cost: $400-600
Oil Consumption (High-Mileage or Tracked Cars)
Occasional · medium severityTypical onset: 80,000+ mi or track-driven
Symptoms: burning 1 quart per 1,000-2,000 miles, blue smoke on deceleration, low oil warning light, fouled spark plugs
Fix: Piston ringland damage or worn rings cause oil burning. Often a precursor to full engine failure. If caught early and compression is still good, some shops will replace rings (15-20 hours labor). Most end up needing engine rebuild or short block.
Estimated cost: $2,500-7,000
Buy one if you love driving dynamics, but budget $2,000-3,000 for eventual engine work and check compression before purchase—the valve spring lottery is real.
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.