The 2016 FR-S is a solid platform built with Subaru's FA20 boxer engine, but it has a well-documented Achilles heel: valve spring failure and catastrophic oil starvation issues under hard use, plus cricket-chirping fuel delivery problems that eventually lead to pump failure.
Valve Spring Failure Leading to Engine Rebuild
Occasional · high severityTypical onset: 60,000-100,000 mi
Symptoms: Metallic ticking or tapping from engine that increases with RPM, Misfires under load or at high RPM, Check engine light with cylinder misfire codes, Loss of power and rough idle, Metal shavings in oil
Fix: Valve springs fracture and drop into the cylinder, destroying pistons, cylinder walls, and valves. Requires complete engine teardown, often short block replacement or full rebuild with upgraded valve springs. 20-30 hours labor depending on damage extent and parts availability.
Estimated cost: $4,500-8,000
Oil Starvation and Bearing Failure During Spirited Driving
Occasional · high severityTypical onset: 40,000-80,000 mi
Symptoms: Knocking or rod knock sound during or after hard cornering, Oil pressure warning light during high-G maneuvers, Metallic debris in oil filter, Sudden catastrophic engine failure, Loss of oil pressure at sustained high RPM
Fix: FA20 boxer design causes oil to slosh away from pickup during hard cornering or track use, starving bearings. Spun bearings destroy crankshaft and require complete engine rebuild or replacement. Prevention requires aftermarket oil pan baffle or accusump. Rebuild takes 25-35 hours.
Estimated cost: $5,000-9,000
Fuel Pump Crickets and Premature Failure
Common · medium severityTypical onset: 50,000-90,000 mi
Symptoms: Cricket chirping sound from rear of car, especially on startup, Hard starting when tank is below 1/4, Rough idle or hesitation under acceleration, Intermittent stalling, Fuel pressure fluctuations
Fix: OEM fuel pump develops loud cricket noise before failing completely. Requires fuel tank drop and pump assembly replacement. TSB issued but many pumps still fail early. 3-4 hours labor for pump replacement.
Estimated cost: $600-1,000
Throwout Bearing (TOB) Chirping and Premature Wear
Common · low severityTypical onset: 30,000-70,000 mi
Symptoms: Chirping or squealing when clutch pedal is depressed, Grinding noise during shifts, Clutch pedal feel becomes notchy or inconsistent, Noise disappears when clutch is fully engaged
Fix: Factory TOB is inadequately lubricated and wears prematurely, especially with aggressive driving. Requires transmission removal to replace. Smart owners replace clutch assembly at same time since labor is identical. 6-8 hours labor.
Estimated cost: $800-1,400 (TOB only), $1,200-2,000 (with clutch)
Transmission Mount Deterioration
Common · low severityTypical onset: 60,000-100,000 mi
Symptoms: Excessive drivetrain clunk during shifts or acceleration, Vibration felt through shifter, Difficulty getting into first or reverse, Shifter movement under throttle, Metallic bang when letting off throttle
Fix: Rubber transmission mount deteriorates from heat and stress, allowing excessive drivetrain movement. Relatively simple replacement but requires lifting powertrain slightly. Many upgrade to polyurethane mounts during replacement. 2-3 hours labor.
Estimated cost: $250-500
Transmission Oil Cooler Line Leaks
Occasional · medium severityTypical onset: 70,000-120,000 mi
Symptoms: Transmission fluid dripping from front of vehicle, Low transmission fluid level without obvious leak, Transmission overheating during highway driving, Burnt transmission fluid smell, Pink fluid residue on driveway
Fix: Factory crimped cooler lines crack at fittings or develop pin holes from road debris and corrosion. Requires line replacement and fluid refill. Often caught during oil changes. 2-3 hours labor depending on line routing accessibility.
Estimated cost: $400-700
Buy one if you understand the valve spring and oil starvation risks and plan to address them preventively — otherwise this is a $5k repair waiting to happen on a car that begs to be driven hard.
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.