The 2004 Legacy is a solid AWD platform undermined by serious head gasket issues on the 2.5L H4 and transmission cooler failures that can kill the automatic. The H6 is far more reliable but drinks more fuel.
2.5L Head Gasket Failure (External Coolant Leaks)
Common · high severity
Typical onset: 80,000-150,000 mi
Symptoms: Coolant weeping from head-to-block seam, visible as crusty residue low on engine sides, Sweet coolant smell after driving, Gradual coolant loss with no visible puddle, White residue on oil cap if leak becomes severe
Fix: Engine-out job on most shops due to chassis rail clearance. 12-16 hours labor. Must resurface heads, replace timing belt/water pump/pulleys while it's apart. If you wait too long and overheat, you're looking at warped heads or worse.
Estimated cost: $2,200-3,500
Transmission Oil Cooler Line Corrosion (4EAT Auto)
Common · high severity
Typical onset: 100,000-180,000 mi
Symptoms: Pink ATF mixed with coolant in overflow reservoir, Transmission slipping or erratic shifts after cooler contamination, Coolant in transmission pan (milky fluid), Sudden transmission failure if cross-contamination goes unnoticed
Fix: Steel cooler lines rust through where they enter the radiator. Coolant mixes with ATF and destroys clutch packs. Requires new radiator, transmission flush, or full rebuild if contamination sat. Preventive replacement of lines: 2-3 hours. Full trans rebuild after contamination: 10-14 hours plus $1,800-2,800 in parts.
Estimated cost: $400-700 preventive, $3,500-5,000 if trans damaged
Rear Wheel Bearing Failure
Common · medium severity
Typical onset: 90,000-140,000 mi
Symptoms: Growling or humming from rear that increases with speed, Noise changes with cornering load, ABS light may illuminate if bearing collapses far enough
Fix: Press-in bearing hub assembly. Requires hydraulic press and sometimes heat. 2-3 hours per side at a shop with proper tooling. Fronts fail less often but same labor.
Estimated cost: $350-550 per corner
Ignition Coil Pack Failure (2.5L)
Occasional · medium severity
Typical onset: 70,000-120,000 mi
Symptoms: Misfires under load or when damp, Check engine light with P030X codes, Rough idle, hesitation on acceleration
Fix: Coil-on-plug design. Replace the failed coil and inspect plug boots for arcing. If caught early, 0.5 hour per coil. If you ignore it, unburned fuel can damage the cat. Always replace spark plugs at same time if original.
Estimated cost: $150-250 per coil plus plugs
Front Crossmember Rust (Salt Belt)
Occasional · high severity
Symptoms: Visible rust perforation on front subframe near control arm mounts, Clunking over bumps if mount points deteriorate, Fails state safety inspection in rust states
Fix: Subframes rot from inside out in the Northeast/Midwest. By the time you see holes, structural integrity is compromised. Replacement subframe: 8-10 hours to drop engine/trans, swap frame, realign. Some try welding but it rarely lasts.
Estimated cost: $2,000-3,500 for subframe replacement
Catalytic Converter Failure (2.5L)
Occasional · medium severity
Typical onset: 120,000-180,000 mi
Symptoms: P0420 code (cat efficiency below threshold), Rotten egg smell, Loss of power, poor fuel economy, Rattling from under car if substrate breaks apart
Fix: Factory cats are integrated into the exhaust manifold on early 2.5L. Aftermarket options exist but fitment varies. 3-4 hours labor if no manifold studs break. If they do, add another 2 hours for extraction.
Estimated cost: $800-1,400 with OEM-style parts
Owner tips
If buying a 2.5L, budget for head gaskets immediately unless already done with receipts. Check for coolant weepage before purchase.
Inspect transmission cooler lines at every oil change — surface rust is normal, flaking rust means replace NOW before they leak.
Use OEM-spec coolant (Subaru blue or equivalent) and change every 30k to slow head gasket degradation.
In salt states, undercoat the subframe or walk away from rusty examples — frame replacement costs more than the car is worth.
Buy the 3.0L H6 if you can find one; otherwise budget $3k for head gaskets and cooler lines on any 2.5L, or keep shopping.
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.
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AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE · 20V001000
2020-01-02 · EA15001
Subaru of America, Inc. (Subaru) is recalling certain 2009-2013 Forester, 2003-2006 Baja, 2004-2011 Impreza, 2004-2014 WRX (STI included), 2003-2014 Legacy and Outback, and 2005-2006 Saab 9-2X vehicles originally sold, or ever registered, in the states of Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands or "Zone A."
These vehicles had their passenger frontal air bag inflators previously replaced under a prior recall using inflators of the same design. The inflators may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling.
Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Subaru will notify their owners. General Motors will notify Saab owners. Dealers will replace the passenger air bag inflators with alternate inflators, free of charge. The recall began January 7, 2020. Subaru Owners may contact Subaru customer service at 1-844-373-6614. Saab owners may contact the Saab Customer Assistance Center at 1-800-955-9007. Subaru's number for this recall is TKA-20.
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE · 20V002000
2020-01-02 · EA15001
Subaru of America, Inc. (Subaru) is recalling certain 2009-2013 Forester, 2003-2006 Baja, 2004-2011 Impreza, 2004-2014 WRX (including STI), 2003-2014 Legacy and Outback, and 2006 Saab 9-2X vehicles originally sold, or ever registered, in the states of Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, and West Virginia or "Zone B."
These vehicles had their passenger frontal air bag inflators previously replaced under a prior recall using inflators of the same design. The inflators may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling.
Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Subaru will notify their owners. General Motors will notify Saab owners. Dealers will replace the passenger air bag inflators, free of charge. The recall began January 7, 2020. Subaru owners may contact Subaru customer service at 1-844-373-6614. Saab owners may contact the Saab Customer Assistance Center at 1-800-955-9007. Subaru's number for this recall is TKB-20.
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE · 20V003000
2020-01-02 · EA15001
Subaru of America, Inc. (Subaru) is recalling certain 2009-2013 Forester, 2003-2006 Baja, 2004-2011 Impreza, 2004-2014 WRX (including STI), 2003-2014 Legacy and Outback, and 2005-2006 Saab 9-2X vehicles originally sold, or ever registered, in the states of Alaska, Colorado, Connecticut, Idaho, Iowa, Maine, Massachusetts, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, Oregon, Rhode Island, South Dakota, Utah, Vermont, Washington, Wisconsin, and Wyoming or "Zone C."
These vehicles had their passenger frontal air bag inflators previously replaced under a prior recall using inflators of the same design. The inflators may explode due to propellant degradation occurring after long-term exposure to high absolute humidity, temperature and temperature cycling.
Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Subaru will notify their owners. General Motors will notify Saab owners. Dealers will replace the passenger air bag inflators, free of charge. The recall began January 7, 2020. Subaru owners may contact Subaru customer service at 1-844-373-6614. Saab owners may contact the Saab Customer Assistance Center at 1-800-955-9007. Subaru's number for this recall is TKC-20.
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE · 16V358000
2016-05-25 · EA15001
Subaru of America, Inc. (Subaru) is recalling certain model year 2003-2004 Legacy, Outback, 2009-2011 Legacy, Outback, Forester, 2006-2011 Impreza, Tribeca, 2003-2006 Baja, and 2006 Saab 9-2x vehicles originally sold or that have ever been registered in Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands, or "Zone A."
These vehicles may be equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules, and used as original equipment or replacement equipment. In the event of a crash necessitating deployment of the front air bags, these inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.
Consequence: An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.
Remedy: Subaru will notify their owners. General Motors will notify Saab owners. Dealers will replace the passenger frontal air bag inflator, free of charge. The recall began August 26, 2016. Owners may contact Subaru customer service at 1-856-488-8500. Saab owners may contact GM at 1-800-955-9007. Subaru's number for this recall is TKA-16.
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE · 16V359000
2016-05-25 · EA15001
Subaru of America, Inc. (Subaru) is recalling certain model year 2003-2004 Legacy, Outback, 2006-2008 Impreza, Tribeca, 2006 Saab 9-2x, and 2003-2006 Baja vehicles originally sold or that have ever been registered in Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, and West Virginia, or "Zone B."
These vehicles may be equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules, and used as original equipment or replacement equipment. In the event of a crash necessitating deployment of the front air bags, these inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.
Consequence: An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.
Remedy: Subaru will notify their owners. General Motors will notify Saab owners. Dealers will replace the passenger frontal air bag inflator, free of charge. The recall began August 24, 2016. Owners may contact Subaru customer service at 1-856-488-8500. Subaru's number for this recall is TKB-16.
Note: This notice is only for vehicles that were not covered by 16V-358 for Zone A.
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE · 16V361000
2016-05-25 · EA15001
Subaru of America, Inc. (Subaru) is recalling certain model year 2003-2004 Legacy, Outback, and Baja vehicles originally sold or that have ever been registered in Alaska, Colorado, Connecticut, Idaho, Iowa, Maine, Massachusetts, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, Oregon, Rhode Island, South Dakota, Utah, Vermont, Washington, Wisconsin, and Wyoming, or "Zone C.".
These vehicles may be equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules, and used as original equipment or replacement equipment. In the event of a crash necessitating deployment of the front air bags, these inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.
Consequence: An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.
Remedy: Subaru will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge. The recall began August 24, 2016. Owners may contact Subaru customer service at 1-856-488-8500. Subaru's number for this recall is TKC-16.
Note: This recall covers vehicles that were not previously covered in 16V-358 for Zone A or 16V-359 for Zone B.
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE · 15V323000
2015-05-28 · EA15001
Subaru of America, Inc. (Subaru) is recalling certain model year 2003-2004 Subaru Baja vehicles manufactured January 22, 2003, to July 21, 2004, 2004-2005 Impreza vehicles manufactured January 28, 2003, to May 31, 2005, 2003-2008 Subaru Legacy vehicles manufactured January 22, 2003, to May 2, 2008, 2003-2008 Subaru Outback vehicles manufactured February 18, 2003, to May 5, 2008, and 2005 Saab 9-2x vehicles manufactured February 11, 2004, to March 17, 2005. The affected vehicles are equipped with a passenger side frontal air bag that may be susceptible to moisture intrusion which, over time, could cause the inflator to rupture upon its deployment.
Consequence: In the event of a crash necessitating deployment of the passenger's frontal air bag, the inflator could rupture with metal fragments striking the vehicle occupants potentially resulting in serious injury or death.
Remedy: Subaru will notify their owners and General Motors will notify Saab owners. Dealers will replace the passenger air bag inflator, free of charge. The Subaru recall began on June 17, 2015. Owners may contact Subaru customer service at 1-800-782-2783. The Saab recall began on July 27, 2015. Owners of Saab vehicles may call 1-800-955-9007. Subaru's number for this recall is WQR-53. Note: The recall completely supersedes recall 14V-399 (WQL-48) and partially supersedes recall 14V-763 (WQP-51) in that model year 2004 through 2005 Subaru Impreza and model year 2005 Saab 9-2x vehicles are now only part of this campaign. Note: On December 18, 2015 Subaru informed NHTSA of an expansion of this recall to include certain model year 2003-2004 Subaru Baja, 2003-2008 Subaru Legacy and 2003-2008 Subaru Outback vehicles.
AIR BAGS · 14V763000
2014-12-01 · PE14016
Subaru of America, Inc. (Subaru) is recalling certain model year 2003-2004 Legacy and Outback vehicles, and 2003-2005 Baja vehicles sold, or ever registered, in geographic locations associated with high absolute humidity. Specifically, vehicles sold, or ever registered, in Puerto Rico, Hawaii, the U.S. Virgin Islands, Guam, Saipan, American Samoa, Florida and adjacent counties in southern Georgia, as well as the coastal areas of Alabama, Louisiana, Mississippi and Texas. Upon deployment of the passenger side frontal air bag, excessive internal pressure may cause the inflator to rupture.
Consequence: In the event of a crash necessitating deployment of the passengers frontal air bag, the inflator could rupture with metal fragments striking the vehicle occupants potentially resulting in serious injury or death.
Remedy: Subaru will notify their owners. Dealers will replace the passenger air bag inflator, free of charge. The recall began on January 15, 2015. Owners may contact Subaru at 1-800-782-2783. Subaru's number for this recall is WQP-51. Note: This recall supersedes recall 14V-471. This recall has been partially superseded by 15V-323. All 2005 model year Subaru Legacy and Outback vehicles will now be repaired under recall 15V-323.
Airtex Products LP (Airtex) is recalling certain model E8598M, E8518M, E8600M, E8596M, and E8597M fuel pumps manufactured July 26, 2013, and July 29, 2013 and used as aftermarket replacements on Subaru Baja's, Outback's and Legacy's. The affected fuel pumps were sold or installed into the aftermarket applications on or after July 26, 2013, and may may leak fuel from the base of a fuel line connection when the gas tank is full.
Consequence: A fuel leak in the presence of an ignition source increases the risk of a fire.
Remedy: Airtex will notify owners, and will replace the fuel pump, free of charge. Recall is expected to begin on January 2, 2014. Customers may contact Airtex at 1-800-880-3056. The recall is expected to begin during January 2014. This recall is being conducted by Airtex, not by Subaru.
VEHICLE SPEED CONTROL:CABLES · 04V128000
2004-03-16
ON CERTAIN PASSENGER SEDANS, WAGONS, AND SPORT UTILITY VEHICLES, THE CRUISE CONTROL CABLE COULD COME OUT OF ITS TRACK ON THE CRUISE CONTROL LEVER AND LODGE ON THE CONTROL LEVER TAB WHEN THE ACCELERATOR PEDAL IS RELEASED. IF THIS CONDITION OCCURS, THE THROTTLE WILL NOT RETURN TO THE IDLE POSITION AND WILL REMAIN IN AN OPEN POSITION.
Consequence: IF THIS OCCURS DURING VEHICLE OPERATION, THE DRIVER COULD LOSE CONTROL OF THE VEHICLE, WHICH COULD RESULT IN A CRASH.
Remedy: DEALERS WILL INSTALL A CRUISE CONTROL CABLE RETAINING CLIP TO THE CRUISE CONTROL LEVER TAB ON THE THROTTLE SHAFT IN ORDER TO PREVENT THE CRUISE CONTROL CABLE FROM COMING OUT OF ITS TRACK. OWNER NOTIFICATION BEGAN ON APRIL 12, 2004. OWNERS SHOULD CONTACT SUBARU AT 1-800-782-2783.
FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP · 03V303000
2003-08-20
CERTAIN PASSENGER OR SPORT UTILITY VEHICLES MAY HAVE A LOOSE OR OUT OF POSITION FUEL FILLER HOSE CLAMP.
Consequence: THIS COULD RESULT IN FUEL LEAKAGE. FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.
Remedy: DEALERS WILL INSPECT AND TIGHTEN THE CLAMP ON THE FUEL FILLER HOSE. OWNER NOTIFICATION BEGAN AUGUST 27, 2003. OWNERS SHOULD CONTACT SUBARU AT 1-800-782-2783.
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