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Subaru · Known Issues

2004 Subaru WRX Problems: 6 Known Issues

2004 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026

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Issue summary

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Subaru WRX has 6 documented known issues, with 2 rated critical. The most serious are Firewall Spot-Weld Cracking and Clutch Pedal Bracket Flex Causing Hard Shifting or Clutch Engagement Problems ($400-$1,800 repair) and Takata Airbag Inflator Rupture Risk on 2003-2014 Impreza WRX (Multiple Recall Campaigns) ($0-$0 repair). Across all issues with published estimates, repair costs range from $50 to $1,800. DIY maintenance guides at au7o.io.

In This Article

  • WRX Body/Panels1
  • WRX Safety/Recalls1
  • WRX Suspension2
  • WRX Fuel System1
  • WRX Cooling1
  • Recalls13
  • FAQ
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In This Article

  • Body/Panels1
  • Safety/Recalls1
  • Suspension2
  • Fuel System1
  • Cooling1

All 6 Known Issues

Filter:
ALL YEARS202520242023202220212020201920182017201620152014201320122011201020092008200720062005200420032002

When Issues Typically Appear

Power Steering Pump and Suction Hose Air Leak Causing Whine, Foamy Fluid, and Heavy Steering
50K-180K
Firewall Spot-Weld Cracking and Clutch Pedal Bracket Flex Causing Hard Shifting or Clutch Engagement Problems
60K-150K
Radiator End Tank Cracking and Coolant Leaks on Plastic-Aluminum OEM Radiators
70K-180K
Fuel Filler Neck Corrosion Causing EVAP Leaks, Fuel Smell, and Check-Engine Light
80K-180K
050K100K150K200K mi

On the 2002-2007 Subaru WRX, on GD-chassis WRX models, repeated clutch pedal loads can crack the firewall around the clutch master cylinder and pedal bracket mounting area. Owners report the pedal assembly moving, popping noises from the firewall, inconsistent clutch engagement, and difficulty selecting gears. Subaru issued service information and many forum threads document visible sheetmetal cracking or broken spot welds in the pedal box/firewall area.

Common Symptoms

  • clicking or popping when pressing clutch pedal
  • clutch engagement point changes
  • difficulty shifting into gear
  • visible firewall flex
  • pedal bracket movement under dash

How to Fix

Diagnosis involves inspecting the clutch pedal bracket, master cylinder mounting area, and firewall from both cabin and engine-bay sides while an assistant depresses the pedal. Repairs range from reinforcement plates and bracket replacement to welding cracked seams and installing aftermarket firewall reinforcement kits; alignment of the pedal assembly and master cylinder pushrod should be checked afterward. Ignoring it can worsen shifting issues and lead to repeated clutch hydraulic problems.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • Humble Rumble V3 Firewall Spot Weld Replacement Hardware Kit

    six position-specific replacement fasteners after spot-weld failure is visually confirmed and sheet metal remains repairable by the kit method Fitment/availability: 2008-2011 Impreza and 2008-2014 WRX/STI GR/GV/GH/GE only; not 2002-2007 …

Owner tips & cautions

  • TipHave a helper press the clutch while you watch the master cylinder/firewall area for movement; this is the quickest confirmation before transmission removal.
Typical repair cost:$400 - $1,800

Research This Issue

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Community Reported
High Confidence

On the 2003-2014 Subaru WRX, impreza WRX models from roughly 2003 through 2014 were built with Takata phase-stabilized ammonium nitrate airbag inflators (driver and/or passenger side, depending on year and expansion phase). After years of humidity and temperature cycling the propellant degrades and the inflator can rupture on deployment, spraying metal fragments into the cabin. Subaru's WRX population was pulled in over several expansion waves between 2015 and 2019, totalling hundreds of thousands of Subaru vehicles, and many older WRXs still show open Takata recalls on VIN lookup.

Common Symptoms

  • Open Takata recall on VIN lookup
  • Recall notice letter
  • No driving symptom — defect only manifests on deployment

How to Fix

Run the VIN on the NHTSA recall lookup or Subaru's recall page; the dealer replaces the affected inflator(s) free of charge with no time limit. Because some cars received interim (like-for-like) inflators in early waves, a car that was 'done' years ago may have a second open remedy.

Typical repair cost:$0 - $0

Research This Issue

GoogleRedditYouTubeNHTSA
Community Reported
High ConfidenceVerifiedReviewed Sep 2026

On the 2002-2014 Subaru WRX, a common WRX complaint is a groaning or whining power steering system, especially when cold, often traced to the pump inlet O-ring or suction hose allowing air into the system. Aerated fluid becomes foamy in the reservoir and steering assist can feel inconsistent or heavy at low speeds. On higher-mileage cars, the pump itself may also wear out after running with air-contaminated fluid.

Common Symptoms

  • whining or groaning while turning
  • foamy power steering fluid
  • heavy steering when cold
  • fluid seepage near pump or hose
  • intermittent loss of steering assist

How to Fix

Inspect the reservoir for bubbles/foam, check fluid level and condition, and examine the suction hose, clamps, and pump inlet O-ring for seepage or looseness. Replacing the inlet O-ring and any hardened hose sections often cures the issue; if noise remains, the pump may need replacement and the system should be flushed with the correct Subaru-compatible fluid. Belt condition and tension should also be verified because belt slip can mimic pump noise.

Owner tips & cautions

  • TipReplace the pump inlet O-ring first before condemning the whole pump; it is a very common low-cost fix.
Typical repair cost:$50 - $700

Research This Issue

GoogleRedditYouTubeNHTSA
Community Reported
High Confidence

On the 2002-2007 Subaru WRX, 2002-2007 (GD chassis) WRX front wheel bearings fail early — often well under 80k miles — with a speed-dependent hum or roar that changes when the car is loaded into a turn. The community consensus, backed by a Subaru service bulletin covering 2001+ Impreza models, is that the factory grease breaks down under heat, and Subaru later supplied bearings packed with a different grease. Aggressive driving, wider wheels and lowering springs accelerate it. Replacement bearings that are pressed incorrectly frequently fail again within weeks, which is a repeated theme in owner threads.

Common Symptoms

  • Speed-dependent hum or roar from front
  • Noise changes when turning left or right
  • Play at the wheel at 12 and 6 o'clock
  • ABS light in advanced cases

How to Fix

Replace the wheel bearing with the updated Subaru part or a quality Koyo/NTN bearing, pressing it into the knuckle with proper support on the outer race (or replace the complete knuckle/hub assembly). Torque the axle nut to spec with the wheel on the ground. Some owners repack bearings with high-temperature grease. No recall remedy.

Typical repair cost:$250 - $700

Research This Issue

GoogleRedditYouTubeNHTSA
Community Reported
Medium ConfidenceVerifiedReviewed Sep 2026

On the 2002-2007 Subaru WRX, rust-belt GD-chassis WRX models are known for corrosion of the steel fuel filler neck and vent tubes behind the left rear wheel area. As the neck rusts through, owners notice a raw fuel smell, difficulty filling the tank, or EVAP leak codes from the compromised venting system. Subaru issued recalls and service campaigns on related Impreza models in salt-belt states because the corrosion could lead to fuel leakage.

This issue also affects: Subaru Outback

Common Symptoms

  • raw fuel smell near left rear of car
  • check engine light with EVAP leak code
  • difficulty filling fuel tank
  • visible rust on filler neck
  • fuel seepage after fill-up

How to Fix

Inspect the filler neck and vent pipes by removing the left rear wheel and splash shield, looking for rust perforation, dampness, or fuel staining. Repair usually requires replacing the filler neck assembly and associated hoses/clamps; heavily corroded fasteners may need cutting. After repair, clear EVAP codes and verify the system seals with a smoke test.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • Genuine Subaru 42066FE100 Fuel Filler Pipe

    complete rear filler pipe after corrosion/perforation is confirmed Fitment/availability: 2005-2007 Impreza WRX filler-neck branch; supersedes 42066FE060, confirm VIN and associated hoses/clamps Fitment/availability: ships in 1-3 business…

    SubaruPartsDeal

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Owner tips & cautions

  • TipCheck recall eligibility by VIN first, especially for cars originally sold in salt-belt states.
Typical repair cost:$300 - $900

Research This Issue

GoogleRedditYouTubeNHTSA
Community Reported
High Confidence

On the 2002-2014 Subaru WRX, many 2002-2014 WRX owners report coolant leaks from the crimped plastic end tanks of the factory radiator, especially as the car ages and sees repeated heat cycles. Cracks often form near the upper tank seam or hose neck, leading to a sweet coolant smell, low coolant level, and eventual overheating if ignored. This is widely documented in owner forums and repair databases across both EJ205 and EJ255 cars.

Common Symptoms

  • coolant smell after driving
  • low coolant reservoir level
  • visible coolant at radiator seam
  • engine temperature rising in traffic
  • white residue on radiator tank

How to Fix

Pressure-test the cooling system and inspect the radiator tank seams, upper neck, and side crimps for wetness or dried coolant residue. Replacement of the radiator is the standard repair; many owners upgrade to a quality all-aluminum unit or a fresh OEM-style radiator along with new hoses and cap. After replacement, the system should be properly burped to avoid trapped air and false overheating symptoms.

What you need to fix it

Only diagnosis- and fitment-reviewed repair parts are linked here.

  • Mishimoto MMRAD-WRX-01 Performance Aluminum Radiator

    early-generation replacement/upgrade after a radiator leak is proven Fitment/availability: 2002-2005 WRX EJ205 and 2006-2007 WRX EJ255; confirm transmission and factory oil-cooler plumbing, automatic applications may require relocation F…

    Mishimoto
  • Mishimoto MMRAD-STI-08 Performance Aluminum Radiator

    later-generation replacement/upgrade after a radiator leak is proven Fitment/availability: 2008-2014 WRX EJ255; also cataloged for 2008-2021 STI, confirm transmission, fan/shroud and modification clearance Fitment/availability: Add to Ca…

    Mishimoto

As an Amazon Associate, we earn from qualifying purchases; other part links may also earn au7o a commission. Confirm fitment by VIN before buying.

Owner tips & cautions

  • TipPressure-test before replacing parts; small seam leaks can be hard to see when the system is cold.
Typical repair cost:$250 - $900

Research This Issue

GoogleRedditYouTubeNHTSA
Community Reported
High Confidence
NHTSA Recalls13 recalls

EXTERIOR LIGHTING:BRAKE LIGHTS:SWITCH

Subaru of America, Inc. (Subaru) is recalling certain 2014-2016 Forester, 2008-2016 Impreza sedans, 2012-2016 Impreza station wagons, 2008-2014 WRX sedans (including STI), and 2013-2017 Crosstrek vehicles. Exposure to certain contaminants may cause the brake light switch to malfunction, preventing the brake lights from illuminating and also preventing keyless ignition vehicles from starting and CVT/automatic transmissions from being able to be shifted out of Park.

Campaign #19V14900028/02/2019

AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE

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.

Campaign #20V003000
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Other Subaru Models

Subaru Forester46Subaru Outback40Subaru Ascent25Subaru Solterra24Subaru Crosstrek23Subaru Legacy18

Frequently Asked Questions

What are the most common Subaru WRX problems?

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Subaru WRX has 6 documented issues. The most frequently reported are: Firewall Spot-Weld Cracking and Clutch Pedal Bracket Flex Causing Hard Shifting or Clutch Engagement Problems, Takata Airbag Inflator Rupture Risk on 2003-2014 Impreza WRX (Multiple Recall Campaigns), Fuel Filler Neck Corrosion Causing EVAP Leaks, Fuel Smell, and Check-Engine Light. Of these, 2 are rated critical and should be addressed promptly.

Is the Subaru WRX reliable?

The 2004 Subaru WRX has 6 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 2 issues are rated critical: Firewall Spot-Weld Cracking and Clutch Pedal Bracket Flex Causing Hard Shifting or Clutch Engagement Problems and Takata Airbag Inflator Rupture Risk on 2003-2014 Impreza WRX (Multiple Recall Campaigns). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Subaru WRX problems?

Repair costs for known Subaru WRX issues range from $0 to $1,800, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Firewall Spot-Weld Cracking and Clutch Pedal Bracket Flex Causing Hard Shifting or Clutch Engagement Problems, typically costs $400-$1,800 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 2002-2007 Subaru WRX Firewall Spot-Weld Cracking and Clutch Pedal Bracket Flex Causing Hard Shifting or Clutch Engagement Problems?

On GD-chassis WRX models, repeated clutch pedal loads can crack the firewall around the clutch master cylinder and pedal bracket mounting area. Owners report the pedal assembly moving, popping noises from the firewall, inconsistent clutch engagement, and difficulty selecting gear… Repairs typically run $400-$1,800. Severity: high.

What is the 2003-2014 Subaru WRX Takata Airbag Inflator Rupture Risk on 2003-2014 Impreza WRX (Multiple Recall Campaigns)?

Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.

Data compiled from NHTSA recalls, manufacturer TSBs, automotive forums, and AI-assisted research. No aggregated owner-report counts available for this vehicle yet.

  • Recalls13
  • FAQ
  • 02/01/2020

    AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE

    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.

    Campaign #20V00100002/01/2020

    AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE

    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.

    Campaign #20V00200002/01/2020

    ELECTRICAL SYSTEM:IGNITION:SWITCH

    Subaru of America, Inc. (Subaru) is recalling certain 2009-2013 Forester vehicles, 2008-2011 Impreza vehicles, 2008-2014 WRX vehicles, 2005-2014 Legacy vehicles, 2005-2014 Outback vehicles and 2006-2008 Tribeca vehicles equipped with a mechanical key ignition switch installed as a replacement part. The ball spring inside the switch may break, reducing the strength of the ignition switch. If this occurs, the weight on the key ring and certain road conditions could cause the ignition switch to move out of the run position to the accessory position, turning off the engine.

    Campaign #19V29700011/04/2019

    + 8 more recalls. Check all on NHTSA.gov

    Enter your VIN at NHTSA.gov to check recalls specific to your vehicle.

    Impreza WRX models from roughly 2003 through 2014 were built with Takata phase-stabilized ammonium nitrate airbag inflators (driver and/or passenger side, depending on year and expansion phase). After years of humidity and temperature cycling the propellant degrades and the infla… Repairs typically run $0-$0. Severity: high.

    What is the 2002-2007 Subaru WRX Fuel Filler Neck Corrosion Causing EVAP Leaks, Fuel Smell, and Check-Engine Light?

    Rust-belt GD-chassis WRX models are known for corrosion of the steel fuel filler neck and vent tubes behind the left rear wheel area. As the neck rusts through, owners notice a raw fuel smell, difficulty filling the tank, or EVAP leak codes from the compromised venting system. Su… Repairs typically run $300-$900. Severity: medium.

    What is the 2002-2014 Subaru WRX Power Steering Pump and Suction Hose Air Leak Causing Whine, Foamy Fluid, and Heavy Steering?

    A common WRX complaint is a groaning or whining power steering system, especially when cold, often traced to the pump inlet O-ring or suction hose allowing air into the system. Aerated fluid becomes foamy in the reservoir and steering assist can feel inconsistent or heavy at low… Repairs typically run $50-$700. Severity: medium.

    What is the 2002-2014 Subaru WRX Radiator End Tank Cracking and Coolant Leaks on Plastic-Aluminum OEM Radiators?

    Many 2002-2014 WRX owners report coolant leaks from the crimped plastic end tanks of the factory radiator, especially as the car ages and sees repeated heat cycles. Cracks often form near the upper tank seam or hose neck, leading to a sweet coolant smell, low coolant level, and e… Repairs typically run $250-$900. Severity: medium.

    What is the 2002-2007 Subaru WRX Front Wheel Bearing Grease Breakdown Causing Premature Bearing Failure and Highway Hum on GD-Chassis WRX?

    2002-2007 (GD chassis) WRX front wheel bearings fail early — often well under 80k miles — with a speed-dependent hum or roar that changes when the car is loaded into a turn. The community consensus, backed by a Subaru service bulletin covering 2001+ Impreza models, is that the fa… Repairs typically run $250-$700. Severity: medium.