2004 Subaru Baja Problems: 4 Known Issues

2004 Subaru Baja Problems: 4 Known Issues | Au7o

NHTSA Recalls16 recalls

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 #20V00300002/01/2020

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

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 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.

Campaign #16V35800025/05/2016

AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE

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.

Campaign #15V32300028/05/2015

+ 11 more recalls. Check all on NHTSA.gov

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Frequently Asked Questions

What are the most common Subaru Baja problems?

According to Au7o's analysis of 2,620+ owner reports, the 2004 Subaru Baja has 4 documented issues. The most frequently reported are: EJ25 Head Gasket Failure, Turbo Baja (EJ255) Turbocharger Failure and Banjo Bolt Screen Restriction, Rear Strut Tower Rust and Structural Weakening. Of these, 3 are rated critical and should be addressed promptly.

Is the Subaru Baja reliable?

The 2004 Subaru Baja has 4 known issues documented across 2,620+ owner reports. 3 issues are rated critical: EJ25 Head Gasket Failure and Turbo Baja (EJ255) Turbocharger Failure and Banjo Bolt Screen Restriction and Rear Strut Tower Rust and Structural Weakening. 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 Baja problems?

Repair costs for known Subaru Baja issues range from $50 to $3,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, EJ25 Head Gasket Failure, typically costs $1,500-$2,800 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 2003-2006 Subaru Baja EJ25 Head Gasket Failure?

The Subaru Baja's 2.5L EJ25 naturally-aspirated engine suffers from the same chronic head gasket failure that affects all EJ25-equipped Subarus. The composite gaskets degrade over time, typically between 80,000-150,000 miles, causing external oil and coolant leaks. The Baja's eng… Repairs typically run $1,500-$2,800. Severity: high.

What is the 2004-2006 Subaru Baja Turbo Baja (EJ255) Turbocharger Failure and Banjo Bolt Screen Restriction?

The Baja Turbo uses the EJ255 turbocharged engine with a TD04 turbocharger. The oil supply banjo bolt that feeds the turbo contains a small mesh screen filter that can clog over time, restricting oil flow to the turbo bearings. Oil starvation causes the turbo to fail prematurely,… Repairs typically run $50-$2,500. Severity: high.

What is the 2003-2006 Subaru Baja Rear Strut Tower Rust and Structural Weakening?

The Baja's rear strut towers (located under the bed) are highly susceptible to rust, which can compromise the structural integrity of the suspension mounting point. Water and debris accumulate around the strut towers due to the bed design, and inadequate factory rustproofing allo… Repairs typically run $300-$2,000. Severity: high.

What is the 2003-2006 Subaru Baja Bed and Rear Quarter Panel Rust?

The Baja's composite bed and steel rear quarter panels are prone to significant rust, particularly in salt-belt states. The junction between the composite bed panels and steel body structure traps moisture and road salt, accelerating corrosion. The rear wheel arches, bed floor se… Repairs typically run $200-$3,000. Severity: medium.

2004 Subaru Baja Problems: 4 Known Issues

All 4 Known Issues

2003-2006 Subaru Baja: EJ25 Head Gasket Failure#

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2004-2006 Subaru Baja: Turbo Baja (EJ255) Turbocharger Failure and Banjo Bolt Screen Restriction#

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2003-2006 Subaru Baja: Rear Strut Tower Rust and Structural Weakening#

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2003-2006 Subaru Baja: Bed and Rear Quarter Panel Rust#

Common Symptoms

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Other Subaru Models

Frequently Asked Questions

What are the most common Subaru Baja problems?

Is the Subaru Baja reliable?

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

What is the 2003-2006 Subaru Baja EJ25 Head Gasket Failure?

What is the 2004-2006 Subaru Baja Turbo Baja (EJ255) Turbocharger Failure and Banjo Bolt Screen Restriction?

What is the 2003-2006 Subaru Baja Rear Strut Tower Rust and Structural Weakening?

What is the 2003-2006 Subaru Baja Bed and Rear Quarter Panel Rust?