2002 Subaru Forester Problems: 5 Known Issues

2002 Subaru Forester Problems: 5 Known Issues | Au7o

NHTSA Recalls23 recalls

SEAT BELTS

Subaru of America, Inc. (Subaru) is recalling certain 2009-2013 Forester vehicles. The front seat belt assembly force-limiter may not operate correctly in the event of a crash.

Campaign #22V83800010/11/2022

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

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

+ 18 more recalls. Check all on NHTSA.gov

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Frequently Asked Questions

What are the most common Subaru Forester problems?

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2002 Subaru Forester has 5 documented issues. The most frequently reported are: EJ25 Head Gasket Failure (External Leak), Oil Pump Backing-Plate Screws Loosening — Front Crank Seal Push-Out and Low Oil Pressure, 4EAT Transfer Clutch Torque Bind — Duty Solenoid C / MPT Clutch Pack Failure (Automatic AWD). Of these, 1 is rated critical and should be addressed promptly.

Is the Subaru Forester reliable?

The 2002 Subaru Forester has 5 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 1 issue is rated critical: EJ25 Head Gasket Failure (External Leak). 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 Forester problems?

Repair costs for known Subaru Forester issues range from $80 to $3,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, EJ25 Head Gasket Failure (External Leak), typically costs $1,800-$3,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 1998-2010 Subaru Forester EJ25 Head Gasket Failure (External Leak)?

The EJ25 2.5L horizontally-opposed engine in 1998-2010 Foresters is notorious for external head gasket failure. Unlike typical blown head gaskets that cause overheating, the Subaru EJ25 gaskets fail externally, leaking coolant and oil down the sides of the engine. The failure is… Repairs typically run $1,800-$3,500. Severity: high.

What is the 1998-2010 Subaru Forester Oil Pump Backing-Plate Screws Loosening — Front Crank Seal Push-Out and Low Oil Pressure?

The EJ-series front-mounted oil pump has a rotor cover (backing plate) held on by five small screws installed without thread locker at the factory. On high-mileage engines these screws routinely work loose. Pressurized oil then escapes past the rotor cover into the pump body behi… Repairs typically run $150-$900. Severity: medium.

What is the 1998-2010 Subaru Forester 4EAT Transfer Clutch Torque Bind — Duty Solenoid C / MPT Clutch Pack Failure (Automatic AWD)?

On automatic-transmission Foresters with the 4EAT gearbox, all-wheel drive is managed by an electronically controlled multi-plate transfer (MPT) clutch on the tail of the transmission, modulated by the 'Duty C' solenoid. When the solenoid sticks or the clutch pack glazes, the clu… Repairs typically run $250-$1,800. Severity: medium.

What is the 1998-2005 Subaru Forester Knock Sensor Housing Cracking — P0325 and Permanent Timing Retard?

The single knock sensor bolted to the top of the EJ block on SF- and early SG-generation Foresters has a brittle plastic/resin housing that cracks after years of heat cycling directly on the block. Once cracked, the piezo element's circuit reads out of range and the ECU sets P032… Repairs typically run $80-$250. Severity: low.

What is the 1998-2008 Subaru Forester Rear Differential Mount / Outrigger Bushing Collapse — Driveline Clunk on Gear Engagement?

The rear differential on SF and SG Foresters hangs on rubber bushings — a large front mount bushing plus rear outrigger bushings tying the diff nose and carrier to the body. The rubber dry-rots and cracks with age, letting the differential rotate and move vertically before it tra… Repairs typically run $150-$700. Severity: low.

2002 Subaru Forester Problems: 5 Known Issues

All 5 Known Issues

1998-2010 Subaru Forester: EJ25 Head Gasket Failure (External Leak)#

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How to Fix

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1998-2010 Subaru Forester: Oil Pump Backing-Plate Screws Loosening — Front Crank Seal Push-Out and Low Oil Pressure#

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1998-2005 Subaru Forester: Knock Sensor Housing Cracking — P0325 and Permanent Timing Retard#

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1998-2010 Subaru Forester: 4EAT Transfer Clutch Torque Bind — Duty Solenoid C / MPT Clutch Pack Failure (Automatic AWD)#

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1998-2008 Subaru Forester: Rear Differential Mount / Outrigger Bushing Collapse — Driveline Clunk on Gear Engagement#

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Other Subaru Models

Frequently Asked Questions

What are the most common Subaru Forester problems?

Is the Subaru Forester reliable?

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

What is the 1998-2010 Subaru Forester EJ25 Head Gasket Failure (External Leak)?

What is the 1998-2010 Subaru Forester Oil Pump Backing-Plate Screws Loosening — Front Crank Seal Push-Out and Low Oil Pressure?

What is the 1998-2010 Subaru Forester 4EAT Transfer Clutch Torque Bind — Duty Solenoid C / MPT Clutch Pack Failure (Automatic AWD)?

What is the 1998-2005 Subaru Forester Knock Sensor Housing Cracking — P0325 and Permanent Timing Retard?

What is the 1998-2008 Subaru Forester Rear Differential Mount / Outrigger Bushing Collapse — Driveline Clunk on Gear Engagement?