2004 Subaru WRX Problems: 3 Known Issues
2004 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated October 2026
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Subaru WRX has 3 documented known issues, with 1 rated critical. The most serious is Firewall Spot-Weld Cracking and Clutch Pedal Bracket Flex Causing Hard Shifting or Clutch Engagement Problems ($400-$1,800 repair). Across all issues with published estimates, repair costs range from $250 to $1,800. DIY maintenance guides at au7o.io.
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All 3 Known Issues
NHTSA Recalls6 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.
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.
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.
EXTERIOR LIGHTING
CERTAIN AAI MOTORSPORTS COMBINATION LAMPS SOLD AS REPLACEMENT LAMPS FOR USE ON THE ABOVE LIST PASSENGER VEHICLES. COMBINATION LAMPS NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT."
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE
Subaru of America, Inc. (Subaru) is recalling certain 2004-2005 Impreza and WRX vehicles that received replacement front passenger air bag inflators under a previous recall. The replacement air bag inflators may have been installed incorrectly.
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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 3 documented issues. The most frequently reported are: Firewall Spot-Weld Cracking and Clutch Pedal Bracket Flex Causing Hard Shifting or Clutch Engagement Problems, Fuel Filler Neck Corrosion Causing EVAP Leaks, Fuel Smell, and Check-Engine Light, Front Wheel Bearing Grease Breakdown Causing Premature Bearing Failure and Highway Hum on GD-Chassis WRX. Of these, 1 is rated critical and should be addressed promptly.
Is the Subaru WRX reliable?
The 2004 Subaru WRX has 3 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 1 issue is rated critical: Firewall Spot-Weld Cracking and Clutch Pedal Bracket Flex Causing Hard Shifting or Clutch Engagement Problems. 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 $250 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 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 2002-2007 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.
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.