2020 Subaru Outback Engine Problems

Vehicle: 2020 Subaru Outback Onyx/Limited/Touring XT (2.4L Turbo FA24) Component: Engine Lubrication / Oil Pan Sealant I am reporting a manufacturing defect involving the engine oil pan seal on the 2020 Subaru Outback 2.4L Turbo. Upon inspection of fluid accumulation at the transmission joint, a Subaru dealership diagnostic confirmed that the engine oil pan seal has failed. The dealership noted that engine oil is leaking and being forced rearward by airflow while the vehicle is in motion, saturating the transmission assembly. Technician Admission: The service department at the Subaru dealership explicitly stated that this is a "known manufacturing issue" with the FA24 engine series. Financial Concession: To acknowledge the nature of this premature failure, the dealership waived the $185 diagnostic fee, resulting in a $0 invoice (attached). Inadequate Coverage: Despite the dealership’s admission and a repair quote exceeding $1,100 (file is attached), Subaru has not yet issued a recall or extended warranty for this specific 2020+ turbo application, though similar issues with RTV sealant have plagued the brand’s newer engine platforms. The technician confirmed that the leak is significant enough that oil is traveling the length of the transmission. This presents a potential fire hazard if oil contacts high-temperature exhaust components (such as the turbocharger or catalytic converter) and contributes to environmental contamination. This is the Turbo (XT) model. Turbochargers generate much higher heat, which makes an oil leak significantly Subaru National Customer Service has advised me to file this complaint with the NHTSA. I am requesting that the NHTSA investigate the frequency of oil pan seal failures on the 2020+ 2.4L Turbo (FA24) engine to determine if a mandatory recall or extended warranty (similar to past CVT or engine seal settlements) is warranted to protect consumers from the high cost of a documented manufacturing flaw.

The contact owns a 2020 Subaru Outback. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to an independent mechanic, who diagnosed a failure with the thermo-control valve. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 90,000.

On 12/6/2023, as I slowly turned right into a parking space, my car suddenly surged forward and accelerated without my input to the gas pedal. The brakes did not work, and there was no resistance from the brake pedal when I repeated to push it. The car continued to accelerate for about 80 ft as I focused on steering to avoid hitting other cars parked in the lot. The car ran over a curb, up a grassy area, and crashed into a row of trees. The airbag did not deploy. I sustained neck muscle strain/whiplash, and bruises to my chest and right knee. My safety was at risk, as well as anyone or anything that was in the car's path since I had no control over the acceleration or the brakes. The car is a 2020 Subaru Outback with about 44000 miles. It is in a body shop and they have not yet determined if it is safe to work on. So far, they have observed the engine race when the car was turned on. There were no warning signs prior to the acceleration. When I called the Subaru dealer service department, I was told that they never heard of this before and it had to have been my fault. They said I could bring it in after the body damage is repaired, and that I can pay for a diagnotic report. However, they expect that the report will not show anything.

A well-known failure of the Thermal Control Valve (TCV) occurred, which disabled many or most of the safety features on the car in addition to crippling the heat output in the cabin. Additionally, depending on which way the valve sticks, it could overheat the car and ruin the engine, or worse. Car is under 4 years old and repair estimate is nearly $1900. There is a technical safety bulletin [XXX] that outlines a redesigned TCV. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The factory 2020 Subaru Outback Wagon is built with a Thermo Control Valve that is, essentially, made out of a composite plastic. As this part is part of the engine cooling system, it is placed under both heat and pressure. While it controls the anti-freeze to the heater core in the passenger compartment, it is also attached under cover to metal fittings. While the car now has about 90,000 miles, this control valve cracked and began to leak anti-freeze on top of the engine. Without cooling, the engine would likely be ruined. Thus, the car required immediate service. When a fault like this occurs, by the way, the Subaru Eyesight System shuts down taking with it various safety features. I had the defective part replaced and it's replacement is not made of composite plastic but, rather and more appropriately, metal. It is my belief that the selection of the orignal part was a design defect ignoring the potential for differential expansion of the parts when exposed to such temperatures. Failure was inevitable. It is worth noting this is not an inexpensive repair as numerous parts have to be removed to access this valve. Likewise, the service representative made note that numerous other customers have had to have the same service.

At one year and 7,358 an engine oil leak had to be repaired, and still seepage and monitor is recommended. Then at three years and 28,175 the coolant bypass valve failed and was repaired. Both problems were covered by warrently, but as I live 60 miles from the dealer it was a hassle. I bought the car new in March 2020. I can not recommend Sabaru to people who ask about it and it is highly unlikely I would purchase another Subaru. However it is comfortable and practical and do not plan to sell or trade it for another car at this time. Now at four months after the latest repair it appears to be doing well, and I monitor the oil level.

I just purchased a Outback XT with the 2.4l turbo engine. After more researching with owning the car I discovered these cars with this engine can have a oil pan leak due to the bad RTV sealant applied to the lower oil pan from the factory. I went outside to go look under my car to see if this issue is occurring to mine. To discovery my car has a small oil leak from the rear of the oil pan. it has 31k miles. Further research shows the WRX whom has the same engine also has an issue with RTV falling apart within the oil pan and having the oil pick up tube sucking up the gasket in small pieces. These pieces are then and can get stuck at the top of the tube where a small screen is and can STARVE the engine from oil! MULTIPLE pictures of various shops have shown this LITERALLY. This is a big issue and is common for these engines to have this from the factory many YouTube, forums, blogs are saying this! Search " '22 WRX RTV oil pan pick up tube issue" , "Subaru 2.4l Turbo oil pan leak" , "Subaru 2.4l Oil peak up with RTV" This MUST BE CORRECTED it can cause SEVERE engine failure. THIS NEEDS to be RECALLED IMEDIATELY!

Check engine light came on with error code p26a5 which seems to be known issue with the Thermo Control Valve.

Vehicle just quit running going down the road called roadside assistance after approximately two plus hours no help policeman comes along and said need to move car so he called a tow service and within minutes tow truck comes and tows my vehicle to Subaru dealership in Des Moines Ia. This happened last Sunday come Monday morning I get a call about my car they look into the problem told me I had a bad thermal control valve and parts would not be here until December. I asked if I could have it towed to dealership in Bellevue Nebraska where I live they said call Subaru of America and I did I explained the situation to them and they gave me a case number then said they would call the next day it didn’t happen called them back and they say working on it we’ll it’s been a week and still no call back and I don’t know where the car is I feel I’m being blown off

The contact owns a 2020 Subaru Outback. The contact stated while driving 30 MPH, the vehicle began to jerk and then stalled. The check engine warning light and several unknown warning lights were illuminated. The contact was unable to veer to the side of the road. The contact was able to restart the vehicle and continued driving; however, the failure reoccurred that same day. The contact veered to the side of the road and restarted the vehicle. The contact was able to drive to her residence; however, the failure persisted. The vehicle was towed to the dealer where it was diagnosed that the Engine Control Module (ECM) was malfunctioning. The dealer reset the warning lights; however, the failure had recurred more increasingly. The vehicle was then towed to a second dealer, Subaru of Pembroke Pines (16100 Pines Blvd, Pembroke Pines, FL 33027) where the fuel pump and high-pressure fuel pump were replaced; however, the failure persisted. The dealer then replaced the Engine Control Module (ECM). The vehicle was not fixed and remained at the dealer since July 12, 2022. The manufacturer was notified of the failure and followed up with the dealer. The contact was awaiting a call back from the manufacturer. A case was opened. The failure mileage was approximately 9,846.

The EyeSight system will randomly not load at times and need to be reset for Rear Automatic Braking and other EyeSight safety features to become available. This usually only occurs within 30 seconds of engine startup but always occurs when plugging in a phone with Android Auto (a phone with Apple Car Play has never been used for verification). Warning message is displayed on driver's side message center stating EyeSight, RAB, and other safety features are not available. Reproduction of problem is difficult as it seems random.

My car stalled at a stop light when I attempted to go when the light turned green. The car was in auto shut off mode so the engine was not running at the time. When I took my foot off the brake to go, the car didn’t restart and started shaking and all the lights on the dash came on. There was also a piercing warning sound and the infotainment screen showed that the “eyesight “ and all other driver assistance program were off but my audiobook continued to play. I tried restarting the car but it would not restart. I put the car in park and tried to get it to turn off but it wouldn’t. Since I was at a light and cars were behind me, I put on my hazards and waited a few minutes and got the car to restart and to get that noise to stop, sounded like a siren. My fuel warning had just come on but it indicated that I had 50 miles so not sure if it has anything to do with it?

The contact owns a 2020 Subaru Outback. The contact stated that while enter a freeway the speed suddenly reduced to approximately 15 MPH. The vehicle failed to exceed 15 MPH. Additionally, the vehicle lurched forward and would not immediately stop while depressing the brake pedal. During the failure several warning lights had illuminated including the check engine, brakes, and stability control. The vehicle was towed to the local dealer who reprogrammed the computer however, the failure continued. The manufacturer was notified of the failure. The failure mileage was 23,000.

WIFE REPORTED CAR STALLED WHEN MAKING A TURN AFTER STOPPING. WHILE TURNING SHE SAID IT FELT LIKE THE CAR WAS NOT GETTING ANY GAS AND HAD NO POWER. SHE LET THE VEHICLE ROLL TO A STOP ON THE SIDE OF THE ROAD. SHE SAID IT TOOK SEVERAL ATTEMPTS FOR THE CAR TO START BACK UP. THIS HAPPENED 3 TIMES TODAY DURING A TRIP TO THE DENTIST IN THE CITY OF LYNCHBURG, VIRGINIA. I CALLED TERRY SUBARU OF LYNCHBURG WHEN SHE GOT HOME AND REPORTED THE PROBLEM. THEY TOLD ME TO BRING IT IN TOMORROW TO HAVE IT CHECKED OUT.

TL* THE CONTACT OWNS A 2020 SUBARU OUTBACK. THE CONTACT STATED THAT WHILE DRIVING 45 MPH EXITING THE HIGHWAY, THE VEHICLE STARTED TO SHAKE THEN STALLED. THE CHECK ENGINE, OIL AND BATTERY WARNING LIGHTS ILLUMINATED. THE CONTACT PUT THE VEHICLE IN PARK QUICKLY. THE CONTACT WAS IN THE MIDDLE LANE WITH NO SHOULDER. THE CONTACT WAITED THIRTY SECONDS TO RESTART THE VEHICLE. THE STARTED TO SHAKE AGAIN. THE VEHICLE WAS UNABLE TO RESTART. THE TOW TRUCK OPERATOR ATTEMPTED TO RESTART THE VEHICLE BUT WAS UNABLE TO. THE VEHICLE WAS TOWED TO REYNOLDS' SUBARU (268 HAMBURG RD, LYME, CT 06371) HOWEVER, THE MECHANIC WAS UNABLE TO DUPLICATE THE FAILURE. THE VEHICLE REMAINED AT THE DEALER. THE CONTACT MENTIONED THAT THE DEALER INFORMED HER THAT NATIONAL SUBARU INFORMED THEM TO RETURN THE VEHICLE BECAUSE THEY WERE UNABLE TO DUPLICATE THE FAILURE. THE CONTACT MENTIONED THAT SHE DIS NOT WANT TO DRIVE THE VEHICLE BECAUSE SHE TRANSPORTED HER GRANDCHILDREN IN THE VEHICLE. THE CONTACT ALSO MENTIONED THAT THE VEHICLE REMAINED AT THE DEALER FOR TWO WEEKS AND A DAY STILL UNREPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND A CASE NUMBER WAS PROVIDED. THE FAILURE MILEAGE WAS APPROXIMATELY 10,950.

THERE IS NO WAY TO DISABLE THE AUTO START/STOP SYSTEM. IN FLORIDA THE TEMP CAN GET OVER 95 DEGREES. AFTER 10-15 SECONDS OF THE CAR BEING OFF THE CAR STARTS TO HEAT UP. MY WIFE WHO HAS BREATHING PROBLEMS STARTS HAVING PROBLEMS. I HAVE ASK THE DEALER TO PERMANENTLY DISABLE THIS FEATURE BUT THEY SAID NO. YOU CAN DO IT EACH TIME YOU START THE CAR BUT IT IS SEVERAL SCREENS DEEP ON THE INFORMATION SYSTEM. PEOPLE WHO DO NOT DRIVE THE CAR OFTEN (LIKE MY WIFE) WOULD HAVE TROUBLE TURNING THIS FEATURE OFF AND COULD PASS OUT SITTING AT A LIGHT. I RECOMMEND SUBARU OFFER A WAY TO DISABLE THIS FEATURE FOR PEOPLE WHO HAVE BREATHING ISSUES. AT A VERY MINIMUM THEY NEED TO MOVE THE DISABLING OF THIS FEATURE ON EVERY START TO THE MAIN INFORMATION SCREEN WHERE ANYONE CAN FIND IT.

The contact owns a 2020 Subaru Outback. The contact stated that the coolant needed to be replenished frequently. The contact had taken the vehicle to the dealer where a pressure test was performed however, the mechanic did not discover failure with the vehicle. The manufacturer was notified of the failure but offered no assistance. The vehicle was not repaired. The failure mileage was unknown.