Complaint 2209253

Complaint Summary

UNKNOWN OR OTHER

Owner Narrative

I am submitting this complaint regarding a known exhaust manifold/flex pipe failure affecting my 2020 Subaru Ascent Touring (VIN: [XXX] ). My vehicle was diagnosed by a Subaru dealership with a “broken flex pipe on the header” causing excessive exhaust noise and exhaust leak concerns. Repair estimate was slightly over $2,000. After researching the issue, I discovered numerous reports from other Subaru Ascent owners describing identical failures involving cracked exhaust manifold welds and failed flex pipe sections. Subaru has also issued TSB 09-106-23 involving exhaust manifold weld cracking and redesigned replacement components for this issue. Symptoms began in the low 70,000-mile range and progressively worsened before formal diagnosis at approximately 83,000 miles. This appears to be a widespread defect involving emissions/exhaust components. Many owners online report loud cold-start exhaust noise, cracked manifold welds, failed flex pipe sections, exhaust fumes/smells, and expensive manifold replacement repairs. My concern is both the widespread nature of the defect and Subaru’s handling of complaints regarding the issue. Initially, Subaru denied assistance because the vehicle has a branded title. After documentation was provided showing federally mandated emissions-related coverage/extensions were active for this VIN regardless of title status, the denial basis changed to mileage. After explaining symptoms began prior to the mileage threshold, Subaru then cited lack of dealership service history after my ownership despite the vehicle being regularly maintained by a local mechanic. I am requesting NHTSA review whether this exhaust manifold/flex pipe defect represents a broader reliability and emissions-related defect trend affecting Subaru Ascent vehicles. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Owner-submitted narrative on file with NHTSA. Complaint narratives are self-reported and have not been verified.