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2002 Subaru Outback

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By Research the Car 5 min read

The 2002 Subaru Outback is a popular wagon known for its practicality, reliability (generally), and standard all-wheel drive. Engine options included a 2.5L SOHC EJ25 flat-4 engine producing 165 horsepower and 166 lb-ft of torque and a 3.0L DOHC EZ30 flat-6 engine producing 212 horsepower and 210 lb-ft of torque. The 2.5L engine was available with either a 5-speed manual or a 4-speed automatic transmission, while the 3.0L engine came exclusively with the 4-speed automatic. Owners generally appreciate the Outback’s spacious cargo area, comfortable ride, and off-road capability, while common complaints include head gasket issues on the 2.5L engine and the age-related issues that come with owning a 20+ year old vehicle.

Engine

2.5L SOHC EJ25 Flat-4

  • Head Gasket Failure
    • Description/Symptoms: Overheating, coolant loss (internal or external), white smoke from exhaust, “milky” oil due to coolant mixing with oil, engine misfires.
    • Solution: Replace head gaskets, machine cylinder heads to ensure flatness, replace head bolts.
    • Estimated Cost to Fix: $1500 - $2500+
    • Recalls: None Found
  • Oil Leaks
    • Description/Symptoms: Oil drips under the car, burning oil smell, low oil level, visible oil leaks around valve covers or other engine seals.
    • Solution: Replace valve cover gaskets, camshaft seals, front crankshaft seal, rear main seal.
    • Estimated Cost to Fix: $100 - $800+ depending on the source and severity of the leak.
    • Recalls: None Found
  • Catalytic Converter Failure
    • Description/Symptoms: Check engine light on (typically P0420 catalyst system efficiency below threshold), reduced engine performance, rattling sound from exhaust.
    • Solution: Replace catalytic converter.
    • Estimated Cost to Fix: $400 - $1000+
    • Recalls: None Found

3.0L DOHC EZ30 Flat-6

  • Oil Leaks
    • Description/Symptoms: Oil drips under the car, burning oil smell, low oil level, visible oil leaks around valve covers or other engine seals.
    • Solution: Replace valve cover gaskets, camshaft seals, front crankshaft seal, rear main seal.
    • Estimated Cost to Fix: $100 - $800+ depending on the source and severity of the leak.
    • Recalls: None Found
  • Catalytic Converter Failure
    • Description/Symptoms: Check engine light on (typically P0420 catalyst system efficiency below threshold), reduced engine performance, rattling sound from exhaust.
    • Solution: Replace catalytic converter.
    • Estimated Cost to Fix: $400 - $1000+
    • Recalls: None Found

Transmission

4-Speed Automatic (Both Engines)

  • Shifting Problems/Slipping
    • Description/Symptoms: Harsh or delayed shifting, transmission slipping out of gear, failure to shift into certain gears, check engine light illuminated.
    • Solution: Perform a transmission fluid flush and filter change. If the issue persists, a more extensive repair may be required, such as replacing solenoids, valve body, or a full transmission rebuild.
    • Estimated Cost to Fix: $150 (fluid flush) to $3000+ (rebuild/replacement).
    • Recalls: None Found

5-Speed Manual (2.5L Engine Only)

  • Clutch Failure
    • Description/Symptoms: Clutch slippage (engine revs but car doesn’t accelerate), difficulty shifting gears, grinding noises when shifting, high clutch pedal engagement point.
    • Solution: Replace clutch disc, pressure plate, throwout bearing, pilot bearing, and resurface the flywheel.
    • Estimated Cost to Fix: $600 - $1200+
    • Recalls: None Found

Suspension

  • Worn Out Struts and Shocks
    • Description/Symptoms: Bouncy ride, excessive body roll in corners, poor handling, nose dive during braking, uneven tire wear.
    • Solution: Replace struts and/or shocks.
    • Estimated Cost to Fix: $400 - $1000+ (depending on parts and labor).
    • Recalls: None Found
  • Sagging Rear Suspension
    • Description/Symptoms: The rear of the vehicle sits lower than the front, especially when loaded. This is common on Outbacks with the self-leveling suspension.
    • Solution: Replace rear shocks or struts with conventional (non-self-leveling) units, or replace the self-leveling units with new ones if desired.
    • Estimated Cost to Fix: $500 - $1500+ depending on the selected solution.
    • Recalls: None Found

Electrical

  • Alternator Failure
    • Description/Symptoms: Dimming headlights, battery warning light on, difficulty starting, dead battery.
    • Solution: Replace alternator.
    • Estimated Cost to Fix: $300 - $600+
    • Recalls: None Found
  • Power Window Failure
    • Description/Symptoms: Window will not go up or down, or moves very slowly.
    • Solution: Replace power window motor or regulator.
    • Estimated Cost to Fix: $200 - $400+ per window.
    • Recalls: None Found
  • Battery Drain
    • Description/Symptoms: Battery is dead in the morning, having to jumpstart the vehicle.
    • Solution: Diagnose the cause of the battery drain and fix the problem, replace the battery as needed.
    • Estimated Cost to Fix: $100 (new battery) - $500+ (depending on the source of the drain).
    • Recalls: None Found

Exterior

  • Rust
    • Description/Symptoms: Rust around wheel wells, rocker panels, and other body panels. Especially prevalent in areas with road salt.
    • Solution: Rust repair (patching or panel replacement) and paint.
    • Estimated Cost to Fix: $200 - $2000+ depending on the severity.
    • Recalls: None Found
  • Headlight Hazing/Yellowing
    • Description/Symptoms: Headlights appear cloudy or yellowed, reducing visibility at night.
    • Solution: Headlight restoration kit (DIY) or professional headlight restoration.
    • Estimated Cost to Fix: $20 - $100 (DIY kit) or $100 - $200 (professional restoration).
    • Recalls: None Found

Interior

  • Cracked Dashboard
    • Description/Symptoms: Cracks appearing on the dashboard, particularly in warmer climates.
    • Solution: Dashboard replacement or dashboard cover.
    • Estimated Cost to Fix: $200 - $1000+ depending on the solution.
    • Recalls: None Found
  • Climate Control Issues
    • Description/Symptoms: HVAC system blowing only hot or cold air, or not blowing at all. Failure of the blend door actuator is common.
    • Solution: Diagnose the issue and replace the faulty component (blend door actuator, blower motor resistor, etc.).
    • Estimated Cost to Fix: $100 - $500+
    • Recalls: None Found

Summary

The 2002 Subaru Outback is a generally reliable vehicle, but given its age, common issues include head gasket failure (primarily on the 2.5L engine), oil leaks, rust, and suspension wear. Electrical issues and interior wear and tear are also common. Repair costs can range from relatively minor fixes (e.g., headlight restoration) to more substantial expenses (e.g., head gasket replacement, transmission repair). Potential buyers should have a pre-purchase inspection performed by a qualified mechanic to assess the vehicle’s overall condition and identify any potential problems.

Subaru, Outback
Subaru Outback 2002
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