Subaru Legacy ball joint problems

Filed Dec 22, 2025 · OH

Description of the Safety Defect: The front subframe on my 2011 Subaru Legacy exhibits advanced structural corrosion with measurable material loss, concentrated primarily on the driver-side subframe. The corrosion affects a primary load-bearing structural member responsible for supporting suspension mounting points and maintaining chassis integrity. The deterioration is asymmetric, with the driver side showing severe degradation while the passenger side remains comparatively intact. This non-uniform corrosion pattern is not consistent with normal environmental exposure, age-related wear, or routine vehicle operation, and indicates a localized failure of corrosion protection or material integrity. The extent of corrosion compromises the subframe’s ability to safely support suspension loads and maintain alignment geometry. This presents a progressive structural safety risk, as continued operation may lead to sudden loss of suspension mounting integrity, steering instability, or loss of vehicle control without prior warning. Safety Risk Description: The front subframe is a critical safety component designed to: Support engine and transmission loads Secure lower control arms and suspension geometry Maintain steering stability and predictable handling Absorb and distribute crash forces Structural degradation of this component increases the risk of: Suspension separation or displacement under normal driving loads Alignment instability during braking or cornering Reduced crash energy management capability Failure of this component could result in loss of directional control, increasing the risk of a crash. Subaru of America has acknowledged prior subframe corrosion issues on other Subaru models through recalls, service campaigns, or goodwill repairs. However, Subaru has declined assistance for this vehicle based solely on time and mileage, without addressing whether the observed structural deterioration constitutes a safety defect.

Filed Sep 12, 2025 · Body · 130,000 miles · OH

The contact owns a 2014 Subaru Legacy. The contact stated that while depressing the brake pedal, there was a clicking sound coming from underneath the vehicle, and the vehicle swayed slightly before coming to a stop. The failure became more persistent, and the clicking sound became louder within a week. The vehicle was taken to a certified mechanic, who determined that the frame had severe rust that had created a hole near the ball joints on the driver’s side front wheel and informed the contact that the vehicle was not safe to drive. The vehicle was not repaired. The manufacturer was made aware of the failure and opened a case. The failure mileage was 130,000.

Filed Jul 17, 2025 · Body, Suspension · MI

While turning the wheel to back out of a parking spot, we heard a loud clunking sound. From that point on, while braking there were loud clunking sounds and the car pulled to the right. We brought it to our mechanic and was informed the front sub frame/ engine cradle, was completey rusted out due to corrosion from the inside. There was a mounting bolt protruding through a hole in the subframe and the suspension components were loose and damaged. They provided a photo showing the large hole and mounting bolt protruding. We were told it was unsafe to drive. We have to replace the sub frame, control arms and sway bar links. The sub frame supports these components, the engine and other parts!

Filed May 30, 2023 · WI

While driving heard a loud crunching noise coming from front driveside wheel area car was hard to control took it to mechanic and found out subframe is rotted and Control arm pulled right out of the subframe

Filed Feb 1, 2023 · Suspension · PA

While braking at lower speed the driver's side lower control arm broke out causing the car to pull very hard to the left. Both lower control arms and the subframe had to be replaced.

Filed Dec 1, 2021 · Suspension · 130,000 miles · MA

The contact owns a 2001 Subaru Outback. The contact stated that while his son was driving at highway speeds, the vehicle would wobble without warning. After the contact test drove the vehicle and experienced the failure himself, he took the vehicle to an independent mechanic and discovered that the rear control arm had rotted out due to severe corrosion. Upon investigation, the contact discovered that the vehicle had been placed under the federal safety agency Campaign Number: 03V153000 (Suspension). The manufacturer was then notified of the failure and confirmed the prior recall on the vehicle; however, they could not offer any further assistance. The contact also took the vehicle to the dealer where they informed him that the entire subframe had rotted out due to corrosion. The vehicle was not repaired and remained in their possession. The failure mileage was approximately 130,000.

Filed Jun 27, 2017 · Brakes · TX

June 26 2017 I went to have my front brake pads replaced, because they felt spongy and difficult to stop the vehicle. The mechanic told me I needed to replace the brake pads, rotors, and outer tie rods on both ends. All these parts were dangerously worn preexisting conditions before I purchased the vehicle in december 2016. The brake repair was done at: 424 west henderson street, cleburne, texas 76033. 817 645 7848. On june 26, 2017 I purchased the vehicle from brad deery honda in iowa used, as is. Since then I have had to have numerous expensive repairs. There should be laws to protect consumers from dealerships that sell vehicles that are unsafe and falling apart, and refusing to help pay repair bills. Used vehicles do not qualify for help under the lemon laws. Please let me know if there is something I can do to get help with my repair bills on my vehicle for unsafe preexisting mechanical conditions. [xxx] information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6).

Filed Sep 21, 2015 · Suspension · 202,000 miles · PA

Tl* the contact owns a 2005 subaru legacy. The contact stated that while driving at approximately 35 MPH, the passenger side lower control arm fractured. The failure recurred on one occasion. The vehicle was taken to dealer where it was diagnosed that the lower control arm needed to be replaced. The vehicle was repaired. The manufacturer was made aware of the failure and stated that the VIN was not included in the federal safety agency campaign number: 11v464000 (suspension). The approximate failure mileage was 202,000.

Filed Sep 21, 2015 · Suspension · 202,000 miles · PA · crash

2005 subaru legacy with 202,000 miles had a failure of the right lower control arm due to excessive corrosion. The car had a current safety inspection for pa where it was being driven at the time of the failure. The failure caused loss of control of the vehicle and it skidded off the road to a stop. There is currently a the federal safety agency recall campaign ( number: 11v464000 ) for this very problem but not for this vehicle model. The lower control arm on the legacy was not manufactured by fiji heavy industries USA, inc, according to subaru and that is why it was not part of this recall campaign. However, the failure on our 2005 subaru legacy was due to excessive corrosion as we live in the "salt belt". When being repaired at the dealership we were told the left lower control arm had excessive corrosion and we had them replaced it along with the failed right lower control arm.

Filed Aug 31, 2013 · Airbags, Suspension · 94,000 miles · MA

June 2012 - replaced front control arm bushings which were worn after only ~80,000 miles, earlier than would be expected. Rear control arm bushings are also wearing and will need to be replaced. August 2013 - airbag warning light on dashboard came on and stayed on while driving with a passenger in the front seat. Brought the car to the shop who informed me it was a faulty map light assembly. Was also informed that this is common with subaru's which research online confirmed.