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Leaked Documents Reveal Subaru Is Concerned With New 2020 Outback Quality

The new 2020 Subaru Outback is close to launching but the automaker is concerned with pre-production quality issues.

Customers are waiting for the all-new seventh-generation 2020 Subaru Outback to arrive in September and it should be a big hit with a more powerful 2.4-liter turbo engine, new Global Platform with improved driving dynamics, a roomier cabin, and improved safety tech. But Subaru’s success in the U.S. could spur problems for the new Outback according to a report from Automotive News.

Torque news recently wrote about dealer concerns about the Ascent and the new 2020 Outback quality. Subaru’s U.S. National Retail Advisory Board wrote in a September 18th resolution, “We continue to be concerned that Subaru is not making the necessary investments and changes fast enough to ensure that vehicles are being produced with the quality the brand and its customers deserve.”

2020 Subaru Outback

The new AN report says internal documents were leaked and say because production has ramped up at the U.S. plant in Indiana, suppliers cannot keep up with the demand for the new Subaru vehicles. The document is reported to say almost half of Subaru's North American suppliers are operating at quality levels below Subaru's internal target. To boost performance, Subaru is overhauling its own production processes and working with suppliers to fix the problem.

2020 Subaru Outback Quality issues

Subaru needs to get the all-new 2020 Outback launched with few quality issues this summer because it’s the brand’s most popular all-wheel-drive vehicle in the U.S. market. Issues with the all-new Ascent family hauler that launched last year is not helping the situation.

Tom Doll, CEO of Subaru of America at the Chicago Auto Show acknowledged dealers concerns with the new 2020 Outback quality. “A lot of it’s growing pains, right? But we’re not concerned at all about whether or not it’s going to get fixed or not. It will get fixed. We’re hopeful that it gets fixed fairly quickly.”

2020 Subaru Outback

The leaked internal report says, the new 2020 Outback in the pre-production stages, has had problems with brake noise, seat wrinkles, 2.4-liter turbo engine oil dilution, extensive smoking following cold engine start, and battery failure.

Subaru also just recently received a less than stellar report from J.D. Power in its IQS scorecard and the Japanese automaker is aware they need to improve quality in their vehicles. Subaru’s quality planning and management department is apparently experiencing a defect rate with the Ascent SUV that is twice as high as the company's internal goal.

High Recall Rates

Subaru has also been stung with multiple recalls, and an April report says 70 percent of Subaru vehicles are the object of recalls or service campaigns within two years of being purchased. The report says Subaru wants to lower the recall rate to an acceptable 10 percent.

Subaru of Indiana Automotive (SIA), says part of the problem is upstream and the design team in Japan needs to get some of these problems fixed before they ever make it to the U.S. plant. Problems “should have been identified during development and pre-production confirmation testing,” the report said. SIA also sites "workforce instability" has been brought on by the rapid on-boarding of new workers as they get ready to start 2020 Outback production.

Subaru’s impressive growth in the past 10 years has led to growing pains in Japan and the U.S. market. Customers are eagerly waiting for the newly-redesigned 2020 Outback to arrive and expectations are high for the new SUV/Crossover all-wheel-drive vehicle. As the 2020 Subaru Outback begins pre-production, there are internal concerns the new seventh-generation SUV will have quality issues. Stay tuned.

You Might Also Like: 5 New Technologies On Redesigned Subaru Outback To Know About Before You Buy The Old Model

Watch How Subaru Makes The 2020 Outback in Indiana Plant and Click to Subscribe Torque News Youtube Channel for Daily Automotive News.

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Photo credit: Subaru Global, Subaru USA

Comments

David (not verified)    October 28, 2019 - 6:15PM

In reply to by Rick G. (not verified)

The only recall on 2020 outback was for a break noise on the pads. This was in a very limited number of the original cars made. I have test driven both the regular 2.4L and the 2.4xt- I leased one and took delivery last Friday 10/25/19- drives like a dream car- I think Subaru is on top of this. Very little of the car parts are from Japan, like 20%, the rest comes from Canada and US, and assembled in US. I do note the doors are a bit lighter- but the vehicle is a bit bigger than the outgoing Outback and the weight of the Touring xt is nearly 4,000 pounds. Gas mileage is supposed to be 30 on highway and in 20's in the city. My prior 3.6 liter 6, was a gas hog in the city, but on the road was very good; 28 -29 or better. The six had a steady flow on pick up, where the 4 xt is still a hair slow from line and then turbo kicks in like a beast. It is at least as quick overall and perhaps a bit more so, than my prior 6, and much quieter as well.

Mark Kennedy (not verified)    September 12, 2019 - 8:14PM

The problem of workforce instability lies at the heart of a right to work state. Low morale, sub standard pay and benefits. Job hopping in right to work states is not uncommon. Leaving a corporation with poor quality.

Kazoo86 (not verified)    December 3, 2019 - 4:28PM

I would like to point out 2 things. 1) “Pre-production” reports. Many of these things are corrected before going into production! 2) Anything made by man is subject to recalls. Even Mother Nature can create deformities. We live in an imperfect world. Or, are Mother Nature’s deformities, suppose to teach us lessons!

Subie dealersh… (not verified)    December 15, 2019 - 3:25AM

I have been working for Subaru for 27 years and fixing them, seeing all of the changes over the years. I can say this, the new model update school is more involved in the LAN/ CAN bus systems on the cars due to more issues showing up on them. The amount of recalls is just unbelievable. Everything from a reflash to save the batteries life to get the ECM to fall asleep and open the relay to cut power for the coils on the ignition. The valve spring replacement is by far the largest one I have seen or have to do. Brake lines are a scary one... They swell up?
Missing body spot support welds and look in the cowling and if it fails, we buy your car back...
Wow yeah let's be like Chrysler Fiat the joke poor quality company that puts out nothing but junk.

Michael G Sisson (not verified)    January 14, 2020 - 7:37AM

2016 subura outback has 30,000 miles on it have had dead battery issues and have had battery checked and is fine .I have read many complaints on this problem . There is a parisitic drain in the electrical system . Subura will not acknowledge it.

Dana (not verified)    March 4, 2020 - 9:26AM

I just started leasing a gray 2020 Outback. Within just a few weeks I started seeing dozens of inexplicable scratches all over the hood, top, and sides. I spoke to a sales manager about it and will be taking back to the dealer to be looked at this weekend.
I have never seen anything like it. Is anyone else experiencing anything with the glaze or paint cracking on their Subaru?

Joostin420 (not verified)    May 2, 2020 - 11:41PM

In reply to by Dana (not verified)

MY20 wrx limited Ice silver. Traded in MY16 crystal white pearl.

The MY20 has bad paint defects. 888 miles and it has more paint chips and defects then my 4 year old had with 70k miles. Bumper fitment issues front driver side and passenger side rear bumper.

Something is wrong here!

Going to contact Subaru of America this week because this vehicle needs to be inspected.

Chloesmich (not verified)    March 16, 2020 - 4:44AM

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Neil R Borodkin (not verified)    June 3, 2020 - 1:34PM

I have driven the 2020 XT 3 times now, and I am most concerned about the stop and start feature. If Subaru can but a button on the panel external to the main screen, I might buy this car.

Mike (not verified)    July 16, 2020 - 10:06PM

Got a 2020 Outback Touring. Issues with many if the advanced features. Dealer claims they aren't issues. Reverse auto break puts on breaks when backing into garage. Hatchback open by hand doesn't work. Bluetooth connection stops working typically 5 minutes into call. Often Bluetooth doesn't connect at all. Stay in lane function is jerky, occasionally almost hitting car in adjacent lane! XM radio has worse reception than (excellent FM) radio. Not a happy customer.

Barbara O'Connell (not verified)    November 29, 2020 - 4:37PM

I bought an Outback Touring 2020 in September.There was an excelleration problem with only 2,000 miles on the car. The RPM was at 100% and I was only going 55 miles per hour uphill on the freeway. I have taken it in for service at two different Subaru dealerships. Neither one could find what was causing this. Now I have an issue with the delay stop start feature. I brake hard to turn it off but it goes back on. I'm going back to the service department again for the third time. Could this be a lemon?

Barbara O'Connell (not verified)    November 29, 2020 - 4:48PM

I purchased a 2020 Outback Touring Subaru in September. While going uphill on the freeway my car was excelleraing at 100% and I was only going 55mph. It had 2,000 miles at the time. Took it to two different Subaru service departments. Neither one could find the problem. Now it won't hold the feature that bypasse the delay at a stop. Going in for service for the third time. Do I own a lemon?

Jeremy P (not verified)    December 12, 2020 - 7:38AM

Our 2014 Outback is a beast. No issues since birth and while we now own it outright and I love not having any monthly payments... I'm seriously considering the turbo 2.4L!

SharonC (not verified)    December 17, 2020 - 6:46PM

I have a 2017 Subaru Outback 36R fully loaded. I have replaced the battery 4 times within a year. Two days ago, it stalled again. Had a tow truck take it to the dealer. The service manager told me he replaced the battery with a high-end Subaru battery. He told me I shouldn't have anymore problems with it. I soon called a friend in Washington state, and she has a 2018 Outback, fully loaded. Her car was at the dealership for the umpteenth time. We compared notes, and she couldn't believe all that I had been through, especially when my dealership updated my computer, and it still didn't work. She, too, was given the high end battery, hers didn't last long. I am ready to file a lemon law suit. I only have 21000 miles on my car, yet, the resale value is null and void. The shop obviously does not have specialized mechanics to search the electrical system. I am livid over this.

Martin (not verified)    December 22, 2020 - 3:18PM

I owned a 2017 3.6r Limited Outback. Initially loved the driving dynamics, and power. Many issues, started with leaking front engine seal at 30k, big job to fix that. Other issues were front end rattle in the cold. Finally determined it was the steering rack, had to be replaced. Ran out of gas on the highway when it said I had 45km to empty, the computer was not calibrated properly. Issues with electronic sensors failing. Tried towing a 1800lb trailer and it was not good. The CVT is not good for towing ! If you think a new outback is better, do your research. Many issues with direct injection engines, clogged valves, because These newer engines need to meet mileage and emissions standards have side affects.

Chris E (not verified)    January 16, 2021 - 12:07PM

No one ever mentions the techs that have to break their heads attempting to quickly repair vehicles that are now pushing $50k. Most of the Subaru dealerships are ill equipped to perform a clean, professional repair in a timely matter. The pay for these repairs is also mediocre at best, as often the repair times have been acquired in controlled, clean environments. There are many occasions where the port/distribution center ships cars out to the dealers with known damaged parts installed, calling it a "stop-sale" situation, seemingly to let the dealership tech solve the headache/issue that the engineers couldn't. There is a level of poor craftmanship that has taken over the Subaru brand, understandably due to the growth of the company, but nothing is more frustrating than getting paid less than one hour of labor (flat rate) for removing a faulty fuel pump from a plastic gas tank, utilizing a plastic screw on cover that doesn't fit back on properly, meanwhile having to drain fuel from said tank, and taking every precaution in the world to not spill fuel in the back seat area of the $50K Ascent. I can go on and on for ever with the gripes and issues of the dealership world tech, and I'm sure all brands can attest to this problem, not to mention the fact that with Covid-19, techs, mechanics and any one in the auto world who is considered an essential worker never gets any mention or recognition on news outlets, let alone by the brand themselves.

customer (not verified)    January 22, 2021 - 10:13AM

My 2020 Outback is doing OK so far. No problems. BUT, I hate the info-tainment set up. A 3 year old child would have more common sense in setting up this system. Give me the days of pushing the buttons on the features I want to engage instead of going through 7 steps to turn off or on the features that should have been off, subject to my wanting to turn them on. This is backwards. This touch screen system is nothing but the product a bunch of techies and millenial geek designers playing with computer systems and integrating them into the touch screen. If I had known this about the info-tainment system, I would not have bought it.

Victoria olson (not verified)    February 5, 2021 - 7:46PM

I have a 2020 outback bought new. At 22,000 the tires were shot...come to find out the alignment was way off & chopped the tires. Dealer Is think’ unreliable!!

Dan (not verified)    February 17, 2021 - 7:49AM

I have a 2021 Outback XT purchased in November of 2020. I live in Canada, so you’ll have to convert kilometres to miles. At around 7000 km (2 months old) I noticed that my driver’s side seat was creasing. I emailed my salesman and he agreed that the wear seemed ‘excessive’. So they took in my car for further investigation. After a day at the dealership I was informed that Subaru would replace the seat this time, but if it happens again, it will be on a case by case scenario. He told me that Subaru deems this as “normal wear”. As I told him, I’ve owned 3 Accords before I bought this outback XT and neither of them had saggy seats after 7, 10 and 6 years of ownership, respectively. I was told that my car was the first to have this issue and maybe in time it will be a recall if more people have this issue. Poor build quality if you ask me. Not sure why if this was ‘normal’ that they’d be replacing my seat anyway?!
If they don’t fix the issue, not only will this be my last Subaru, but I’ll be a torn in their side until I can pawn it off back to the dealership when it’s paid off. Not acceptable.

Danielle Mark (not verified)    April 26, 2021 - 9:25AM

I just bought a 2020 Outback limited with 2559 miles. I have had the car for less than a week and it died. I did not leave any lights on. I called roadside assistance and they came and jumped the car. He shared that the battery does not hold well for the car. To many bells and whistles for this type of car. I am beyond frustrated and understand why this car was for sale. I am hoping I can give it back, I don't want to have the concern that this car can die at any time since the battery is not sufficient.

Ingrid Minasian (not verified)    July 19, 2021 - 9:21PM

I leased a 2020 outback and regret it. It is a LEMON! The battery has failed and left me stranded. A new battery replaced the original one and now it is doing the same thing. I purchased a Gooloo Battery jumper and take it with me everywhere I go. The
car will not start without it. It is at the Subaru Service Center for the 4th time. This car has less than 9000 miles and I hope they send it to the junk yard. Shame on Subaru for putting this out. People watch me as I assemble my kit to jump my dead battery. Bad advertisement, but hope people will see it for what it really is. Junk!

Cynthia Angell (not verified)    December 18, 2021 - 11:05AM

Looking to replace 2020 outback. Not wanting another subaru due to quality issues. Love many features but battery problems, window problems, trim coming off, interior rattles, weatherstripping coming off. Terrible.