[ChattownOBW]

Hello everyone. Picked up a 2003 outback wagon today. I test drove it last week in a rural middle Tennessee town and it seemed to do great. However, it was 30° out, spitting sleet and I drove about 10 minutes at 45 mph.

Bringing her home today 120 miles was a different story. It was empty so stoped at the first reputable station I could find only to see that the gas cap was MIA. No big deal. Put some fuel in but not too much cause I didn’t know if it would slosh out. So got 20 bucks. A little over half tank.

I opened the door after pumping gas and set the alarm off. Which was strange causeI didn’t even lock the doors with the door or fob.

Continue on to a state highway where the speed limit is 65 and as soon as the road opens up the check engine light comes on. I figure maybe from the missing cap so keep trucking.

Hit 60 mph and thought the steering wheel was going to make an exit out of the car. It would shake from about 55-70 (the fastest I got) so badly that it made me super uncomfortable And I have had a lot of janky cars in the past.

Drove about an hour and stopped to grab a bite to eat. Noticed a smell of antifreeze. And saw an active drip standing in front of the car. Popped the hood and the overflow tank seemed to be the origin. The PO supposedly had all new cooling system parts installed including radiator and all hoses. Overflow tank was pretty full so I figured maybe they just overfilled when they put all the parts on.

Got her home and up on jack stands to crawl under and every bit of rubber in the rear suspension is gone. Both rear shocks are blown and leaking. Driver side boot is torn on the rack and pinion. It the front suspension doesn’t look too bad. And the axles look fairly new.

My ultimate plan for this is to do all new suspension with around 2” of lift total. Haven’t decided on the Rallitek kit or cobbling something together yet but will be doing something. And a little larger, more aggressive tires. That should be about it. This thing will be our little dog hauling, canoe carrying adventure wagon.

Any tips on what to do or how to fix common issues are welcome lol. This is my 4th Subaru with the others being 04 wrx, 01 forester and 05 forester and I am excited to be back in a Subaru!

 

[Wreckster]

seems like you just picked up near the polar opposite of mine. 2003 as well, though the one thing I'm not worried about is how the car runs and it doesn't have any handling issues aside from the bad rear struts. The body, however.. The car isn't beyond saving rust wise, the wheel arches are going to need going over, however. I can live with that, find some patch panels and make it last a whole while longer.

With what you're describing, I would seriously be wondering if a belt had broken on one of the tires. Either way, get it lifted up and check for play, check the tires to see how they're doing, the whole lot.

For the coolant, I'd be veeeery wary that the head gaskets have gone, but there is no saying that for sure over the internet. See how the coolant level plays out, check your oil religiously to make sure it doesn't get contaminated. Head gaskets can be done, entire engine would really suck.

Now for the suspension (I have the same plans in mind) I've researched everything I could to narrow down exactly what I want. I don't want to do a straight spring lift as strut travel would be lessened at full extension. Having built a lifted trailblazer, I have zero interest in raising travel without increasing downward stroke at the same time. What I settled on was 1" strut top mount spacers ($160ish i believe for all 4?). The bolts on the strut mounts get replaced with longer bolts that will actually bolt the spacer to the mount, then bolt to the car, beautiful design. Primitive racing has uprated springs ($369). 'Standard' height will live .25-.5", so figure around 1.5ish inches of lift all together. Not quite high enough to need the rear arm spacers, but still noticeable difference.
Tires, I'm going to pick up a set of Nokian Outpost AT in 215/70r16. Really about as big as you can run, lifted or not, without rubbing.

GL with it. Keep a very careful eye on temps, coolant, oil. let us know how it all works out.

 

[ChattownOBW]

Hey thank you for the reply!
Good call on the belt being broken in one or some haha tires. It’s about to get new ones so fingers crossed that will solve that.
Everything was tight and nothing looked particularly bad when I was under it. Wheel bearings all seemed tight. No brake issues. Axles looked new but had surface rust. Looked like newer sway bar end links on the rear.
The oil level seemed high to me but was very clean and didn’t smell. Almost like it was just done. Also looked like a new filter. And the coolant was also very clean. Which, I guess would be expected with all the cooling bits recently replaced. I’m really hoping that they just overfilled it when replacing parts. The high oil level is concerning though.
I’ve had only one head gasket issue in my previous Subarus and that was on the 05 forester. My wife drove it while it was actively showing her on the temp gauge she shouldn’t be for quite some time haha. Hopefully I won’t be going down that road again.
The heads did have a small amount of oil on the bottom of both but looked more like it was from the valve cover even though I could see what looked like new valve cover gaskets. They were bright blue.
As for the suspension lift portion I didn’t even think about the shock/strut drop out not being suffice for lift springs. I was looking at kings for a while then settled on a Rallitek set up with the 1” springs, 1” spacers and rear link set. Then was going to run kyb’s but maybe I should keep looking.
As for the worn out bits I have no idea. I’ve briefly looked for bushings but haven’t had much luck as of yet.
Thank you for the suggestion on tires. I had some Falken wildpeak’s on my wife’s all4 mini last year and they were great but can’t find them in the correct size for the outback. At least not the more aggressive type.

 

[Wreckster]

New stuff always worries me. Could be very well taken care of, could be they threw everything they could at it to mask a problem. You could definitely be right that they overfilled, the coolant tank doesn't hold much. to be in range.
For the suspension lift, I think you've got the right idea. Spacers will give you a bit more downward travel, so that'll work out. The springs will give you the rest. KYB's seem to be the correct way to go, they don't cost too much more than the cheap stuff.
The only reason I'm keeping under 2", I don't want to spend the money on the rear subframe spacers nor do I want to tempt fate taking those bolts out if I don't have to, the front subframe bolts if they snap look like hell to get out. But more so, budget. This car is 100% budget.

PS, Let me just add, I don't have hands on experience with the lifts, yet. I've just done a ton of research and came up with everything. Another note on tires, I searched for the lightest tires possible as every single pound will matter with these cars. The outpost was I think the lightest of them all. If I'm correct, these would fit if you wanted the falkens - Robot or human?

 

[ChattownOBW]

Those tires are similar to what I had before. They are a little more street oriented. Hers were at/3w’s before. But those will prob do just fine.
I also don’t have any experience with lifting a Subaru. Have done plenty of trucks and jeeps but never anything like these. Same as you, I’ve just searched around for info so far. In my mind I feel like a subframe spacer set would lower everything suspension wise so while giving some more body ground clearance the suspension would still be the same distance to the ground. But I could be all wrong lol.
I rebuilt the rear subframe of an old Mercedes 300D a few years ago and broke a mounting bolt and it was one of the worst mechanical experiences I’ve ever had to deal with. I hope to never have to do anything like that again.

 

[Wreckster]

I had a 300d! Man I miss that car so much. Such a nice riding car, the diesel was perfect for cruising. Unfortunately, the turbo started to cease up and I had no way of paying for the parts. Sold it for a decent price.

 

[ChattownOBW]

Heck yea! I had 2 of them. And one sd but I used it mainly for parts and put that engine in my 85 Toyota pick up haha. They were great cars for sure. This is my 85 the one I broke the bolt off in the subframe mount

 

[estilley]

I had an ‘85 300D as a high schooler back in 2006-2011. Unfortunately the parents donated it to the local radio station for the tax deduction. Had 365k on it then. Years later we all decided that was a big mistake!


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[ChattownOBW]

Ha yea with maintenance those things will last forever. That one had about 240k there. I had a gold 85 that had 340 and my SD was an 83 and I have no clue how many miles it had on it. I never drove it honestly. Just bought it for the engine to put in this truck.

 

[Wreckster]

Brakes and regular maintenance, that's it. Aside from the turbo going out (great grandmother had run it low on oil prior) the only things I needed to do were adjust the fuel rack and steering lash. Old as it was, unbelievably reliable.

 

[ChattownOBW]

Well I crawled under the Outback again today to better inspect things. Also had my buddy come over and check the car out and we went for a drive in it.

With him driving and me as a passenger I noticed that when accelerating the vibration from the steering wheel was almost non existent. But when he eased off giving her the beans it started shaking the steering wheel. When we got back home and I put the car on jack stands I noticed the front driver tire had a small bubble on the sidewall. Not sure if that’s an indication of a broken belt or what but doesn’t look great. It needs tires and I planned to get larger ones anyway so no problem. Just not sure if that’s the cause of the vibration at speed. Maybe a bad front axle??

Like I said before the rear suspension needs everything replaced rubber wise. I’m just wondering if I should get replacement parts with bushing already installed or if I should spend a year replacing all those bits. Talk about a lot of links and bushings lol.

The front looks like it’s in better shape as far as bushings but both ball joints need replaced. They are still tight but the boots are torn on one and pretty much missing on the other and they are pretty dry looking.

There was an intermittent miss while my friend was driving today merging in to traffic. He revved her out to redline, which I have not done, and it missed several times in the process of getting there. I’ve only ran it up to right below 4k rpm. But over all it seemed to rev out and run pretty good.

I think I’ve decided to just get Monroe quick struts. From what I’ve read on here everyone hates them but I’ve not read anywhere where someone has actually had an issue with them. Then I’m going to do 1” or so spacers. Not going 2” just because I don’t want the extra problems from going that high. It’s not like I’m going to be rock crawling with this thing so I think anything sun 2” will be fine with some 215/70r16’s.

I took a few pictures of various bits underneath the car so here they are for your viewing pleasure haha. I haven’t cleaned anything yet but I did after taking these pictures spray everything down with kroil oil in preparation of removing stuff.

 

[ChattownOBW]

Brakes and regular maintenance, that's it. Aside from the turbo going out (great grandmother had run it low on oil prior) the only things I needed to do were adjust the fuel rack and steering lash. Old as it was, unbelievably reliable.

And valve adjustment. That was about it for mine too. I did rebuild the injectors on my gold one as the person before me had ran veggie oil and I just wanted to rebuild them for piece of mind and the experience. It was a fun little project.

 

[ChattownOBW]

Well I switched gears yet again and ordered all KYB shocks, struts and accompanying parts along with 2006 Baja springs. Also ordered the whiteline kta124 kit as it comes with most the bushings I need to replace as well as offering adjustment for whatever issues the height increase may bring.

I’m going to swing by the tire shop tomorrow and put in an order of Toyo open country tires in the 215/70r16 variety so that maybe in a few weeks I can have this thing done as far as suspension and tires goes.

I guess it would be wise, while doing all this, to change or at least check the diff fluids. I will try and get that done this weekend at some point

I read the codes today and as I figured it had a P0457 for the cap missing as well as a P0420. That one I’m not sure about. Reader said catalyst system efficiency below threshold bank 1. Im assuming the cat is shot? I only see one O2 sensor but with this many miles and how the exhaust smells I’m gonna say the cat has given up all 9 lives. I did buy a replacement fuel cap but won’t get to see if that clears the code for a while as it will probably be on jack stands till I get everything installed.

 

[Wreckster]

Better option the KYBs I wager, they're cheap enough. Let us know how it all goes.

 

[ChattownOBW]

Will keep ya posted for sure! Also had to pump the brakes on those tires. They added 200 bucks for mounting and balancing so looking around for a bit cheaper option. Either way I’ll post updates as they come.

 

[Wreckster]

Love/hate for me. I won't say it's beat, but mine is definitely a jalopy for now. Just got the rear struts and mounts, springs are on their way. Not certain if I want to throw those together first or get the fronts and the mount spacers to do it all in one shot.

Oily stuff under the engine looking today, I haven't time to figure out what it is yet, keeping an eye on fluids till I do

 

[ChattownOBW]

I feel ya man. Mine definitely needs some love. I think you have a good plan no matter how you go about it. Depending on the wait time I would maybe just do the rear and keep going like you have been with checking fluids. Then do the front when the parts come and so on. It’s hard for me to slow down sometimes. Most of the time I want to fix everything but also want to drive the thing and it’s a constant struggle haha. But for now this is one of three projects I have going so trying to just slow down a little.

What did you go with for your suspension stuff? I’ve been having a bit of difficulty finding bushings but I think I have them all coming now. Some places will call parts something different from another place so kinda hard to figure out what I need to order. I believe, and hope, that I ordered front and rear trailing arm bushings and the upper link bushings today. So that along with the new links should be all the suspension bushings in the rear. We shall see when everything arrives haha.

I also went with some knock off brand all terrain tires from eBay that were like 428 bucks to my door. I should be able to get them mounted for under 100 bucks so that’s saved me about $350. We aren’t going to daily this car so as little as we will be driving I think it will be fine.

 

[Wreckster]

Everything bushing wise seems serviceable until I get some miles on it. Kyb struts and mounts, king springs from primitive. I'll do the same on the front soon enough.

Rock auto has a front end kit, looks like a good idea really. The rear I'll likely buy entire arms as needed.

 

[ChattownOBW]

Sounds like a good plan! I prob should have done RalliTek or King springs too but what’s done is done haha. Tires, kta124 kit and some trailing arm bushings arrived today. Hopefully will start taking apart next week time permitting.

 

[ChattownOBW]

Well I started taking things apart today. I got about 3 good hours of work in.
Pulled all the wheels/tires off and sprayed more kroil oil lol. Started at the rear and successfully removed the sway bar and links, the two small lower links, the passenger side larger link and the passenger side shock/spring assembly.
The driver side lower mounting bolt on the shock is going to get cut off I have a feeling. I used my big impact to no avail on that bolt as well as the outter bolt on the larger link. I have not yet ran into a bolt that thing wouldn’t take off or break the head off of. But alas, the bolts are still in the car haha. Those fasteners have had penetrating oil on them for a week now. Pretty stubborn.
I’m going to try and pull the upper links out tomorrow and replace the bushings in them. Also I realized I ordered the wrong bushings for the trailing arm where the larger link mounts at the rear. So will try and get the right bushings for that. But I feel like that bushing and the one in the front of the trailing arm is going to be a huge pain in the butt. May be better off getting trailing arms if I can find them.
I cleaned the wheels up and dropped them and the new tires off at the shop to be mounted and balanced. Hopefully will get those back tomorrow even though I won’t put them on for a while.
I’m still waiting on the Baja springs to be shipped. I’m a little nervous about building my struts and shock assemblies up. I’ve done it before a long time ago but hopefully it goes just fine.
I didn’t take any pics today as I was focusing on what I was doing and trying to get nuts and bolts apart and getting a little frustrated haha.
I’ll post more tomorrow hopefully if I have time to work on it.