I dont know...is this a you have had issues with or its a Subaru issue..I could be missing it and all of a sudden realize there are 100 posts about this in the last few months(or years) but I just dont recall this being a giant issue people are up in arms about....which would lead me to believe..it seems to be a more isolated issue or no issue at all..my Subaru has 24K miles on it..exhaust sounds same now as when new..look under car..nothing observable wrong...now unless they are replacing it for free if you think its bac next time id just go to the local muffler shop for the replacement they normally guarantee them for some amount of miles/years...

I know when you tell a person that their issue really isnt a issue feelings can get hurt as it does directly involve them and they ARE being effected(and i believe your story 100% btw) but it just doesnt seem to be a issue after searching for Subaru mufflers going bad early(here and in the interwebz) I dont really get anything..as a matter of fact i got referred to your post and not much else about the mufflers being bad or going bad early....

for instance i did a Subaru mufflers going bad, Subaru exhaust going bad, and then added early nothing really.....then do a search for Subaru head gasket issue and you get a ton of hits/results...so if nothing much is coming up about exhaust issues...id say overall there isnt one...that said I feel your pain we have had nagging issues the dealership could never fix..like 1 ford we had used to eat break pads..first time we replaced them at ford...went bad again WAY too soon..so next time we did what I told you to do..we went to a local muffler/brake place and got their "guaranteed" brakes..paid less then the dealership charged and during that vehicles stint with us...replaces the pads 2X for free as they had a warranty... For instance the local muffler place has this: Save big on mufflers and catalytic converters. Our mufflers come with a LIFETIME warranty on parts and 30-day Best Price Guarantee.

then if it goes bad..free muffler.

 

I dont know...is this a you have had issues with or its a Subaru issue..I could be missing it and all of a sudden realize there are 100 posts about this in the last few months(or years) but I just dont recall this being a giant issue people are up in arms about....which would lead me to believe..it seems to be a more isolated issue or no issue at all..my Subaru has 24K miles on it..exhaust sounds same now as when new..look under car..nothing observable wrong...now unless they are replacing it for free if you think its bac next time id just go to the local muffler shop for the replacement they normally guarantee them for some amount of miles/years...

I know when you tell a person that their issue really isnt a issue feelings can get hurt as it does directly involve them and they ARE being effected(and i believe your story 100% btw) but it just doesnt seem to be a issue after searching for Subaru mufflers going bad early(here and in the interwebz) I dont really get anything..as a matter of fact i got referred to your post and not much else about the mufflers being bad or going bad early....

for instance i did a Subaru mufflers going bad, Subaru exhaust going bad, and then added early nothing really.....then do a search for Subaru head gasket issue and you get a ton of hits/results...so if nothing much is coming up about exhaust issues...id say overall there isnt one...that said I feel your pain we have had nagging issues the dealership could never fix..like 1 ford we had used to eat break pads..first time we replaced them at ford...went bad again WAY too soon..so next time we did what I told you to do..we went to a local muffler/brake place and got their "guaranteed" brakes..paid less then the dealership charged and during that vehicles stint with us...replaces the pads 2X for free as they had a warranty... For instance the local muffler place has this: Save big on mufflers and catalytic converters. Our mufflers come with a LIFETIME warranty on parts and 30-day Best Price Guarantee.

then if it goes bad..free muffler.

WOW...THIS WAS A LOT TO READ...did you read this before you posted it ?

BASICALLY, THE MUFFLER IS poop...this is the second time in 4 years that the baffles have gone bad in the muffler...bottom line is....ITS CRAP.
I have had vehicles i bought new and had for 15 years and NEVER had to replace a muffler on them. Subaru is supposed to be top of the line or so they think they are.
If thats the case why am I expected to pay for a muffler on its second time out when it was just replaced in 2020 because it was defective then. WAY TO GO SUBARU

 

So my 2018 Forrester had the muffler replaced with 16,628 miles on it because the baffles were gone and it was loud, now at 61,000 miles its doing it again and they want me to pay for it, after I paid over $2190 at the time of purchase for an extended warranty they say doesn't cover this.
What a joke, this seems to be a chronic problem with this cars muffler, Now at 4 years old this would be the second time it will have to be replaced.
As if it wasn't bad enough that the seats in this vehicle are hard as a rock and the most uncomfortable seats
I have ever sat on, that makes you sore and fatigued while driving.
Now there is a chronic issue with the Muffler.
I had a bad feeling when it went the first time for the muffler to be replaced at a year and a half into owning the 30,128.00 vehicle that was paid for with cash.
I had a 2002 Dodge Neon that literally rotted to pieces and the muffler never had to be replaced in 15 years. None of my cars had mufflers go bad on them.
COME ON SUBARU cant you do BETTER THAN THIS ?
Had I only known...I would not have purchased it, we bought it because it had the highest ratings and was supposed to be the best on the market. QUESTIONABLE...at this point.

I don’t know where you live but the only way I can think that would happen is that you do a lot of short distance driving and a few long distance trips. Those short drives put a lot of strain on the muffler as it doesn’t heat up enough to get rid of the water.

 

and this is a load of crap....
the muffler baffles went bad a year and a half into owning it and it was bought brand new..it turned 4 Dec 2021 muffler was replaced 2020 now they want me to pay to have it replaced again because the baffles are bad...Im not real impressed with Subaru

 

Subaru's are not known for muffler issue. 2001 Forester here with 230,000 miles still on factory muffler. Muffler life is mainly affecting by 2 things: road/salt corrosion, and short driving distance. Owners that drive less than 3 miles each way to/from work are inviting corrosion to eat their muffler as the moisture is collecting inside the muffler and not being expelled. I also have to wonder if owners that let their engines idle for 20 minutes before driving are also not contributing to this muffler corrosion.

 

If the baffles were burnt out, that is not a usual thing. That suggests excess corrosion inside the exhaust system. Are you using ethanol fuel?

 

Are you using ethanol fuel?

I ran E85 in my 2001 neon for years and never had any exhaust, or other issues. A simple injector swap makes this possible.

I doubt E10 or the proposed E15 will have any different effect on an exhaust system under the same conditions using pure gasoline. Which is not a common thing to find in a lot of places. A local station sells it for use in offroad equipment, but it is not legal for sale on a vehicle driven on a public road. It also costs more, despite not having road tax.

 

Now at 61,000 miles its doing it again and they want me to pay for it, after I paid over $2190 at the time of purchase for an extended warranty they say doesn't cover this.

Did you get the Subaru warranty by Subaru (typically a gold/gold plus)? Is it still in effect?
If the two questions have yes answers, the muffler is definitely a covered part, along with just about everything else that isn't a normal wear item like tires, brake pads, etc.
I would suggest you call SoA and see what they say.
Likely they will tell you with a Subaru warranty, you can go to any dealership in the USA for warranty repairs, and the muffler is covered under that warranty.

If the warranty was a crappy "only good at this dealership" type, read the fine print.
It may be that they exclude lots of things. In that case, it isn't a Subaru problem, it's the stealership you bought the car from.
In that case, I'd still call SoA and tell them that the bozos you bought the car from misrepresented (maybe) the warranty you were sold.

As far as the muffler being an endemic problem, it hasn't been historically.
I'm running Subaru #6 and never had a muffler problem in any of them.

 

It's all a stainless steel. There are SS s that are better for polishing, but they aren't used for most exhausts. Car exhaust made of SS have some steel in the mix to aid in bending, nickel doesn't bend as well ... but that steel is why they do acquire a brownish look in time. Back in the day, we got far better life out of aluminized steel that the 16,628 miles OP got. I've never had to replace a SS muffler due to interior rusting or loose baffles, but have a few of the AS ones. Modern SS systems can generally be expected to outlive the car.

I was a state police officer for 31 years, I do recall back in the early '00s, several of us were holding a checking detail near Glasgow on the highway, checking for operator's licenses, registrations, equipment, and DUIs ... or whatever else came to our attention. It was a nighttime detail, prom night I think. One kid pulled up in a not old red Chevrolet, was a Cavalier, and it was loud. While he was fishing for his license, I looked under the car, someone had used a drill mounted hole saw to cut holes in the muffler sides, but he didn't know whom. I wrote the ticket, and as I was doing it, a older Subaru GL Hatchback pulled up, I heard it, and as that kid (with date) got his license, I looked at the rear mounted muffler (I had a '84 at home). No holes ... but I could see up the exhaust pipe into the muffler, someone had poked holes in the interior baffling with a rod.

It was a "thing" for some to do. The kid with the red Chevrolet ... his mother called my dispatcher, wanted to talk about it. I called back, was the next day ... she said the car was hers (I knew that) but that her son did all the driving. She mentioned taking it to the dealer and getting it fixed under warranty before court, I told her what had been done. Her son had told her it just wore out.

 

I'll bet a dollar that the OP has heat shields coming loose and buzzing, not internal muffler baffles.

A few dollars in stainless hose clamps goes a LONG way.

Dealers do not mess with heat shields because of liability possibilities so they replace mufflers.

 

I think the OP misstated the issue. It is the exhaust bellows that crack, and yes this is an extremely widespread problem. It involves replacing the whole catalytic converter assembly and is very expensive. Yes it will keep failing because it is defective. I had mine replaced under the PZEV warranty in California. Believe me, anything that goes wrong with any of my vehicles, is a widespread problem. I take very good care of my cars. There are many threads about this issue. Just look at all the complaints on Consumer Reports for this issue on the 2017 Forester. Subaru knows it's a bad design and has issued a TSB with an updated part just recently. They also had a recall for this same part on the Outback quite some time ago.

 

... Subaru knows it's a bad design and has issued a TSB with an updated part just recently. They also had a recall for this same part on the Outback quite some time ago.

So likely is changed after '17 I guess .... maybe? Any links?

 

The TSB is very recent that announces the design change. And it doesn’t even mention a problem or failures. You’ll see it on NHTSA if you look at the 17 Forester.

https://static.nhtsa.gov/odi/tsbs/2022/MC-10208656-0001.pdf

 

The TSB appears to be limited to the front end exhaust components and unless he's mistaken, the OP said he had a muffler problem...
Not the same thing....

 

OK...WHATS OP ?
AND NO IM NOT A HIM...im a her and its baffles in the muffler a second time around on a 4 year old Forrester.

 

@DragonSubie7 - Well, the OP hasn't been back yet. But I suspect the OP may be mistaken about what was replaced. I can't conceive of the abuse you'd have to subject your car to in order to have the muffler fail at 16k miles. And I can see confusing "bellows" and "baffles". To most people, loud exhaust = muffler problem.

 

Ok...how about using English..here.
Am I the OP what ever the heck that is?

and Yes the baffles are gone again 2nd time and the car turned 4 in December 2021. ITS BAFFLES NOT BELLOWS as i was told by the dealership the first time they replaced them the car was a year and a half old, some kind of defect I was told now here we go again a year and a half later, on my Dime.

 

So the bottom line here is...
I bought this vehicle brand new In December 2017 the muffler was replaced in 2020 because the baffles apparently went to poop. Now its doing it again and the dealership wants me to pay for the replacement.

So if they cant put a muffler on this car that lasts more than 2 years THERE IS A HUGE ISSUE HERE.

My dodge Neon I bought new, lasted 15 years and literally rusted to the ground and had to be towed out of the yard,
but guess what the muffler never had to be replaced, as was the case with my Chevy Blazer that lasted 16 years.

so why is a vehicle that is 4 years old (turned 4 Dec 28, 2022)
having to have the muffler (defect) replaced a second time on my dollar.

Its apparent that Subaru missed the boat when they put these cars together,
if I have to buy a new muffler every 2 years...there is a CHRONIC ISSUE.

Now I have to pay for it, because they DIDN'T GET IT RIGHT.

Obviously when I bought this car ALL $30,000 (cash) OF IT...I thought i was buying a better vehicle.

Which now Im second guessing since I will have to pay for a muffler every 2 years.
its ridiculous.

 

So the bottom line here is...
I bought this vehicle brand new In December 2017 the muffler was replaced in 2020 because the baffles apparently went to poop. Now its doing it again and the dealership wants me to pay for the replacement.

So if they cant put a muffler on this car that lasts more than 2 years THERE IS A HUGE ISSUE HERE.

My dodge Neon I bought new, lasted 15 years and literally rusted to the ground and had to be towed out of the yard,
but guess what the muffler never had to be replaced, as was the case with my Chevy Blazer that lasted 16 years.

so why is a vehicle that is 4 years old (turned 4 Dec 28, 2022)
having to have the muffler (defect) replaced a second time on my dollar.

Its apparent that Subaru missed the boat when they put these cars together,
if I have to buy a new muffler every 2 years...there is a CHRONIC ISSUE.

Now I have to pay for it, because they DIDN'T GET IT RIGHT.

Obviously when I bought this car ALL $30,000 (cash) OF IT...I thought i was buying a better vehicle.

Which now Im second guessing since I will have to pay for a muffler every 2 years.
its ridiculous.

CORRECTION: THE CAR TURNED 4 - DECEMBER 28, 2021.

 

"OP" = Original Poster, as in, the person who placed the original post. As the post gets responses, it has now become a thread. OP is a lot simpler than "original poster".

 

2018 Florester here with 35,000 miles and I can't tell any difference with the muffler since day 1.

 

This is a chronic issue for you, but apparently for no one else. About the only threads I've seen regarding mufflers is about replacing the OEM mufflers for a different sound and/or more performance. The mufflers I removed from my 2017, with 30k+ miles on them were still in near new condition. A little surface rust, but that was cosmetic. Mufflers just aren't a widespread issue on these vehicles.

Since you hadn't returned to the thread, people were speculating about known exhaust issues in an attempt to be helpful. Your attitude upon return hasn't made me want to help you much more, but I'll still try, since maybe your posts weren't meant in the tone that I attributed to them.

If it is, in fact, the muffler, you've got options. @DragonSubie7 lists some good ones. You may also find used mufflers that would fit. Check with any local Subaru enthusiast groups. (Facebook is a good place to look) People usually don't ask much for used exhaust components, and you'll likely find someone that went aftermarket for sound/performance that has the OEM mufflers just lying around.

Heck, I've got a set, but I don't remember if they're for my XT or from an STI. They're just sitting outside my garage and if you want to pick them up in Greene County, NY, you can have them for free. I'm not sure if the XT muffler would bolt up if you only have a single muffler, though. (And if they're STI, you'd need to cut the bumper fascia to make room for the dual exhaust tips.)

It's literally two bolts to change the muffler. (Four if you have a dual exhaust) And a couple of exhaust hangers that you have to push the brackets through.

 

^ Good advice very likely wasted.
Sometimes, some people just like to vent, and suggestions are not what they want to hear.
Likely the scenario in this case......

 

Just to put in my 2 cents. A stuck open thermostat will never allow the exhaust gases to heat up the muffler and vaporize the water that condenses in the pipes. The water becomes highly acidic and corrodes the muffler. Solution replace the thermostat or read the OBD date and see if the engine reaches 190F.

 

I'm pretty sure it's the exhaust bellows got cracked. It is indeed a known issue and there are lots of complaints online about it. And it happened to me, so that automatically makes it a known issue. I'm not surprised in the least bit as I have read about many people having this happen more than once. If OP can understand what this really is I think some good advice was given by all of us. I totally understand OP's frustration. There are a lot of people flocking to Subaru that think because it's Japanese they can just drive it and change the oil. They are in for a big surprise! Subaru is a very specialized vehicle made for special purposes that entails a lot of time and expense to own. Many new owners just aren't up to the challenge.

 

I'm pretty sure it's the exhaust bellows got cracked. It is indeed a known issue and there are lots of complaints online about it. And it happened to me, so that automatically makes it a known issue. I'm not surprised in the least bit as I have read about many people having this happen more than once.

It could be, but it didn't sound that way based on what was stated.
I wonder what might have changed from earlier versions of the car that didn't have this problem...
None of my six Subaru cars ever had an exhaust issue, but that was prior to the single muffler adoption.
Could it have been a design change that happened when the cars went from dual to single mufflers on the NA engines?
Hmmmm...

 

OP is the original poster. Short trips were brought up because it's usually the cause of premature muffler failures. Everyone understands your upset, it's just that for most of us, it's an overreaction to condemn the whole car and brand because you may have gotten a part with a defect. Hopefully, your service advisor can explain why the muffler failed so early. I hope it works out, and that they at least give you a bit of a discount.

 

lol...
well I bought the car because it was supposed to be the highest rating..the seats are hard as a rock, the pannels have been popping off since I got it, the windshield pannel has been replaced by the wipers and I was told that it popped off because the hood is not in alignment and it was in an accident...which is a crock since i have never had an accident with the car not even a scratch. So there has been multiple issues with the car small things that made me keep going back and forth to the dealership, and when you have to have a muffler replaced at 16,000 miles that was a HUGE red flag, and now here I am with the same muffler issue.
Thanks to this site I did call Subaru America and I am dealing with them right now, hopefully they will do me right on this. If not, I wont be buying another Subaru. Unfortunately, both my Chevy Blazer s10 and My Dodge Neon had more comfortable seats that this subaru, they are so hard they hurt your back on a long drive and make you tired because you have to move around so much to get comfortable which is virtually impossible.
I had ...better hopes when I bought this vehicle.

 

blueyeqq
Ahem..
"First ..you or anyone should ever assume just because someone is talking about cars that its a "HIM" doing the talking."
Really.
How is anyone to know the gender of anyone who doesn't have a handle that isn't obvious?
Why do you assume that I'm a man then? You appear to be just as guilty of gender bias, assuming I'm a man because I post on this forum.

I can assume anything I want as I recall seeing the right to free speech somewhere, that doesn't seem to include the right to not be offended.
In any case this topic isn't relevant to the problem.

As to the thread problem for general consumption...
I learn something new everyday.
Unfortunately one of these items I found is the Subaru Warranty Exclusion Parts list.

As the OP noted, HER muffler is not included in the warranty, so repair and/or replacement is not covered as was correctly noted by the dealership.
So much for the bumper to bumper coverage..

Were it me, I would still give Subaru Corporate a call and an opportunity to step up before giving up on them and going to Midas, although the latter might turn out to be a better option from both the cost and warranty perspectives. It might not.

As Quadraria10 noted, perhaps an explanation from a service advisor as to why there were two muffler failures in a car that isn't prone to them might be helpful, as one might be able to make a case that a part that is covered under the warranty, if that can be determined, caused the premature failures and should therefore be covered under the warranty that remains intact.

Maybe a stretch, maybe not.

 

So my 2018 Forrester had the muffler replaced with 16,628 miles on it because the baffles were gone and it was loud, now at 61,000 miles its doing it again and they want me to pay for it, after I paid over $2190 at the time of purchase for an extended warranty they say doesn't cover this.
What a joke, this seems to be a chronic problem with this cars muffler, Now at 4 years old this would be the second time it will have to be replaced.
As if it wasn't bad enough that the seats in this vehicle are hard as a rock and the most uncomfortable seats
I have ever sat on, that makes you sore and fatigued while driving.
Now there is a chronic issue with the Muffler.
I had a bad feeling when it went the first time for the muffler to be replaced at a year and a half into owning the 30,128.00 vehicle that was paid for with cash.
I had a 2002 Dodge Neon that literally rotted to pieces and the muffler never had to be replaced in 15 years. None of my cars had mufflers go bad on them.
COME ON SUBARU cant you do BETTER THAN THIS ?
Had I only known...I would not have purchased it, we bought it because it had the highest ratings and was supposed to be the best on the market. QUESTIONABLE...at this point.

If you have ever owned a toyota before, you'll realize as I quickly did, subarus are not toyotas. subarus break down and are flawed in many aspects - just get a toyota as I will once my subaru corp. extended warranty runs out. subaru cars are similar to the now defunk Yugos (you may not remember those which could have been sold on Costco's floor room).

 

If you have ever owned a toyota before, you'll realize as I quickly did, subarus are not toyotas. subarus break down and are flawed in many aspects - just get a toyota as I will once my subaru corp. extended warranty runs out. subaru cars are similar to the now defunk Yugos (you may not remember those which could have been sold on Costco's floor room).

Sorry but this statement is just ludicrous.

 

('14-'18) - 2017 - Exhaust Leak - Manifold...

I started noticing exhaust fumes in the cabin while idling at a stop. I did some research and found that several Outbacks have had an issue with their exhaust manifold bellows cracking. There was even a Technical Service Bulletin stating that the exhaust manifold may have been installed under...

www.subaruforester.org

More info in this thread.

 

Since it is not covered, possibly the dealership put a crap (non Subaru) part on for the fix to save themselves some of the costs of replacing it. Probably figured it would last long enough to not be their problem anymore.

Not all dealers are shady, but not all are shining examples either.

 

FWIW, my wife's 2017 Forester's muffler/exhaust system is just fine, with sitting for the most part since August of 2016. It has a whopping 8000 miles on it. If anything is tough on an exhaust system, that would be it. If it had the mild steel exhausts they used in the 1970's, the whole thing would be a rust stain on the ground. So being exposed to the humidity of Ohio for the last 5 years and 9 months, and the occasional short drive, it's doing pretty well.

Only the exhaust from the catalytic converter forward will be covered under federal warranty requirements. Anything after the converter has zero bearing on emissions. It could fall off after the converter, and as far as EPA is concerned it's legal.

It doesn't mean it's safe to drive with an exhaust that dumps under the car, but as far as @blueyeqq 's issue, unless there is a hole in or before the muffler, there is no risk of CO fumes entering the car.

It's just simply annoying.

 

FWIW, my wife's 2017 Forester's muffler/exhaust system is just fine, with sitting for the most part since August of 2016. It has a whopping 8000 miles on it. If anything is tough on an exhaust system, that would be it. If it had the mild steel exhausts they used in the 1970's, the whole thing would be a rust stain on the ground. So being exposed to the humidity of Ohio for the last 5 years and 9 months, and the occasional short drive, it's doing pretty well.

Only the exhaust from the catalytic converter forward will be covered under federal warranty requirements. Anything after the converter has zero bearing on emissions. It could fall off after the converter, and as far as EPA is concerned it's legal.

It doesn't mean it's safe to drive with an exhaust that dumps under the car, but as far as @blueyeqq 's issue, unless there is a hole in or before the muffler, there is no risk of CO fumes entering the car.

It's just simply annoying.

thank you, I had wondered about the federal law...
its more loud than anything, but not ever having to replace a muffler on my last 4 vehichles in over 20+ years before I had them towed away, because their life was over, I find it odd that I have to have a muffler replaced at 16,000 then again at 60.

 

So my 2018 Forrester had the muffler replaced with 16,628 miles on it because the baffles were gone and it was loud, now at 61,000 miles its doing it again and they want me to pay for it, after I paid over $2190 at the time of purchase for an extended warranty they say doesn't cover this.
What a joke, this seems to be a chronic problem with this cars muffler, Now at 4 years old this would be the second time it will have to be replaced.
As if it wasn't bad enough that the seats in this vehicle are hard as a rock and the most uncomfortable seats
I have ever sat on, that makes you sore and fatigued while driving.
Now there is a chronic issue with the Muffler.
I had a bad feeling when it went the first time for the muffler to be replaced at a year and a half into owning the 30,128.00 vehicle that was paid for with cash.
I had a 2002 Dodge Neon that literally rotted to pieces and the muffler never had to be replaced in 15 years. None of my cars had mufflers go bad on them.
COME ON SUBARU cant you do BETTER THAN THIS ?
Had I only known...I would not have purchased it, we bought it because it had the highest ratings and was supposed to be the best on the market. QUESTIONABLE...at this point.

Part 21904 walker muffler. Advanced auto parts . Easy 20 min job and under $300