Cars

Used Subaru Crosstrek Reliability: Head Gasket Problems

JH

John H

Senior Cars Expert

8 min read

Used Subaru Crosstrek Reliability: Head Gasket Problems Explained

When shopping for a used compact SUV, the Subaru Crosstrek frequently ranks high on many buyers' lists. Known for its all-wheel drive, fuel efficiency, and rugged design, the Crosstrek has built a solid reputation since its introduction. However, like any vehicle, it's not without its potential issues. One of the most talked-about concerns among owners and mechanics alike is head gasket problems—particularly in certain model years. If you're considering a used Subaru Crosstrek, understanding the reliability of this model, especially regarding head gasket failures, is crucial to making an informed decision.

What Is a Head Gasket and Why Does It Matter?

The head gasket is a critical engine component that seals the combustion chamber and prevents coolant and oil from mixing. It sits between the engine block and the cylinder head, enduring high pressure and temperature. When functioning properly, it ensures the engine runs efficiently and maintains optimal operating conditions.

When a head gasket fails—commonly referred to as a 'blown head gasket'—the engine loses compression, coolant may leak into the combustion chamber, and oil can mix with coolant. This leads to overheating, reduced performance, and potentially catastrophic engine damage if not addressed promptly.

Are Subaru Crosstrek Head Gasket Problems Common?

While not all Subaru Crosstrek models suffer from head gasket issues, certain model years have shown a higher propensity for these failures. Specifically, models from 2012 to 2015 have been reported to experience head gasket problems more frequently than newer versions.

The root cause lies in the design of the Subaru FB25 engine, which was introduced during this time. Some mechanics and owners have pointed to inconsistencies in the casting of the engine block and cylinder head, as well as the use of multi-layer steel (MLS) head gaskets that may not withstand long-term thermal cycling. Over time, repeated heating and cooling cycles can cause warping of the aluminum heads, leading to gasket failure.

Which Engine Years Are Most Affected?

The 2.5L FB25 engine (used in the 2012–2015 Crosstrek) is the primary one associated with head gasket issues. The earlier EJ25 engine, used in pre-2012 Subaru models, had its own history of head gasket problems, but the FB25 was expected to improve on that legacy. Unfortunately, some design flaws carried over or were newly introduced.

It's important to note that newer models (2016 and later) saw improvements in engine design and materials, significantly reducing the likelihood of head gasket failure. The 2016 refresh introduced updates to the cooling system, better head gasket materials, and tighter manufacturing tolerances, all of which have contributed to improved reliability.

Signs of a Failing Head Gasket in a Used Subaru Crosstrek

If you're inspecting a used Crosstrek, knowing the warning signs of a failing head gasket can save you from costly repairs down the line. Here are the most common symptoms:

• White smoke from the exhaust: This is one of the most telltale signs. If the smoke is thick, sweet-smelling, and appears consistently, it likely indicates coolant burning in the combustion chamber.
• Overheating engine: A blown head gasket can cause the engine to run hotter than normal due to coolant leaks and reduced cooling efficiency.
• Bubbling in the radiator or coolant reservoir: This suggests that combustion gases are leaking into the cooling system, a condition known as a 'blown head gasket.'
• Low coolant levels without visible leaks: If coolant is disappearing but there’s no external leak, it may be seeping into the engine.
• Milky oil or sludge under the oil cap: This 'mayonnaise' residue indicates coolant mixing with engine oil—a serious problem requiring immediate attention.
• Misfiring or rough engine performance: Loss of compression in one or more cylinders can cause poor engine performance and difficulty starting.

Why Do These Issues Occur in Older Crosstrek Models?

Several factors contribute to head gasket failures in the 2012–2015 Subaru Crosstrek models:

1. Engine Design Flaws

The FB25 engine, while more efficient and lighter than the older EJ25, faced challenges with thermal expansion. The aluminum heads expand at a different rate than the cast iron block, and under constant heating and cooling cycles, this can stress the head gasket over time.

2. Manufacturing Tolerances

Some reports suggest that uneven machining of the cylinder heads or engine blocks during production allowed for improper sealing. Even minor imperfections can lead to gasket failure after years of use.

3. Cooling System Inefficiencies

The early FB25 engines had cooling systems that weren’t optimized for consistent temperature management. Overheating, even in mild cases, can accelerate head gasket degradation.

4. Use of Multi-Layer Steel (MLS) Gaskets

While MLS gaskets are generally durable, they are sensitive to surface flatness and torque specifications. If not installed perfectly, or if the heads warp over time, the seal can fail.

Are All 2012–2015 Crosstreks Affected?

No, not every 2012–2015 Subaru Crosstrek will experience head gasket issues. Many of these vehicles have reached 150,000 miles or more without major engine problems. However, the risk is higher in this model range compared to other years, so due diligence is essential when purchasing a used model.

Factors such as regular maintenance, driving habits, and climate can influence whether a head gasket fails. Vehicles driven in hot climates or subjected to frequent towing may be more susceptible due to increased engine stress.

How to Check for Head Gasket Issues When Buying a Used Crosstrek

Before purchasing a used Subaru Crosstrek, especially one from the 2012–2015 model years, perform a thorough inspection. Here’s a step-by-step guide to help you identify potential head gasket problems:

1. Review the Vehicle History Report

Use services like Carfax or AutoCheck to look for any prior repairs related to the engine, cooling system, or head gasket. A history of overheating or coolant system work could be a red flag.

2. Check for Service Records

Ask the seller for maintenance records. Look for evidence of regular oil changes, coolant flushes, and any past engine work. Vehicles with consistent maintenance are less likely to have hidden issues.

3. Inspect the Coolant and Oil

Open the radiator cap (when the engine is cool) and look for signs of oil contamination or bubbles. Check the oil dipstick and oil cap for milky residue, which indicates coolant mixing with oil.

4. Perform a Compression Test

A professional mechanic can conduct a cylinder compression test to determine if any cylinders are losing pressure—a clear indicator of head gasket failure.

5. Use a Cooling System Pressure Tester

This tool checks whether the cooling system can hold pressure. A failing head gasket often causes pressure loss due to combustion gases entering the coolant.

6. Conduct a Block Test (Combustion Leak Test)

A block tester uses a chemical solution to detect exhaust gases in the coolant. If the solution changes color, it confirms a head gasket leak.

7. Look for External Leaks

Inspect the engine bay for signs of coolant leaks around the cylinder head area. While not definitive, visible leaks may suggest underlying problems.

What Happens if the Head Gasket Fails?

A failed head gasket doesn’t just mean a simple repair. It can lead to a cascade of engine problems, including:

• Warped or cracked cylinder heads
• Engine overheating and potential warping of internal components
• Contaminated oil leading to bearing damage
• Complete engine failure in severe cases

Once the head gasket fails, the repair process is extensive. It typically involves:

1. Removing the cylinder head(s)
2. Inspecting and resurfacing or replacing warped heads
3. Replacing the head gasket and associated seals
4. Flushing the cooling system and replacing coolant
5. Replacing spark plugs and other affected components

Due to the labor-intensive nature of this repair, costs can range from $1,500 to $3,000 or more, depending on the shop, location, and extent of the damage.

Subaru's Response to Head Gasket Issues

Subaru has not issued a widespread recall for head gasket problems in the Crosstrek. However, the company did extend warranties on certain models and engines under specific conditions. For example:

• Some 2010–2012 Subaru models with the EJ25 engine received a 10-year/120,000-mile warranty extension for head gasket repairs.
• However, this extension generally does not apply to the 2012–2015 Crosstrek with the FB25 engine, leaving many owners responsible for the repair costs.

If you’re buying a used Crosstrek, it’s worth contacting a Subaru dealer with the VIN to check if any warranty extensions apply. While unlikely for the FB25 models, it’s always worth verifying.

How Reliable Is the Used Subaru Crosstrek Overall?

Despite concerns about head gasket issues in certain years, the Subaru Crosstrek remains a relatively reliable compact SUV. According to data from J.D. Power, Consumer Reports, and RepairPal, the Crosstrek scores well in overall reliability, especially in model years from 2016 onward.

Positive Aspects of Crosstrek Reliability

• All-wheel drive standard: Provides excellent traction and handling in all weather conditions.
• Strong resale value: Crosstreks retain their value better than many competitors.
• Spacious interior and cargo room: Surprisingly roomy for a compact SUV.
• Good fuel economy: Especially with the 2.0L engine option.
• Safety features: Even older models often come with strong safety ratings and features like EyeSight (in later trims).

Other Potential Issues to Watch For

Besides head gasket concerns, used Crosstrek owners may encounter:

• Timing chain issues: Some 2.0L models have reported timing chain tensioner problems, though less common.
• CVT transmission concerns: Earlier models (pre-2016) had some CVT complaints, including shuddering or hesitation. Newer versions are much improved.
• Infotainment glitches: Older systems may have slow response times or screen issues.
• Rust: In snowy or coastal regions, undercarriage rust can develop, especially on lower trims without full undercoating.

Overall, the Crosstrek’s strengths often outweigh its weaknesses, particularly if you avoid the higher-risk model years or ensure proper maintenance.

Are Newer Used Crosstreks Safer from Head Gasket Problems?

Yes. Models from 2016 to 2019 show significantly fewer reports of head gasket issues. Subaru made several engineering improvements during this time, including:

• Better head gasket materials and sealing techniques
• Enhanced cooling system design
• Improved manufacturing quality control
• Updated FB25 engine revisions with better thermal management

The 2018 and 2019 models, in particular, are considered among the most reliable in the Crosstrek lineup. Even the base 2.0L engine in these years has proven durable with minimal major issues reported.

How to Maintain Your Used Crosstrek to Prevent Head Gasket Failure

Whether you own a pre-2016 model or a newer one, proper maintenance is key to maximizing engine life and avoiding head gasket problems. Follow these best practices:

1. Regular Coolant Flushes

Replace coolant every <