This bulletin announces the service manual correction regarding clutch master cylinder reservoir service procedures.
full bulletin at NHTSA ↗2005 Subaru Legacy powertrain problems
severe 11 complaints filed with NHTSA · avg repair $2,500 · see powertrain across all vehicles →
Failure mileage
Complaints
11
Recalls
0
Avg fix
$2,500
1crash
When does it fail?
Of the 11 powertrain complaints filed for the 2005 Subaru Legacy, here's the actual mileage breakdown — failures cluster heaviest at 75,000-100,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
No new NHTSA powertrain complaint has been filed on this vehicle in over 13 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering powertrain on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
This Service Information bulletin announces a design change to the clutch release bearing used on the models as listed above. During assembly of the bearing, a different type of grease is used which has a higher resistance to heat. In cases where the operator keeps a foot on the clutch pedal for extended periods, an increased amount of heat is generated which can cause the grease inside the bearing to deteriorate. In a case of prolonged clutch pedal application, seizure of the bearing can occur with potential damage to other related components.
full bulletin at NHTSA ↗This Service Information bulletin announces a design change to the clutch release bearing used on the models as listed above. During assembly of the bearing, a different type of grease is used which has a higher resistance to heat. In cases where the operator keeps a foot on the clutch pedal for extended periods, an increased amount of heat is generated which can cause the grease inside the bearing to deteriorate. In a case of prolonged clutch pedal application, seizure of the bearing can occur with potential damage to other related components.
full bulletin at NHTSA ↗This Bulletin provides production change, repair procedure and parts information to address a customer concern of a high-pitched sound coming from the transmission extension housing area. In cold temperatures, thermal contraction causes shrinking of the transmission case. In high temperatures, expansion of the case occurs. These temperature changes affect the amount of preload on the transfer driven shaft bearings. In some rare cases, when preload is very near the limit of specification combined with unusual driving conditions, this thermally-induced pre-load change may cause damage to the bearings and result in the sound heard by the customer. A change has been made to the extension case an
full bulletin at NHTSA ↗This Bulletin provides production change, repair procedure and parts information to address a customer concern of a high-pitched sound coming from the transmission extension housing area.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners consistently report clutch slip accompanied by acrid or sulphurous burning odors during normal driving and stop-and-go traffic. The smell persists beyond the break-in period and can make occupants nauseous. One owner had a full clutch assembly replaced at the dealer only to have the problem recur; another describes squeaking from the clutch pedal that returns even after replacing the clutch spring.
Engine stuttering and hesitation plague acceleration from dead stops and during gear shifts. The issue occurs at both low and highway speeds and is not consistent with typical turbo lag. One owner reports the throttle position sensors disagree (P2138 code), causing the engine to enter fail-safe mode and lose all acceleration—a hazard that happened twice and dealerships refused to service without replication.
Turbocharger failures at 48,000 and 132,000 miles are tied to a maintenance requirement owners were never informed about: cleaning the banjo bolt filter to prevent oil starvation. Subaru Technical Bulletin 02-103-07 exists but wasn't communicated. One repair cost $2,300. Transmission problems include gears popping out under highway driving and grinding after rebuild.
One owner reports the engine stalling while driving over 60 mph when the clutch is engaged. Another experienced loss of traction on a wet highway despite the vehicle's advertised symmetrical AWD system.
Failure modes owners describe
Clutch Slip and Burning Smell
Clutch slips during normal driving, particularly on mild grades and in stop-and-go traffic, producing a strong acrid or sulphurous burning odor. Owners report the smell persists even after several thousand miles of ownership and can cause nausea. One owner reported the entire clutch assembly was replaced at the dealer but the problem recurred.
When: During normal driving, especially starting from a dead stop, in rush-hour traffic, and uphill; reported as early as 4,000 miles
Symptoms owners cite: Clutch slips during acceleration; Strong acrid or sulphurous burning smell; Smell lasts minutes or longer in traffic; Occupants report nausea from odor
Repairs/costs cited: One owner reports clutch assembly replacement at dealer did not resolve issue
Clutch Squeak and Pedal Vibration
Clutch pedal produces a squeaking noise after 5-10 minutes of driving, with vibrations felt on the brake pedal. One owner had the entire clutch assembly replaced, then the clutch spring replaced. The squeak went away temporarily but returned.
When: After 5-10 minutes of driving
Symptoms owners cite: Clutch squeak noise; Vibrations felt on brake pedal; Recurring issue after repairs
Repairs/costs cited: Clutch assembly replaced, then clutch spring replaced; squeaking returned after repairs
Recalls/TSBs owners mention: Dealer verified the issue and performed repairs (clutch assembly and spring replacement)
Engine Stuttering and Hesitation
Engine stutters, pauses, or hesitates causing the car to jump slightly. Occurs when starting from a dead stop, shifting from 1st to 2nd gear, and during both low and high acceleration. One owner reports occasional stutter on acceleration at highway speeds. Another owner reports studder or flutter in acceleration that is not constant turbo lag.
When: Starting from dead stop, during gear shifts, and at highway speeds
Symptoms owners cite: Engine stutters and hesitates; Car jumps slightly during stuttering; Occurs under low and high acceleration; Stutter on gear shift (1st to 2nd); Occasional flutter on acceleration at highway speeds
Throttle Position Sensor Disagreement (P2138 Code)
Check engine light comes on and vehicle enters fail-safe mode, eliminating the ability to accelerate. The diagnostic trouble code P2138 indicates the two throttle position sensors are not in agreement. This has occurred twice on the same vehicle and poses a serious safety hazard when driving at highway speeds.
When: Twice during ownership; second occurrence over 1,000 miles away from first
Symptoms owners cite: Check engine light illuminates; Vehicle enters fail-safe mode; Loss of acceleration ability; Vehicle does not respond to throttle input
Codes mentioned: P2138
Repairs/costs cited: Dealer unable to replicate issue and declined to perform service
Turbocharger Failure and Oil Starvation
Turbocharger failed at 48,000 miles and at 132,000 miles on separate vehicles. Owners report learning after failure that the banjo bolt and filter screen should be cleaned to prevent oil starvation to the turbo. Subaru Technical Bulletin 02-103-07 addresses this issue but owners were not informed of the maintenance requirement. The VF40 turbo used in 2005 models was not used in 2006 models. Repair costs reported at $2,300.
When: At 48,000 miles and 132,000 miles on different vehicles
Symptoms owners cite: Turbocharger failure; Loss of engine power
Repairs/costs cited: Turbo replacement cost $2,300; banjo bolt and filter replacement performed on second instance
Recalls/TSBs owners mention: Subaru Technical Bulletin 02-103-07 exists but owners were not notified; warranty claim disputed until oil change receipts were provided
Transmission Gear Popping and Grinding
Transmission popped out of fifth gear while driving on highway, stripping the teeth off the gear. After transmission rebuild, fourth gear began grinding. This is a complete transmission failure requiring rebuild.
When: During highway driving
Symptoms owners cite: Transmission pops out of gear; Stripped gear teeth; Grinding in other gears after rebuild
Repairs/costs cited: Transmission required rebuild; fourth gear grinding after repair
Transmission Whine on Cold Start
Transmission produces a whining sound when the clutch is engaged in the morning, which disappears after 2-3 minutes of driving. Owner replaced all clutch components two years prior and drives gently. Owner suspects throwout bearing issue based on online reports from Impreza WRX owners with the same transmission.
When: Cold start in the morning
Symptoms owners cite: Whining noise from transmission; Noise occurs when clutch engaged; Disappears after 2-3 minutes of driving
Repairs/costs cited: All clutch components replaced two years prior
Engine Stalling with Clutch Engagement
Engine cuts off while driving over 60 mph when the clutch is engaged. Owner considers this a life-threatening situation. This appears on a base model 2005 Legacy 2.5i automatic or semi-automatic transmission.
When: While driving over 60 mph
Symptoms owners cite: Engine cuts off during driving; Occurs when clutch engaged
AWD Traction Loss in Wet Conditions
Vehicle lost traction on a wet highway and pulled to the left, colliding with the center concrete median. The vehicle's symmetrical AWD system did not maintain traction and control as advertised. The vehicle continued to spin counterclockwise and was declared a total loss by insurance.
When: During wet road conditions on highway
Symptoms owners cite: Vehicle pulls to the left; Loss of traction; Vehicle spins uncontrollably; AWD system fails to maintain control
Recalls/TSBs owners mention: Vehicle touted for superior traction and control from symmetrical AWD system
Synthesized from 11 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 2 most recent
For the second time my check engine light has come on and my car has gone into a fail safe mode while driving (eliminating the ability to accelerate). The code the computer provides is p2138, which refers to the throttle position sensors (there are two) not being in agreement. I took the car to white bear lake Subaru in white bear lake, mn to have this issue resolved. They did not replicate…
The turbocharger simply went at about 132000 miles. From what I read online regarding the failed legacy turbo,the turbo could have been saved if the union ( banjo) bolt with filter was changed. Subaru does not notify the consumer regarding this potential problem; that is irresponsible. It cost me $2300 to replace the turbo...I made sure that the union bolt was replaced as well. *tr
Had powertrain trouble with your 2005 Subaru Legacy?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the powertrain problem on the 2005 Subaru Legacy?
It's a meaningful issue. 11 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $2,500.
At what mileage does the powertrain typically fail?
Across the 10 complaints that reported odometer mileage, most powertrain failures cluster between 4,000 and 93,000 miles, with the median around 72,000. A quarter of owners report trouble before 4,000; a quarter make it past 93,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $2,500 for powertrain repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to powertrain?
No active recalls currently cover powertrain issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2005/Subaru/Legacy.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.