NHTSA Complaint #11634430 — 2017 SUBARU OUTBACK

On 08/17/17 I purchased a new Outback off a Subaru dealers' lot. The fall of 2023 I noticed rust starting on the column portion of the driver's side door. It is on the CAR INTERIOR, ABOVE THE WINDOW. This is a highly unusual area for rust to start. Typically rust starts on the bottom of a car, not 2/3 of the way up from the bottom. I was told by the dealership that it was not covered under warranty, and I was on my own. On 10/22/24 I went to an autobody shop to have the rust repaired. I was told that based off of the bubbling that was occurring on the rust, the rust is not surface rust but occurring on the interior of the door. He said that this was a flaw in production as this should not be occurring. This is evident by the fact that there is no rust on any of the other doors or anywhere else on the car. I called the Subaru dealership and had them look at it. They did not have an autobody shop but the appointment clerk submitted a request for a review to Subaru of Americ. The outcome of the review was a rejection due to being beyond the warranty of the car. This was a production error. I drove out of the lot with a defective door. This resulted in the door being completely rusted on the interior as is evident by the rust through on the INTERIOR of the door. Also, the rust is now presenting itself on the bottom seam. To have this patched is a waste of money as the whole door interior is rusted. I am concerned about the integrity of the door. If I was T-boned or in a roll-over accident, would this door provide the safety I am expecting from a fairly new car? I believe it will crumble in a pile of rust. Subaru is aware of this issue as there are a couple of forums about this reoccurring problem. I hope enough people file a complaint so some action can be taken to keep us safe. I am now forced to pay out $3,368.53 in order to replace the door so I and my passengers have the safest auto construction this car should offer. Car is available.