NHTSA Complaint #11640184 — 2018 SUBARU CROSSTREK

I am writing to formally raise a significant safety concern regarding my 2018 Subaru Crosstrek. I recently discovered a malfunction in the transfer case (pictures attached), specifically involving the center differential gear set, which necessitated immediate replacement. This issue first became apparent while driving at low speeds when I heard a loud, distinctive "clunking" noise, indicating a possible malfunction within the transmission. As a precaution, I took the vehicle to my service mechanic for further diagnosis. After thorough inspection, my mechanic at Roberts Auto Shop (invoice attached) promptly identified the transfer case as the source of the problem. Subsequently, I contacted my local Subaru dealership, North Tampa, where I have previously serviced my vehicle, to inquire whether this issue is known to affect earlier models of the Crosstrek. The service manager expressed surprise that this problem occurred in my manual transmission vehicle, noting that it is typically documented in vehicles with CVT transmissions but rarely in manual models. I further inquired about the availability of any extended warranties or safety recalls related to this known issue. The manager informed me that the vehicle's powertrain warranty covers only up to 60,000 miles or five years, both of which I have exceeded, as my vehicle currently has just over 70,000 miles. My primary safety concern arises from the discovery of metal shavings inside the defective transfer case during its replacement. While the amount is currently minimal, there is a significant risk that this could quickly escalate into a complete transmission failure, posing a considerable safety hazard. I am planning to report this issue to Subaru of America for further investigation and would appreciate your assistance in investigating this matter. I also request that Subaru be held accountable for this known defect, particularly given its potential to jeopardize vehicle safety. Thank you for your support.