NHTSA Complaint #11679319 — 2024 SUBARU IMPREZA

I own a 2024 Subaru Impreza purchased new 7 months ago. While driving under normal conditions, a small rock entered through the factory grille and struck the air conditioning condenser. The condenser was punctured, causing refrigerant (likely R-1234yf) to escape directly into the atmosphere. This refrigerant is regulated under the U.S. EPA Clean Air Act, Section 608, due to its environmental impact and potential health risks when inhaled. The sudden, uncontrolled release of refrigerant from a poorly protected component may constitute a violation of federal environmental regulations regarding the proper containment and handling of refrigerants. This leak also poses a health and safety risk to occupants, as the refrigerant can enter the ventilation system and be inhaled by the driver and passengers, potentially causing dizziness or other symptoms. The repair facility quoted over $2,000 for replacement of a condenser that retails for approximately $300. Subaru refused warranty coverage, claiming “road debris” damage. However, the condenser’s exposed position directly behind an inadequately protected grille makes it highly vulnerable to impact from small rocks under normal driving conditions — a foreseeable and preventable hazard. This is not an isolated incident. Multiple Subaru owners have reported similar issues Subaru has previously acknowledged condenser vulnerabilities in other contexts, issuing Technical Service Bulletins (TSBs 15-222-18 and 15-223-18R) addressing condenser assembly issues and Service Program WRB-21 for condenser corrosion in 2017–2018 Foresters. These actions demonstrate that Subaru is aware of condenser weaknesses and has taken corrective measures in the past. Given the safety risks, potential EPA refrigerant handling violations, and recurring nature of this issue across multiple Subaru models and years, I request that NHTSA investigate the grille/condenser design in the 2024 Impreza constitutes a safety defect and regulation failure