NHTSA Complaint #11699279 — 2024 SUBARU ASCENT

My 2024 Subaru Ascent developed a recurring clunk/thump noise from the steering system during low-speed turning (10–15 mph) and when turning the wheel at a stop. The noise was present daily and worsened over time. I took the vehicle to two Subaru dealerships. Sterling Subaru dismissed the steering noise completely and stated they could not duplicate it. Dulles Subaru also initially dismissed the issue. Only when I returned to pick up the vehicle and insisted on demonstrating the noise did their technician acknowledge it. They compared my vehicle to another Ascent on the lot and confirmed the noise was abnormal. Dulles then replaced the steering gear box assembly (steering rack) under warranty. This confirms there was a mechanical defect in the steering system. Before this repair, I also reported excessive inner-edge wear on both front tires. The technician documented “excessive wear on both front inner tires” and recommended replacing all four tires and performing an alignment. Inner-edge wear on both front tires is not caused by lack of rotation—it is consistent with misalignment or steering geometry deviation, which matches the confirmed steering defect. Subaru America has refused to replace the damaged tires even though the tire manufacturer (Falken) stated in writing that irregular wear caused by a mechanical defect is the vehicle manufacturer’s responsibility. Safety concern: A defective steering rack caused abnormal steering behavior and front-end geometry issues, which led to rapid inner-edge tire wear. If unnoticed, this can result in loss of steering control or a tire failure at highway speeds. Both dealerships initially dismissing the issue is also concerning. I am filing this report so NHTSA can track potential steering-related defects and resulting tire safety issues on the 2024 Subaru Ascent. I can provide service records, photos, and Subaru correspondence upon request.