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Subaru Outback fault code

A month after buying our 3.0R 2007 Subaru Outback last year a "fault code" caused the CEL, ESC lights to come on and the "cruise" light to flash. After resetting it, the Subaru dealer said it could have been some bad fuel, but it happened again a couple of months later and I was told that perhaps the O2 sensor needed replacing and to bring it back when it happened again. It didn't occur again until three weeks ago and I've now been told by the dealership that the catalytic converter could need replacing at a cost of more than $5000 plus labour. Also, no aftermarket part would do. They contacted Subaru for a goodwill claim to contribute to the cost of the repair, but they declined to help in any way. The cost of the part seems extreme and unreasonable. Secondly, what if it's just the O2 sensor. I've also read that cat cons should last a lot longer. The car has only been fed premium unleaded, regularly serviced and drives beautifully. What action should I take?

First, you need to have it checked out to find out exactly what is wrong, there’s no point in guessing. The cost of catalytic converters, particularly genuine factory ones, is very high and the cost you quote doesn’t surprise me, but it is possible to source non-factory parts and they work just fine at a fraction of the cost. I would also suggest you take it to an independent Subaru mechanic to have it checked. They will have the clues on replacement converters if that is indeed what you need.

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