The Badlands Boxer Engine
A reliability-focused Subaru engine built by Dakota Subaru Experts to address the most common failures seen in the EJ 2.5i (non-turbo) platform.
Developed through years of hands-on Subaru repair and engine work, the Badlands Boxer was created as a reliability-focused engine option designed to address several of the most common problems found in the naturally aspirated EJ25 platform.
Naturally Aspirated
EJ25 Platform
Built
In-House
Reliability-Focused Components
Engine-Only
with Installation Options
Naturally Aspirated
EJ25 Platform
Built
In-House
Reliability-Focused
Components
Engine-Only
with Installation Options
How The Badlands Boxer Engine Came to Be
The Badlands Boxer engine didn’t start as a product idea. It grew out of years of hands-on experience working with Subaru engines and understanding how they behave over time.
Tanner Osborn has been working on Subaru vehicles since he was a teenager. What began as curiosity through taking engines apart to understand how they worked slowly developed into a deep familiarity with the Subaru platform. Over the years he continued building that knowledge both through hands-on repair work and professional experience working at a Subaru dealership.
But engines were never just a job. They were something Tanner genuinely wanted to understand.
That curiosity extended beyond the automotive world as well. While pursuing aviation and earning his pilot certifications, Tanner spent years studying how engines operate under demanding conditions. In the experimental aircraft community, Subaru engines are often converted for aircraft use because of their compact design and horizontally opposed layout. That overlap only deepened his interest in how these engines are built and how they can be improved.
After nearly fifteen years of working with Subarus, certain patterns became impossible to ignore. The same engine issues appeared repeatedly such as oil consumption, head gasket failures, and engines that eventually reached the end of their life far sooner than owners expected.
Rather than simply continuing to repair the same problems, Tanner began refining a better approach to the platform itself.
That process eventually led to the development of the "Badlands Boxer engine", built in house by Dakota Subaru Experts as a reliability-focused Subaru engine designed to address the most common weaknesses seen in these engines after years of real-world use.
The Problem Many Subaru Owners Eventually Face
Subaru vehicles have earned a reputation for durability and longevity. Many owners drive them upwards of three hundred thousand miles and continue to rely on them for years.
That reliability is one of the reasons people choose Subaru in the first place.
But after working on these vehicles for many years, certain engine patterns begin to appear.
Two issues in particular show up again and again as these engines accumulate miles.
The first is oil consumption. Over time some engines begin using oil faster than owners expect. In the early stages it may only require topping off between oil changes, but if the issue progresses it can lead to more serious internal wear. When oil levels drop too low the rotating assembly inside the engine can suffer damage, which is when problems such as rod knock begin to appear.
The second common issue involves head gasket failure. As engines age and experience thousands of heat cycles, the sealing surfaces between the cylinder heads and the engine block can begin to weaken. When this happens, coolant leaks or combustion gases can move between areas that are meant to remain sealed. In many cases this leads to overheating or cooling system problems that require major repair.
For many Subaru owners this moment arrives at a difficult crossroads. The vehicle itself may still be in great condition, but the engine has reached the point where major work is required.
Some choose to repair the engine and keep the car they already trust. Others consider replacement engines but often find themselves facing uncertainty about long term reliability.
After seeing these same situations play out repeatedly over the years, Tanner began asking a different question.
Instead of simply repairing the same engines again and again, what would it look like to build one the right way from the start.
That question ultimately became the foundation for the Badlands Boxer engine.
The Badlands Boxer Engine
The Badlands Boxer engine was created as a response to the patterns that appear after years of working on Subaru engines.
Instead of simply replacing the same components and sending engines back out with the same underlying weaknesses, Tanner began focusing on what it would take to build a Subaru engine that directly addressed the issues he had seen over and over again in real world vehicles.
That process led to the Badlands Boxer.
Each Badlands Boxer engine is built in house by Dakota Subaru Experts with the goal of restoring the Subaru engine platform while strengthening the areas that have historically caused problems for owners. Rather than approaching the engine as a temporary repair, the focus is on creating a reliable foundation that Subaru owners can depend on for years to come.
The platform begins with a fully refreshed long block assembly. Critical components throughout the engine are inspected, replaced, or upgraded so the engine can return to proper factory specifications while improving the durability of the sealing surfaces and internal components that experience the most stress over time.
Tanner approaches each engine with the same mindset that shaped his experience working on Subarus for nearly fifteen years. The goal is not simply to assemble an engine that runs. The goal is to build an engine that solves the problems that Subaru owners eventually encounter.
This philosophy is what led to the combination of components used in the Badlands Boxer, including upgraded head sealing systems, carefully selected gasket materials, and a complete approach to refreshing the engine platform so it can perform the way Subaru engines were originally intended to.
For many owners, this engine becomes a way to extend the life of a vehicle they already trust. Instead of replacing the car itself, the Badlands Boxer provides a renewed foundation for the vehicle that can carry it through many more miles of driving.
The result is an engine platform built from experience, designed specifically for Subaru owners who want reliability they can count on.
What Makes The Badlands Boxer Different
Every Badlands Boxer engine is built with a clear purpose. The goal is to strengthen the areas of the Subaru engine platform that have historically caused problems for owners while restoring the engine to proper operating condition.
Years of working on Subarus allowed Tanner to see which components held up over time and which areas needed improvement. The Badlands Boxer engine reflects those lessons.
Six Star MLS Head Gaskets
One of the most important improvements in the Badlands Boxer engine is the use of Six Star multi layer steel head gaskets.
Within the Subaru community, Six Star gaskets are widely recognized for their durability and reliability when compared with many standard gasket materials. The multi layer steel design allows the gasket to better handle the heat cycles and pressure changes that occur in the engine over time.
Because head gasket failure is one of the most common issues Subaru owners encounter, using a proven gasket design is a critical part of building a reliable engine platform.
ARP Head Studs
Instead of traditional head bolts, the Badlands Boxer engine uses ARP head studs.
Head studs provide more consistent clamping force between the cylinder heads and the engine block. This added stability helps maintain proper sealing under heat and pressure, which is especially important for long term head gasket integrity.
By replacing the factory bolt design with a stud system, the engine gains an additional layer of durability where it matters most.
Complete Engine Sealing System
The Badlands Boxer engine is not limited to addressing a single component. The entire sealing system of the engine is refreshed.
This includes the replacement of critical gaskets such as intake manifold gaskets, valve cover gaskets, and other sealing components throughout the engine. Refreshing these components ensures the engine is properly sealed and helps prevent the oil and coolant leaks that often appear as engines age.
Upgraded Rod and Main Bearings
The rotating assembly is fitted with upgraded rod and main bearings to improve durability and oil film stability. These components play a critical role in long term engine reliability and help ensure the bottom end remains properly supported under load.
New OEM Oil Pump and Sealing Components
Each engine receives a new OEM oil pump along with updated gaskets and sealing components. Maintaining proper oil pressure and consistent lubrication is essential for long term engine life.
Upgraded Oil Pickup Tube
The factory oil pickup tube used in many EJ engines is known to develop cracks around the mounting flange over time. When this occurs the engine can lose oil pressure which may lead to severe internal damage.
The Badlands Boxer platform upgrades this component to improve strength and long term reliability.
Updated Rear Separator Plate
Early EJ engines used a plastic rear separator plate that can warp and begin leaking as the engine ages. During the Badlands Boxer build this component is replaced with the updated metal separator plate and improved fasteners to prevent future oil leaks.
Upgraded Passenger Side Cam Gear
Some early EJ25 engines used a plastic passenger side cam gear that can crack internally over time. If the gear fails it can cause timing belt failure and severe engine damage.
The Badlands Boxer platform replaces this component with an upgraded version to eliminate this known failure point.
These updates are part of the overall philosophy behind the Badlands Boxer platform. The goal is to address the known weaknesses in the EJ25 naturally aspirated engine while creating a stronger and more reliable long block foundation.
Precision Assembly and Machining
Equally important to the parts themselves is the way the engine is assembled.
Each Badlands Boxer engine is carefully inspected and assembled to proper specifications so that clearances, sealing surfaces, and internal components all work together as intended. Attention to these details is essential for long term engine reliability.
The result is an engine platform that addresses the most common Subaru engine issues while restoring the precision and performance the vehicle was designed to have.
Who the Badlands Boxer Engine Is Built For
The Badlands Boxer engine was developed for Subaru owners who want to keep the vehicle they already trust and restore the foundation that makes it reliable.
Many Subaru owners reach a point where the rest of the vehicle is still in excellent condition but the engine has begun showing signs of wear. Oil consumption, head gasket issues, or internal engine noise can leave owners facing a difficult decision. They can either replace the vehicle entirely or invest in rebuilding the one they already know and rely on.
For many people, the better choice is restoring the engine properly and continuing to drive the Subaru they already love.
The Badlands Boxer engine is designed for owners who want that option.
Some customers come to Dakota Subaru Experts after experiencing a major engine failure such as rod knock or severe oil consumption. Others are dealing with cooling system issues caused by head gasket failure. In both situations the vehicle itself is often still worth keeping. The Badlands Boxer provides a reliable path forward by restoring the engine platform and addressing the issues that commonly develop over time.
There are also Subaru owners who simply want the confidence of starting fresh with a properly built engine. These owners understand that their vehicle still has many years of life left if the engine foundation is solid.
For them, the Badlands Boxer engine offers the opportunity to reset that foundation and continue driving the vehicle for many more miles.
Inside the Badlands Boxer
Building a reliable engine requires more than replacing a few parts. It requires understanding how every component works together inside the engine and taking the time to assemble it correctly.
Each Badlands Boxer engine is built through a careful process that focuses on restoring the engine platform while strengthening the areas that have historically caused problems for Subaru owners.
The process begins with a complete evaluation of the engine components. Critical parts of the engine are inspected and measured to ensure they meet proper specifications before assembly begins. This step is essential because the long term reliability of an engine depends on precise tolerances and properly prepared surfaces.
Once the foundation of the engine has been prepared, the assembly process focuses on refreshing the components that control sealing, lubrication, and long term durability. The upgraded head gasket system, reinforced head stud design, and complete gasket replacement all work together to strengthen the areas where Subaru engines most often experience problems as they age.
We approach each engine with the same mindset that shaped his experience working on Subarus for many years. The goal is not simply to get an engine running again. The goal is to build an engine that Subaru owners can rely on for the long term.
Every Badlands Boxer engine reflects that philosophy. It represents years of hands on Subaru experience, careful component selection, and the belief that when an engine is rebuilt it should be done in a way that truly restores the vehicle.
Vehicle Compatibility
The Badlands Boxer engine platform is designed for Subaru EJ25 naturally aspirated engines.
This includes the following engine codes:
EJ251
EJ252
EJ253
These engines were used in many Subaru vehicles including:
Subaru Forester
Subaru Outback
Subaru Legacy
Subaru Impreza
Because Subaru used several variations across different years and trims, the best way to confirm compatibility is by verifying the engine code.
If you are unsure which engine your vehicle has, Dakota Subaru Experts can help confirm compatibility before moving forward.
Who This Engine Is Not Designed For
The Badlands Boxer platform is designed specifically for naturally aspirated Subaru EJ25 engines.
It is not intended for turbocharged Subarus:
Subaru WRX
Subaru WRX STI
Forester XT models
Turbocharged Legacy or Outback models
Turbocharged Subaru engines require different internal components and build strategies.
If you have a turbocharged Subaru, please contact Dakota Subaru Experts to discuss other options.
Badlands Boxer Engine Pricing
The Badlands Boxer engine was developed as a long term reliability solution for Subaru owners who want to restore the foundation of their vehicle. Because every engine is built with careful attention to the components, machining, and assembly process, the Badlands Boxer represents a complete engine platform rather than a temporary repair.
Current pricing for the Badlands Boxer engine is as follows.
Badlands Boxer (Engine Only)
This option includes the Badlands Boxer long block engine built by Dakota Subaru Experts and ready for installation.
This option is often chosen by customers who have their own installer or are completing an engine swap project themselves. Shipping is available within the United States for customers outside our region.
$8,500
Badlands Boxer + Installation
For customers who prefer a complete solution, Dakota Subaru Experts also offers professional installation of the Badlands Boxer engine at our shop in Bismarck.
The installation package includes the engine installation along with fresh fluids and filters so the vehicle leaves our shop ready to drive.
$10,500
How to Get Started
If you are considering the Badlands Boxer engine for your Subaru, the first step is simply reaching out so we can learn more about your vehicle.
Subaru owners contact Dakota Subaru Experts for many different reasons. Some are dealing with a failed engine and need a reliable replacement.
Others are planning ahead and want to restore the engine in a vehicle they intend to keep for many more years.
The best way to start the conversation is by calling or texting our shop directly.
Once we understand your Subaru model, engine type, and current condition, we can help determine whether the Badlands Boxer engine is the right solution and walk you through the next steps.
Your Subaru gets you where you need to go. Mechanical issues should not be the reason it stops.
Call or Text Dakota Subaru Experts to discuss your Subaru.
Independent Specialty Service & Repair for Subaru vehicles.
Bismarck, North Dakota
Bonded & Insured
12-Month / 12,000-Mile Workmanship Warranty
Contact
1409 Lockheed Dr. #10
Bismarck, ND 58504
(701) 401-5842
[email protected]
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Disclaimer: Dakota Subaru Experts is an independent automotive repair business specializing in Subaru vehicles. We are not affiliated with, authorized by, sponsored by, endorsed by, or associated with Subaru of America, Inc. or Subaru Corporation. Subaru and related names, logos, and trademarks are the property of their respective owners.