2002 Mitsubishi Lancer Problems

What owners report

Owners of the 2002 Lancer most often report a heater/AC temperature control knob that becomes hard to turn and then breaks, a clutch hydraulic (slave/master cylinder) failure that leaves the car unable to shift, airbags that did not deploy in front-end collisions, and premature front brake pad wear. Reports span a wide mileage range, from near-new cars to well past 200,000 miles, and many complaints describe gradual symptoms (a stiff knob, a slowly worsening clutch pedal) rather than a single sudden event.

1. 1
   Visibility (wipers, defrost, mirrors)

   Heater/AC temperature control knob breaks

   • 21 complaints (14%)
   • median 90,500 mi at 8.1 yrs old (14 state mileage)
   • owner-quoted repair $900 (median of 9 quotes)
   • filed 2007–2013

   Owners describe the temperature control knob on the center console becoming progressively harder to turn and then snapping off, sometimes leaving a stub of plastic behind the dash. Complaints say the heater and defroster then cannot be adjusted, which owners link to fogged or icy windows in cold, damp weather. According to complaints, dealers typically say the whole control module or cable must be replaced rather than the knob alone, and owners cite repair quotes in the hundreds of dollars. Reported from roughly 63,000 to 170,000 miles, often noticed as stiffness that worsens over months before the knob breaks, frequently mentioned in cold weather.

   1 related service bulletin

   What to check: Turn the temperature knob through its full hot-to-cold range and check for stiffness, grinding, or a broken stub. Ask whether the control module or cable has already been replaced.

   2 excerpts from owner complaints in NHTSA records

   “I have a 2002 Mitsubishi Lancer and the temperature control knob in the vehicle has been difficult to turn since I bought the car. The knob broke off two weeks ago. I contacted my dealer who stated that I can not just change the knob I have to change the whole unit which will cost me around $ 600.00 plus services fees to install it. This should be a recall item, since heating (and cooling) a vehicle allows it to be operable during hot and cold temperatures. It is now beginning to get cold.”

   NHTSA complaint #10430916, filed 2011-10, 110,000 miles

   “I own a 2002 Mitsubishi Lancer (oz rally) that was purchased in 2002. During the last few months of 2009, I noticed my temperature control knob was becoming harder and harder to turn. On monday, march 1, 2010 it broke completely off, leaving a partial stub of plastic in the console and the remaining plastic inside the knob. I first went to two auto parts stores to see if they carried this replacement piece, and their personnel informed me I needed to have it repaired a Mitsubishi dealership. …”

   NHTSA complaint #10316641, filed 2010-03, 100,500 miles
2. 2
   Transmission and drivetrain

   Clutch pedal loses pressure, cannot shift

   • 12 complaints (8%)
   • median 60,215 mi at 5.2 yrs old (11 state mileage)
   • filed 2004–2011

   Owners of manual-transmission cars report the clutch pedal sinking to the floor or losing pressure, leaving the car stuck in gear or unable to go into gear. Complaints commonly attribute this to a failed clutch slave or master cylinder, sometimes with fluid leaking onto the clutch disc and pressure plate. According to complaints, repairs often involve replacing the cylinder along with the clutch assembly, and some owners say dealers could not reproduce the problem beforehand. Mostly reported between roughly 43,000 and 146,000 miles, often while driving or shifting under normal conditions.

   3 related service bulletins

   What to check: On a manual car, press the clutch pedal several times and check for a spongy or sinking feel, and look for fluid around the slave cylinder and under the transmission. Ask whether the clutch hydraulics have been replaced.

   2 excerpts from owner complaints in NHTSA records

   “I was driving in heavy, stop and go traffic, when my clutch suddenly wouldn't disengage. I was unable to shift into gear, I killed the engine, put it in second, and started it back up, just enough to get back home. Right now the car in nearly undrivable, and this apparently has happened to a lot of other people.”

   NHTSA complaint #10159758, filed 2006-06, 60,215 miles

   “Pushed in clutch pedal, heard a loud pop, and clutch pedal went to the floor. The clutch would not disengage. I was able to pull into a parking lot were the car stalled. Got the vehicle towed to dealership. Dealer stated seals inside slave cylinder blew out and coated the clutch disc, pressure plate, and flywheel with fluid. Replaced slave cylinder and pressure plate, and resurfaced the flywheel. I had to pay $1009.35 to get the vehicle back.”

   NHTSA complaint #10093825, filed 2004-10, 49,995 miles
3. 3
   Air bags

   Airbags did not deploy in a crash

   • 23 complaints (16%)
   • median 49,176 mi at 4.9 yrs old (11 state mileage)
   • 23 mention a crash, fire or injury
   • filed 2002–2017

   Complaints describe front-end and side impacts at moderate speeds in which the airbags did not deploy, with drivers and passengers reporting injuries. Owners say the vehicles were damaged severely enough that deployment was expected, and several note the car was declared a total loss. Complaints generally say nothing was done to diagnose or correct the non-deployment afterward. Reported across a wide range of mileages, from about 38,000 to 90,000 miles, in collisions at roughly 25-60 mph.

   Recall 04V428000

   What to check: Check that the airbag warning lamp comes on briefly at start-up and then goes out, and ask whether the car has any stored airbag fault codes or prior collision repair.

   2 excerpts from owner complaints in NHTSA records

   “I went into a ditch (was run off the road) passenger door hit a pole, air bag did not deploy and passenger fractured her collar bone. This happened in 2005. Also the blow motor has rusted and needs to be replaced, I found out through the internet that water flows into the motor through the wipers. It cost over $400. To replace the motor.”

   NHTSA complaint #10149693, filed 2006-02, 38,003 miles

   “1) I was driving south down the road at 25-30 MPH, and another car was waiting to pull out of a parking lot on my right, he was going to turn left (north). - he says he didn't see me and pulled out in front of me and I t-boned him. 2)his airbags deployed, but mine did not. The accident was significant enough that they should have deployed. 3) nothing has been done to correct the failure, the car is going to the body shop today.”

   NHTSA complaint #10198266, filed 2007-08, 75,000 miles
4. 4
   Brakes

   Front brake pads wear quickly

   • 17 complaints (11%)
   • median 34,000 mi at 2.3 yrs old (12 state mileage)
   • 4 mention a crash, fire or injury
   • filed 2002–2017

   Owners report front brake pads wearing out at low mileage and needing repeated replacement, with some describing several sets within a few years. Complaints also mention squealing, clicking, and in some cases long pedal travel or a soft pedal that required extra pressure to stop. According to complaints, dealers frequently described the wear as normal, while some owners were told a brake component had been incorrectly specified. Often reported under about 45,000 miles, with some pads replaced by 15,000 miles.

   2 related service bulletins

   What to check: Measure front pad and rotor thickness and check for uneven wear or grooving, and ask for brake service records showing how often pads were replaced.

   2 excerpts from owner complaints in NHTSA records

   “In 2003 I bought a 2002 Mitsubishi Lancer from a Mitsubishi dealer. The car had approximately 25,000 miles on it and had the original brakes. In december 2004 I took the car to the dealer for an oil change and was told the brakes needed to be replaced. I had the work done and the car had approximately 42,000 miles on it and it was now on it's second set of brakes. In april 2006 I noticed the brakes were squeaking ,and took the car to a brake repair shop. …”

   NHTSA complaint #10156782, filed 2006-05, 42,000 miles

   “Vehicle requires extreme pedal pressure to stop. Vehicle has a long extended stopping distance. Does not matter if brakes are cold or hot. Issue began when car had approximately 12000 miles on it. Brakes have been inspected and no problems found with system. Vehicle now has 22000 and condition still exists and is worsening.”

   NHTSA complaint #10016224, filed 2003-04, 12,500 miles
5. 5
   Suspension

   Rear suspension noise and strut/bushing wear

   • 6 complaints (4%)
   • median 19,500 mi at 2.0 yrs old (6 state mileage, few)
   • filed 2003–2006

   Owners describe squeaks, clunks, and intermittent noises from the rear of the car that return after repair attempts. Complaints mention worn control arm bushings, leaking struts, and in one case a strut separating completely. According to complaints, dealers tried lubrication or replacement of bushings and struts with mixed results, and some repairs were covered under warranty. Mostly reported under about 50,000 miles, sometimes within the first year of ownership.

   Recall 16V4580001 related service bulletin

   What to check: Listen for rear squeaks or clunks on a test drive over bumps, look for leaking struts, and ask whether the front lower control arms were inspected or replaced under the corrosion recall.

   2 excerpts from owner complaints in NHTSA records

   “I am having problems with the rear suspension of my 2002 Mitsubishi Lancer. Service tells me that they have received a bulletin from Mitsubishi regarding an issue with the control arm bushings. Apparently both are bad on my automobile. The recommended fix to this problem according to the service bulletin is a special lube, however after two attempts the problem has not been corrected. …”

   NHTSA complaint #10013795, filed 2003-04, 20,000 miles

   “Mitsubishi Lancer es 2002, vehicle has been making an annoying squeeking sound coming from the rear ot the car. Three attempts have been made by the dealer to correct problem, to no avail. It seems that every time the vehicle is worked on the sound dissappears for several minutes (30 mns.) and than it returns. They claim to be stemming from the rear suspension system to poor bushings to lack of lubrication. They claim that alll of the above have been repair or replaced but not successfully.”

   NHTSA complaint #10078719, filed 2004-06, 19,000 miles

Buying note. Check the climate control knob operation, clutch pedal feel, brake wear, and rear suspension noise on any example, since these are the most frequently reported items. Ask for service records and confirm whether open recalls, particularly the front control arm corrosion recall, have been completed.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.