2003 Mitsubishi Outlander Problems

What owners report

Owners of this model year most often report front suspension and steering problems — pulling to one side, clunks and squeaks from worn front-end parts — plus cracked, clouded headlight lenses that let water in. A second cluster of complaints centers on a temperature control knob that becomes hard to turn and eventually breaks, and on cooling fan failures that lead to overheating. Many complaints come in above 60,000 miles, though several front-end and headlight reports involve low-mileage vehicles.

1. 1
   Suspension

   Front suspension and steering pulling or knocking

   • 43 complaints (37%)
   • median 64,225 mi at 5.8 yrs old (29 state mileage)
   • 2 mention a crash, fire or injury
   • filed 2003–2024

   Complaints describe the vehicle pulling to the right at speed, rear-end squeaks and knocking over bumps, and, in some cases, worn lower control arms or tie rods. Owners report repeated alignments and replacement of arms or sway bar parts without a lasting fix, and some dealers said they could not reproduce or explain the noise. A subset of reports concerns corrosion of the front crossmember and control arm area, which some owners link to a later recall. Pulling was often reported from the first few thousand miles; corrosion-related failures mostly appear from about 65,000 to over 200,000 miles.

   Recall 16V4580004 related service bulletins

   What to check: Have a mechanic check the front control arms, crossmember and tie rods for play and rust, and confirm whether recall 16V458000 was completed. A test drive at highway speed will show any steady pull.

   2 excerpts from owner complaints in NHTSA records

   “I took my vehicle in to the dealer twice in 2006 about a squeak that I heard from the rear passenger side while driving. The first time a service tech drove the around the neighborhood, but couldn't hear anything. The second time...the same and your service department did not check it out on my request. The problem is that I wasn't simply that I was hearing things. At this point, the squeak is so pronounced that it can be heard from the inside and from the outside of the vehicle. …”

   NHTSA complaint #10233402, filed 2008-07, 23,000 miles

   “Since the purchase of our 2003 Outlander, it has veered badly to the right. I notified the dealer of the problem from the date of purchase. I have had it in the dealership to correct the problem 3 times and the problem still exists. If you are traveling at a low speed it is not as obvious, but when traveling at higher speeds (60-70mph) if you do not apply pressure to the steering wheel, you will veer right and in 5 to 7 seconds be in a ditch, or if passing another vehicle, you would crash into them. …”

   NHTSA complaint #10079070, filed 2004-06, 150 miles
2. 2
   Exterior lighting

   Cracked, clouded headlight lenses taking on water

   • 16 complaints (14%)
   • median 55,000 mi at 6.0 yrs old (10 state mileage)
   • owner-quoted repair $800 (median of 6 quotes)
   • filed 2007–2014

   Owners describe both front headlight assemblies developing fine cracks, a milky or crazed appearance, and moisture collecting inside the lens, which dims the beam or leads to failing bulbs. Some say the lenses were already showing this within the first few years of ownership and that the vehicle then failed inspection. Complaints describe replacement of the entire assemblies as expensive, and dealers reportedly declined to cover it once warranty ended. Reported from as low as 15,000 miles up to roughly 140,000 miles, often on garage-kept cars over several years.

   3 related service bulletins

   What to check: Inspect both headlight lenses in daylight for internal cracking, haze or condensation, and check whether the bulbs actually light the road at night. Service bulletins describe the cracking appearance and how to tell normal dew from water intrusion.

   2 excerpts from owner complaints in NHTSA records

   “My Mitsubishi Outlander headlights are cracked and hazed, this is not from normal use, this is defect in the manufacturing of the headlight assy. They have caused me to slam on my brakes 3 times due to poor illumination of the road. I believe that Mitsubishi should offer to fix the headlights, or offer a discount, not $300 hundred dollars a piece to replace!!!!!”

   NHTSA complaint #10318896, filed 2010-03, 15,000 miles

   “The headlights on my 2003 Mitsubishi Outlander have stress cracks eventually resulting in them fogging over and even taking in water and blowing bulbs. When I researched it online, it appears this is a common problem among this make/model of vehicle. Replacement assembly kits are only available through the dealer and this is not covered under any kind of warranty.”

   NHTSA complaint #10276711, filed 2009-07, 25,000 miles
3. 3
   Engine cooling

   Overheating from cooling fan and fan controller failure

   • 9 complaints (8%)
   • median 51,785 mi at 4.8 yrs old (8 state mileage, few)
   • filed 2004–2016

   Complaints describe the engine overheating in traffic or on the highway, sometimes with the air conditioner blowing warm air and no warning light, traced by shops to a failed cooling fan motor or fan control module. Owners report repeat module replacements and, in some cases, radiator or cylinder head damage after the overheating. Some say a cooling fan recall had already been applied to the vehicle but the problem returned, and a few report being offered parts but not labor. Mostly reported between about 12,000 and 150,000 miles, often in stop-and-go traffic or hot weather.

   4 related service bulletins

   What to check: With the engine warm and the A/C on, confirm both cooling fans spin; ask whether the fan controller has been replaced and whether the radiator hoses have been checked for collapsing.

   2 excerpts from owner complaints in NHTSA records

   “I was stuck in traffic for 45 minutes and my vehicle (2003 Mitsubishi Outlander) overheated. As a result of this I blew the seal in the radiator. I was never notified that there was a recall on the cooling fans but the dealership had my address and did not notify me. When I contacted the dealership, they stated that the notices are mailed from Mitsubishi and not their dealership.”

   NHTSA complaint #10228038, filed 2008-05, 150,000 miles

   “I purchased a mitshbishi Outlander in 2003. It recently overheated and I took to my regular auto shop. He changed the radiator because of the heating damage however, when he checked the fan system , he realized that the power motor was burnt out. He looked the vehicle up and notified me that there was a dealer recal l on the 2003-2006, cooling fan system. Because he had already worked on the car, I paid him ~$400 (I can't recall the exact amount at this time). …”

   NHTSA complaint #10225904, filed 2008-04, 134,000 miles
4. 4
   Visibility (wipers, defrost, mirrors)

   Temperature control knob hard to turn or broken

   • 10 complaints (9%)
   • median 88,000 mi at 7.3 yrs old (8 state mileage, few)
   • filed 2009–2023

   Owners describe the heater/air-conditioning selector knob stiffening over time and then breaking free or snapping off, leaving the system stuck on hot or cold. Complaints say the cable and blend door behind it seize, and that the repair requires dash work quoted in the hundreds to over a thousand dollars. Several owners report the dealer recognized the problem immediately but said it was not covered by a recall. Reported from roughly 10,000 to 152,000 miles, often noticed after several winters of use.

   What to check: Turn the temperature knob slowly through its full range with the engine running and confirm the air actually changes from hot to cold and that the windshield defrosts.

   2 excerpts from owner complaints in NHTSA records

   “I own a Mitsubishi 2003 Outlander - the heating cooling knob is very hard to turn and eventually broke off - I spent over $300 to fix it - they installed a $150.00 part but said I would need a more extensive fix to get the knob to turn from heating to cooling. That would cost over $1500 also to turn it I have to get down on the floor and push on a part under the heating system - this is dangerous with a risk of burns because it gets hot down there. …”

   NHTSA complaint #10364210, filed 2010-11, 81,000 miles

   “Hvac knob has always been hard to turn from heat to cool, but it has now completely broken. If you turn it to heat it bounces back to cool. I have no heater or defrost! I was quoted $1,500 to fix the problem because the HVAC cable and door are stuck shut. The dealer knew my exact problem and the part number off the top off his head! He said it is a very common problem, but they don't recall it because it isn't a safety hazard. I don't see how this is so. …”

   NHTSA complaint #10654554, filed 2014-11, 103,700 miles
5. 5
   Fuel system

   Fuel smell and fumes from the fuel tank area

   • 5 complaints (4%)
   • median 131,000 mi at 12.6 yrs old (4 state mileage, few)
   • filed 2003–2017

   Owners report a strong gasoline odor inside and around the rear of the vehicle after filling the tank, fading as the level drops, with no visible puddle on the ground. Shops reportedly found a deteriorated or holed tank top or filler area, and in one case the tank was flagged along with the muffler. Complaints describe checking with multiple dealers who said they had seen the same problem on other vehicles. Reported from about 98,000 to 160,000 miles, mostly noticeable right after refueling.

   What to check: Smell around the rear wheel and under the rear seat after a fill-up, and have the tank and filler neck inspected for rust or holes; check that the check engine light is off.

   2 excerpts from owner complaints in NHTSA records

   “Over the last 4-6 months I noticed a gasoline odor after filling the gas tank (affected part). The gas odor has gotten significantly stronger outside and inside the vehicle each month. If I fill the gas tank today there is an extreme gas odor/fume that is leaking from the gas tank. As the gas tank empties the odor decreases. There isn't a gas liquid leakage that you would see on the ground, but a flume leakage that fills the passenger compartment and surrounds the outside rear area of the vehicle. …”

   NHTSA complaint #10579658, filed 2014-04, 110,000 miles

   “Heavy smell of gasoline when fuel tank is filled. Fill garage with fumes. Check engine light is on. If filled to a half tank or so, no indication of fuel smell. Does not appear to be leaking. I had an ase certified mechanic look at it and the fuel tank as well as filler nozzle are deteriorated. I called Mitsubishi motors north america and they acted as if this was the first time they ever heard of this problem. I called multiple dealers, and all have experienced the same problem with their customers. …”

   NHTSA complaint #11029708, filed 2017-09, 160,000 miles

Buying note. On a car this old, rust in the front and rear suspension and subframe matters as much as mileage, so inspect underneath and confirm recall 16V458000 was done. Also check the headlight lenses and the heater knob, since both are common and can be costly to put right.

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.