2004 Mitsubishi Outlander Problems

What owners report

Owners of the 2004 Mitsubishi Outlander most often describe rust and corrosion in the front cross members, control arms, and subframes, sometimes with parts breaking or detaching. Steering that drifts or pulls to one side, engine stalls or power loss, headlight lenses that crack or collect moisture, and airbags that did not deploy in collisions are other recurring themes. Where mileage is listed, the corrosion reports cluster at roughly 74,000 to 180,000 miles, while the steering drift reports are at or under about 2,000 miles.

1. 1
   Suspension

   Corrosion of cross members, control arms, subframes

   • 20 complaints (38%)
   • median 140,500 mi at 13.5 yrs old (12 state mileage)
   • filed 2006–2022

   Owners describe rust and corrosion in the front cross members, control arms, and subframes, with parts that broke, fractured, or detached during ordinary driving. Some complaints describe severe undercarriage rust, and some describe corrosion spray applied over existing rust, with holes still present afterward. According to complaints, the dealer found severe corrosion of the rear cross member during recall work and did not repair it, and the manufacturer declined to cover the rear cross body. A complaint quotes recall text that links the corrosion to long-term exposure to snow melt water and anti-freezing agents. Where mileage is listed, reports cluster at roughly 74,000 to 180,000 miles, and the corrosion is described as developing over time.

   Recall 16V458000

   What to check: Ask for the recall status of 16V458000 for this VIN and whether the front cross members and lower control arms were inspected or replaced. Have a mechanic check the undercarriage, subframes, and control arm mounts for rust, holes, and flaking before buying.

   2 excerpts from owner complaints in NHTSA records

   “I received a safety recall regarding the front cross body regarding rust and corrosion. My front cross body failed with total rust through. Mechanic showed me that the rear cross body is also affected and has a rust through hole the size of my fist. Mitsubishi has refused to cover the rear. This is a true safety hazard and needs to be covered by Mitsubishi.”

   NHTSA complaint #11035319, filed 2017-10, 169,214 miles

   “When I started the car and put it in reverse, I heard a loud sound like I had ran over something metal, when I got out to check the left rear tire was leaning out. I had someone look at it and was told the rear control arm rusted and broke in half. I was unable to drive the car and had to have it towed. I received a recall for the front control arm rusting but was told by the dealer that the front arm was not included.”

   NHTSA complaint #10947406, filed 2017-01
2. 2
   Steering

   Steering drifts or pulls to one side

   • 6 complaints (12%)
   • median 550 mi at 0.3 yrs old (4 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2003–2006

   Owners describe the vehicle drifting or pulling to the left or right with little steering wheel movement, and a complaint says the driver must keep steering slightly to stay straight. Some complaints describe loose steering, vibration, or a loss of power steering in snow, and a dealer could not duplicate the power steering loss. A complaint describes a pull to the right with tire scuffing even though the tires were rotated regularly, and another says a pull to the right led to a crash after the vehicle hit a curb. Where mileage is listed, reports are at or under about 2,000 miles, and the drift is described as constant.

   What to check: Ask whether a steering and alignment check has been done for drift, looseness, or pull, and check for play in the steering linkage and uneven tire wear. On a test drive on a straight, flat road, note whether the vehicle pulls to one side and how much steering correction is needed.

   2 excerpts from owner complaints in NHTSA records

   “The Outlander has the tendency to drift to the left. A quick check on the website revealed many car owners faced the same problem. It is identified to the actuator latch mechanism of the steering mechanism. This problem us well known to japan & asia. I am extremely surprised that it is not known to us at all. All the time, I have to turn the steering wheel slightly to the right to keep the SUV straight!!!”

   NHTSA complaint #10051213, filed 2003-12, 900 miles

   “Vehicle vibrated badly and had a tendency to pull to the right. Very bad accident occurred july 12, 2006. One car accident. My wife was driving home from houston, texas. A woman driving behind her said they had been driving normally, no speeding or weaving, when my wife's Outlander suddenly pulled hard to the right, hit a large curb and flew through the air, landing and rolling on to the side.”

   NHTSA complaint #10166651, filed 2006-08
3. 3
   Engine cooling

   Engine stalls or loses power while driving

   • 6 complaints (12%)
   • median 49,300 mi at 3.2 yrs old (5 state mileage, few)
   • filed 2004–2016

   Owners describe the engine losing throttle response, cutting out, or stalling, sometimes with a service engine light on. Some complaints say the problem continued after dealer work, and that power returned only after the vehicle was turned off and on repeatedly. A complaint says the engine stalled when the brake pedal was pressed, and another says it lost compression and power under light acceleration while the tachometer dropped. A complaint describes losing power in traffic, which the owner found especially concerning. Where mileage is listed, reports range from about 500 to 105,000 miles, and some describe the power loss as recurring.

   What to check: Ask for any stored codes and repair records for stalling or power-loss complaints, and whether the throttle and fuel system have been inspected. On a test drive, check for hesitation, loss of throttle, or stalling during light acceleration and braking.

   2 excerpts from owner complaints in NHTSA records

   “I have a 2004 Outlander an I have many thing wrong like the heater knob broke off the back windows fell but my major concern is the service engine light will come on an ill lose the throttle. In traffic this is pretty scary. Everything about the car is tip top. 80,000 miles never had any major problems till this, I've done the gas clicking thing to the gas cap. All the fluids are full and the only way I can get power back is by turning the truck off an on 5 times to rest the computer.”

   NHTSA complaint #10276522, filed 2009-07, 69,156 miles

   “Several problems with 2004 mistsubish Outlander. All fixed under warranty, except latest problem. Car won't run. Had to tow to dealership. Car shakes and engine cuts completely out. Dealership not cooperating, fixed the wrong thing, engine still cuts out/stalls, now saying I overfilled the gas tank, ruining the charcoal fuel canister. This is not covered under warranty?! There has to be another reason this happened. I have never overfilled or topped off my gas. I think they messed it up, or perhaps the gauges are wrong. …”

   NHTSA complaint #10182051, filed 2007-02, 49,300 miles
4. 4
   Exterior lighting

   Headlight lenses crack, yellow, or collect moisture

   • 5 complaints (10%)
   • median 49,000 mi at 6.0 yrs old (2 state mileage, few)
   • filed 2006–2013

   Owners describe headlight lenses that crack, yellow, or degrade over time, sometimes on both sides in a similar pattern. Some complaints describe water or condensation inside the lens that does not evaporate, reducing light at night. A complaint says the owner repeatedly restored and sealed the lens, but the lens alone is not available, so the full assembly would need replacing. Some complaints say the cracks do not appear to come from rocks or collisions, and that the dealer declined to address the problem. Where mileage is listed, the value is about 19,000 miles, and the lens degradation is described as developing over a period of years.

   3 related service bulletins

   What to check: Ask whether the headlight lenses were inspected for cracks and internal moisture, and whether any headlamp bulletin was applied. Complaints describe the lens sold only as a full assembly, so check the cost of replacement before buying.

   2 excerpts from owner complaints in NHTSA records

   “After moving to texas the vehicle inspection station alerted me to the severely degraded headlight lens on both sides. I have restored the surface and sealed the cracks numerous times but they are in need of restoration or replacement again. The lens alone is not available and the whole assembly costs over $200.00 each. The car was purchased in december of 2003 at the same time I bought my ford f150 and parked beside the truck every day for more than nine years. The lens on my ford is still crystal clear, no cracks and looks to be new. …”

   NHTSA complaint #10509209, filed 2013-04, 19,000 miles

   “Both headlights on our 2004 Mitsubishi Outlander are cracked in a similar pattern, bottom outer corner to upper inside corner, there are 2 -3 cracks on each headlight. This was not done by rocks, or any collision, considering they are so similar in appearance on both headlights, it must be a defect in the plastic coverings. We have not attempted to replace these, since the estimate to fix this problem consists of replacing the whole headlight, costing almost $600.00 per headlight.”

   NHTSA complaint #10165382, filed 2006-08
5. 5
   Air bags

   Airbags did not deploy in collisions

   • 7 complaints (13%)
   • median 57,500 mi at 5.9 yrs old (7 state mileage, few)
   • 7 mention a crash, fire or injury
   • filed 2004–2017

   Owners describe airbags that did not deploy in collisions, including a rear-end impact, a rollover, a frontal impact with a column, and a high-speed impact with another vehicle. Some complaints describe injuries such as bruising and a body jerking against the steering wheel area, even with a seat belt worn. Some complaints say the vehicle was declared a total loss after the crash, and a complaint says the manufacturer was not made aware of the failure. Where mileage is listed, reports range from about 20 to 280,000 miles, and some crashes happened at moderate speeds or in parking lots.

   What to check: Ask the dealer to scan the airbag system for stored fault codes and to confirm whether any recall or service bulletin applies to it. Request repair records for any prior collision, since complaints describe airbags that did not deploy in impacts.

   2 excerpts from owner complaints in NHTSA records

   “Slammed my front drivers side into a cement column in a parking lot. My airbag did not deploy. No major injury just a bruised jaw and sore neck. Incident 01/17/2013. Usaa auto insurance said car was totalled so I get the cash value.”

   NHTSA complaint #10496880, filed 2013-02, 155,000 miles

   “On 10/17/04, I was was rear ended. The car spun around and the air bags did not open. Model mitshubishi Outlander 2003. My body jerked against the frame of the steering wheel. Yes! I had my seat belt on.”

   NHTSA complaint #10096469, filed 2004-10, 20 miles

Buying note. Before buying a 2004 model year Outlander, have a mechanic inspect the undercarriage, front cross members, and control arm mounts for rust, and check whether recall 16V458000 has been completed. Test drive the vehicle for steering pull, engine stalling or power loss, and headlight condition, and ask for records of any prior collisions and airbag system checks.

Summary written with AI from a sample of 46 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.