2004 Mitsubishi Lancer Problems: 2 Known Issues
2004 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Mitsubishi Lancer has 2 documented known issues, with 2 rated critical. The most serious are Evolution AYC Rear Differential Pump Failure ($800-$2,500 repair) and Evo VIII/IX/X Active Center Differential (ACD) Transfer Case Wear ($1,500-$4,000 repair). Across all issues with published estimates, repair costs range from $800 to $4,000. DIY maintenance guides at au7o.io.
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All 2 Known Issues
NHTSA Recalls4 recalls
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:BELTS AND ASSOCIATED PULLEYS
Mitsubishi Motors North America, Inc. (MMNA) is recalling certain 2009-2012 Lancer, 2008-2012 Outlander, 2010-2012 Lancer Sportback, and 2011-2012 Outlander Sport vehicles equipped with either a 4B11 or 4B12 engine. The drive belt automatic tensioner flange may crack, allowing the accessory drive belt to detach.
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE:BELTS AND ASSOCIATED PULLEYS
Mitsubishi Motors North America, Inc. (Mitsubishi) is recalling certain model year 2008-2011 Lancer, Lancer Evolution, and Outlander; 2009-2011 Lancer Sportback, Lancer Rilliart, and Lancer Sportback Ralliart; and 2011 Outlander Sport vehicles. The affected vehicles, manufactured with 4B1 engines, have an engine pulley and belt arrangement for turning the alternator, the cooling fan and the power steering pump (if equipped). These pulleys may experience unusual wear and allow for belt detachment.
VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:FAN/MOTOR
Mitsubishi Motors North America, Inc. (Mitsubishi) is recalling certain model year 2009-2011 Lancer vehicles manufactured March 16, 2009, to March 30, 2011, 2010-2011 Lancer Sportback vehicles manufactured June 17, 2009, to December 1, 2010, 2010-2011 Lancer Evolution vehicles manufactured July 14, 2009, to January 7, 2011, 2009-2011 Outlander vehicles manufactured February 10, 2009, to June 22, 2011, and 2011 Outlander Sport vehicles manufactured August 26, 2010, to November 19, 2010. In the affected vehicles, the blower motor may fail.
ELECTRICAL SYSTEM:STARTER ASSEMBLY:RELAY
Mitsubishi Motors North America, Inc. (MMNA) is recalling certain 2015-2017 Outlander, 2015-2016 Lancer and Outlander Sport, and 2015 Lancer Evolution vehicles. These vehicles may have defective relays that can result in an engine stall, reduced engine power or the engine overheating.
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Frequently Asked Questions
What are the most common Mitsubishi Lancer problems?
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Mitsubishi Lancer has 2 documented issues. The most frequently reported are: Evolution AYC Rear Differential Pump Failure, Evo VIII/IX/X Active Center Differential (ACD) Transfer Case Wear. Of these, 2 are rated critical and should be addressed promptly.
Is the Mitsubishi Lancer reliable?
The 2004 Mitsubishi Lancer has 2 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 2 issues are rated critical: Evolution AYC Rear Differential Pump Failure and Evo VIII/IX/X Active Center Differential (ACD) Transfer Case Wear. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
How much does it cost to fix common Mitsubishi Lancer problems?
Repair costs for known Mitsubishi Lancer issues range from $800 to $4,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Evolution AYC Rear Differential Pump Failure, typically costs $800-$2,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What is the 2003-2015 Mitsubishi Lancer Evolution AYC Rear Differential Pump Failure?
The Active Yaw Control (AYC) hydraulic pump on the Lancer Evolution rear differential is a known failure point. The pump motor burns out or the internal gears strip, disabling the active torque vectoring rear differential and triggering warning lights. Repairs typically run $800-$2,500. Severity: high.
What is the 2003-2015 Mitsubishi Lancer Evo VIII/IX/X Active Center Differential (ACD) Transfer Case Wear?
The Lancer Evolution Active Center Differential (ACD) transfer case develops internal failures, particularly under hard launching and track use. The ACD clutch pack wears prematurely, and the transfer case bearings can fail, causing grinding noises and loss of AWD function. Repairs typically run $1,500-$4,000. Severity: high.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.