Which parts fail
Components named in complaints (struts, shocks, control arms, ball joints, springs).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Mitsubishi Outlander owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2004 Mitsubishi Outlander. The contact stated that while driving at a slow speed, the front subframe detached. The contact stated that the driver's side front wheel was pointing outwards. The contact received notification of NHTSA Campaign Number: 16V458000 (Suspension) however, the part to do the recall repair was not yet available. The vehicle was towed to the local dealer. The vehicle was not diagnosed or repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the failure. The approximate failure mileage was 180,000. Parts distribution disconnect.
The entire undercarriage is rusted out, it was taken to Ricart near columbus ohio where they simply sprayed an anti rust coating over the existing rust. There is now rusted holes and the vehicle has spun out driving in straight due to control arm issues and whatever else. The vehicle is not believed to be road safe and needs to be addressed.
NHTSA recall number: opens new window takes away from VIN lookup section> 16V458 recall date: August 19, 2016 manufacturer recall number: sr-16-003 summary: the inside and outside surfaces of the front cross members used on certain vehicles, if exposed long term to snow melt water and anti-freezing agents, May corrode due to insufficient performance of the rust protection. Should significant corrosion occur over time, a lower control arm could eventually become detached resulting in loss of vehicle control and a potential collision. Safety risk: should significant corrosion occur over time, a lower control arm could eventually become detached resulting in loss of vehicle control and a potential collision. Remedy: repair not yet available. Recall status: recall incomplete. Remedy not yet available.
Tl* the contact owns a 2004 Mitsubishi Outlander. While driving 25-30 MPH, there was an abnormal noise coming from the rear driver's side of the vehicle. The vehicle was taken to an independent mechanic to be diagnosed. The contact was informed that the rear suspension was fractured and that the driver's side rear wheel separated from the vehicle. The contact stated that the fracture was due to severe rust. The contact was informed that the subframe showed severe and extreme rust. Walpole Mitsubishi (575 boston providence hwy, east walpole, ma 02032, [phone]) was contacted about the failure on the vehicle. The contact was informed that there was no recall on the vehicle. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 170,000.
Tl* the contact owns a 2004 Mitsubishi Outlander. While driving approximately 35 MPH approaching a stop light, the front end of the vehicle gave way and disconnected the front driver side wheel. The vehicle became immobilized in traffic without warning. The police arrived and assisted the contact. The vehicle was towed to a tow yard and was later towed to an independent mechanic who diagnosed that the undercarriage of the vehicle was corroded. The failure caused the lower control arm to fracture. The vehicle was repaired. The manufacturer was not made aware of the failure. The contact later received notification of NHTSA campaign number: 16V458000 (suspension). The failure mileage was 96,484.
Tl* the contact owns a 2004 Mitsubishi Outlander. While the vehicle was being remedied per NHTSA campaign number: 16V458000 (suspension), the dealer observed that the rear cross member was severely corroded and created holes. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 140,000.
Rear subframe rusted through while moving slowly in driveway causing the driver's side rear wheel to misalign, making the car unable to move. Car was towed to repair shop where rear subframe was replaced.
The front control arm where it bolts to the k frame rusted away completly resulting in the front drivers tire to come off. Was in a get in go parking lot turning when this happened luckly no one was hurt.
Tl* the contact owns a 2004 Mitsubishi Outlander. While driving 30 MPH, the contact heard a loud noise from the front driver's side of the contact's vehicle. The vehicle stalled and was unable to be driven. There were no warning indicators illuminated. The vehicle was towed to an independent mechanic, but was not repaired. The dealer diagnosed that the front cross members fractured and needed replacement. The contact received notification of NHTSA campaign number: 16V458000 (suspension). The vehicle had not been repaired. The manufacturer was notified. The failure mileage was unknown.
2004 Mitsubishi Outlander. Consumer writes in regards to vehicle driver side lower control arm / engine cradle malfunction. Consumer seeks reimbursement for lower control arm corrosion recall notice repairs. The consumer stated the on November 20, 2015 the lower control arm on the driver's side of the vehicle broke away from the engine cradle. The driver's side tire snapped back into the wheel well. The consumer contacted the manufacturer for reimbursement but, the manufacturer had not responded. Updated 05/1/2017
Related recalls
Suspension › Front › Control arm › Lower arm
Mitsubishi Motors North America, Inc. (MMNA) is recalling certain model year 2002-2007 Lancer, 2004 Lancer Wagon, 2003-2006 Lancer Evolution, 2003-2006 Outlander and 2007-2013 Outlander V-6 vehicles originally sold in, or ever registered in, Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland,…
Remedy: MMNA will notify owners, and dealers will inspect the front cross members. Depending on the level of existing corrosion, either a sealing/anti-corrosion agent will be applied or the front cross member will be replaced…
Suspension complaints in other Outlander years
Frequently asked questions
How common are suspension problems on the 2004 Mitsubishi Outlander?
NHTSA has 20 complaints about the suspension of the 2004 Mitsubishi Outlander, 38% of the model year's 52 complaints. The component named most often is rear (2 mentions).
Is there a recall for 2004 Mitsubishi Outlander suspension problems?
Yes — NHTSA recall 16V-458 (lower arm, Jun 23, 2016). Recall repairs are free at authorized dealers.
At what mileage do 2004 Mitsubishi Outlander suspension problems start?
Half of the complaints with a recorded mileage happened before about 96,000 miles, and 15% before 25,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.