Cypress, Calif. – Feb. 14, 2018 – Mitsubishi Motors North America has recalled more than 170,000 vehicles possibly equipped with corrosion-prone and improperly installed brake components, according to documentation submitted to the National Highway Transportation Safety Administration.

The safety campaign affects 2014-2016 Mitsubishi Outlander sport utility vehicles produced between April 12, 2013, and Feb. 2, 2016, as well as 2013-2016 Mitsubishi Outlander Sport SUVs manufactured between July 20, 2012, and July 8, 2016. The Japanese automaker suspects all of the models referenced in the action contain the defective components.

The Defect

Affected vehicles could contain parking brake shafts and rear brake caliber boots that are not properly water-sealed. As a result, moisture could penetrate both of these fixtures and cause extensive corrosion damage. Additionally, these models feature defective automatic brake pad adjusters. Together, these parts greatly inhibit braking functionality and therefore pose a serious threat to occupants. However, Mitsubishi has not received reports connecting the defective components to any accidents or injuries.

Timeline of Events

In October 2014, Mitsubishi received a field report from a dealer in the U.K. outlining an instance of rear brake disintegration. The automaker launched an investigation and in October 2014 came to the conclusion that corrosion had caused the parking brake shaft to stick. Engineers took this data and began developing a production solution, which debuted in January 2016. At this point, assembly crews began coating all parking brake components in an anticorrosion covering. Mitsubishi launched an extended field monitoring program to measure the effectiveness of the coated components.

As this situation unfolded, Mitsubishi dealt with another developing safety issue centered on brake assemblies. In February 2015, the company received a field report from the Japanese market that referenced nonworking automatic brake pad adjusters. Mitsubishi engineers investigated the issue for more than one year but could not pinpoint a root cause. They did, however, find that one of the washers installed on one of the problematic brake calibers was scratched. Investigators began working with operations to develop a technical solution that would prevent scratching while also moving forward with their root cause analysis.

In October 2016, Mitsubishi introduced new washers made of stronger material that were impervious to scratching. The investigation moved forward.

Nearly one year later in September 2017, compliance officials at the company discovered that its brake caliber supplier, Akebono Brake Industry, had performed ineffective post-production inspections. This resulted in the release of defective calibers that did not meet predetermined production specifications. These unfit features, combined with the scratched washers, affected the performance of brake the pad automatic adjusters, which in turn led to decreases in braking performance due to increased pad wear.

On Jan. 19, 2018, quality assurance personnel met and decided that a voluntary safety recall aimed at addressing both braking issues was necessary.

The Solution

Mitsubishi intends to direct dealers to inspect and, if necessary, replace the rear brake calibers and parking brake boots on affected vehicles free of charge, according to an NHTSA recall acknowledgment document. The car company plans to notify dealers Feb. 9 and reach out to owners via first-class mail March 27.

Owners in need of more immediate assistance can connect with Mitsubishi customer service staff at (888) 648-7820. Callers should use the internal recall reference code SR-18-002. Owners can also speak with the NHTSA using its Vehicle Safety Hotline at (888) 327-4236.

Cypress, Calif. – Feb. 13, 2018 – Mitsubishi Motors North America has recalled more than 141,000 vehicles potentially equipped with defective drive belt components, according to documentation submitted to the National Highway Transportation Safety Administration. The campaign affects multiple models, including:

• 2009-2012 Mitsubishi Lancer sedans produced between March 20, 2008, and Nov. 17, 2011.
• 2010-2012 Mitsubishi Lancer Sportback sedans produced between June 17, 2009, and Nov. 15, 2011.
• 2008-2012 Mitsubishi Outlander sport utility vehicles produced between June 25, 2008, and Nov. 16, 2011.
• 2011-2012 Mitsubishi Outlander Sport SUVs produced between Aug. 26, 2010, and Dec. 15, 2011.

The Japanese automaker suspects all the vehicles referenced in the recall contain the defective features.

The Defect

The models included in the safety action could contain drive belt automatic tensioners whose flanges are prone to cracking. Such an event could lead to complete drive belt detachment, resulting in the immediate termination of engine and power steering operations, and increasing the likelihood of an accident. As a result, the defective part poses a serious threat to occupants. However, Mitsubishi has not received reports connecting the any accidents or injuries to the defect.

Drivers with vehicles on the verge of shutting down due to drive belt automatic tensioner fracturing will see the battery charge warning light illuminate.

Timeline of Events

Mitsubishi received a field report in September 2010 describing an instance of automatic tensioner breakage. This prompted the company to launch an investigation into the issue to ascertain a root cause. In December 2011, engineers for the automaker found that production staff had swapped the bearing in the automatic tensioner for a lead-free alternative in March 2008 and suspected that the new product was cracking when operating in high-load environments. Mitsubishi reshaped the bearing to reduce surface stress and initiated a field monitoring campaign with an expiration date of November 2015.

In December 2015, the car manufacturer reviewed the results of the four-year field monitoring program and began another program scheduled to conclude in January 2018.

Last month, Mitsubishi conducted another data review and found the occurrence of automatic tensioner breakage was higher than expected and increasing. The company called for a voluntary safety recall Jan. 19 to address the problem.

The Solution

Mitsubishi intends to direct dealers to replace the drive belt tensioners in affected vehicles free of charge, according to an NHTSA recall acknowledgment document. The automaker will notify dealers Feb. 9 and reach out to owners via first-class mail March 27. Those in need of more immediate assistance can contact Mitsubishi customer service at (888) 648-7820. Callers should use the internal recall identification code SR-18-001. Owners can also contact the NHTSA using its Vehicle Safety Hotline at (888) 327-4236.

Cypress, Calif. – Feb. 8, 2018 – Mitsubishi Motors North America has recalled more than 56,600 vehicles potentially equipped with defective sunroof framing components, according to documentation submitted to the National Highway Transportation Safety Administration. The campaign affects multiple models, including:

• 2008-2010 Mitsubishi Lancer sedans produced between Jan. 15, 2007, and March 3, 2010.
• 2009-2010 Mitsubishi Lancer Evolution sport sedans produced between Sept. 1, 2008, and Oct. 30, 2009.
• 2010 Mitsubishi Lancer Sportback sedans produced between June 17, 2009, and Oct. 30, 2009.
• 2007-2010 Mitsubishi Outlander sport utility vehicles produced between Sept. 8, 2006, and Nov. 3, 2009.

The automaker suspects all vehicles referenced in the action contain the defective components.

The Defect

Affected models feature improperly manufactured polyurethane sunroof frames that may degrade in humid or high temperature environments and lead to complete detachment of the sunroof glass. This poses a serious safety risk to occupants, as the falling glass could not only cause injury but also increase the likelihood of an accident. That said, Mitsubishi has not received reports connecting the defect to accidents or injuries of any kind.

Timeline of Events

Mitsubishi received a field report from the Japanese market in March 2015 detailing an instance in which the sunroof glass installed in a vehicle detached from the sunroof frame. This prompted the company to launch an investigation in collaboration with its sunroof assembly supplier, the Webasto Japan Company. Between April 2015 and December 2017, the two parties carried out detailed field investigations and performed internal tests in an effort to duplicate the outcome described in the original report.

In December 2017, Mitsubishi engineers confirmed that Webasto had changed the polyurethane material it used in its sunroof frames in 2009, switching to a more aesthetically appealing alternative that also seemed to exhibit better bonding. The report received in the March 2015 seemed to contradict this assessment and Mitsubishi deemed the material defective, postulating that it lost bonding power in hot, humid weather.

On Jan. 19, the automaker initiated a voluntary safety recall to address the problem.

The Solution

Mitsubishi intends to direct dealers to replace the sunroof assemblies in affected models free of charge, according to an NHTSA recall acknowledgment document. The company plans to notify dealers Feb. 9 and reach out to owners via first-class mail March 27.

Those in need of more immediate assistance can connect with Mitsubishi customer service personnel at (888) 648-7820. Callers should use the internal recall reference code SR-18-003. Owners can also reach out the NHTSA directly using the agency’s toll-free Vehicle Safety Hotline at (888) 327-4236.