Mitsubishi Challenger: common faults & what to check
Thinking about buying a used Mitsubishi Challenger (1999–2015) in New Zealand? We've documented 10 known faults for this model spanning cooling, engine, suspension, and fluid leaks. Each researched and verified before it's published. The most serious issues here are rated critical. Two are set out in full below — the rest, with the symptoms, repair costs and checks for each, are free with an account.
10
Documented faults
Critical
Most serious
$400–$1,400
Typical repair
5
Systems covered
Known Mitsubishi Challenger faults
Every fault below is documented specifically for this model — researched and verified before it’s published.
014D56 coolant loss and overheating - service campaign 020116 and replaced engines
CriticalCommonCooling $400–$9,000 to fix
In November 2014 Mitsubishi ran preventative-action service campaign 020116 covering Challenger and Triton models with the 2.5-litre 4D56HP diesel built before 18 March 2014. These engines could lose coolant through repeated evaporation, particularly after hard work such as towing, and where the top face of the cylinder block was left too rough for the head gasket to seal properly, combustion gases could blow into the coolant and make the overheating worse. The campaign fitted a higher-pressure radiator cap to raise the boiling point and replaced the coolant at 50 percent concentration; Mitsubishi had already changed the engine software in September 2013 to pick up coolant loss earlier, and smoothed the block face from March 2014. A good number of these engines overheated badly enough to be replaced under warranty before those changes landed. On any Challenger of this age the coolant history, and whether the engine in it is the original one, matter more than the odometer reading.
Symptoms to notice
Coolant level in the overflow bottle dropping with no puddle underneath
Temperature gauge climbing above normal on long climbs or when towing
Sweet coolant smell after a hard run, or steam drifting from the front of the engine bay
Creamy mayonnaise-coloured sludge under the oil filler cap, or white smoke once warm
A replacement or reconditioned engine turning up in the service history
What to check
With the engine cold, check the coolant expansion tank level and look at what is in it - clean green coolant up to the mark, or low, rusty, or freshly topped up with plain water. Take the oil filler cap off and look at the underside for creamy mayonnaise-coloured sludge, which points to coolant finding its way into the oil. Ask the seller straight out whether the coolant has ever needed topping up, whether the temperature gauge has ever risen above normal, and whether the engine has ever been replaced or reconditioned. Ask for the service book and look specifically for service campaign 020116, a radiator cap replacement, or an engine replacement, and ask to see the invoices behind them. On the test drive find the longest climb you can, watch the temperature gauge the whole way up, and at the top turn the heater to full hot and confirm it still blows properly hot, because a system that is low on coolant usually goes cold at the vents before the gauge moves.
Where to look: Coolant expansion bottle and radiator at the front of the engine bay, the radiator cap on top, and the temperature gauge on the dash. The oil filler cap sits on top of the rocker cover.
Ask the seller
“Has the temperature gauge ever gone above normal, especially towing or on a long climb?”
“Has the coolant ever needed topping up between services?”
“Has service campaign 020116 been carried out, and is it recorded in the book?”
“Is this the original engine, and if not, why was it replaced and by whom?”
02Power seat recline switch can jam on — seat motor and cushion can melt or burn (2013 recall)
MajorRareInterior $0–$900 to fix
In September 2013 Mitsubishi recalled Challenger 4WD XLS models built from 2010 to 2012 with powered front seats. The recline switch can stick in the operated position instead of springing back, so current keeps flowing to the seat motor after you let go. With nothing to stop it, the motor, the seat cushion and the trim around it can get hot enough to melt and, in the worst case, catch fire. The same defect covered Triton 4x4 double cabs of a similar era. It is a free fix, but a fourteen-year-old four-wheel-drive that has been through several owners and possibly a few trade sales is exactly the sort of vehicle that never went back for it.
Symptoms to notice
Recline switch staying depressed instead of springing back
Seat motor continuing to run after you take your finger off
Hot or burnt smell from around the driver's or passenger's seat base
Discoloured, distorted or melted plastic on the side of the seat
Seat adjustment that works intermittently or not at all
What to check
If the car has powered front seats, work every seat control on both sides several times and watch that each one springs back cleanly the moment you let go, and that the motor stops when the switch does. Hold your hand near the plastic on the outer side of the seat base after you have been playing with it and feel for warmth that should not be there. Look closely at the trim around the switches and the motor for discolouration, distortion or a scorched smell. Ask the seller whether the September 2013 power seat recall was completed, and check the service book for a recall stamp.
Where to look: Power seat switch cluster and motor on the outer side of the front seat base
Ask the seller
“Was the 2013 power seat recall done on this vehicle?”
“Do all the seat controls work, and do they stop when you release them?”
“Has there ever been a burning smell from the seats?”
EngineCritical
EngineCritical
EngineCritical
EngineCritical
SuspensionCritical
SuspensionCritical
Fluid LeaksMajor
EngineMajor
8 more documented faults on the Mitsubishi Challenger
Symptoms, what to check, where to look and what to ask the seller — for every fault above. Free with an account, no card needed. One account covers one vehicle, so make it the car you’re actually looking at.
This page covers the model. Enter the plate of the actual car you’re looking at and see its year, engine, safety rating and register flags — free, no account needed.
Like any used car, it depends on the specific example and its service history. Across the 10 documented faults for the Mitsubishi Challenger, the recurring problem areas are cooling, engine, and suspension. A Mitsubishi Challenger with a full service history and no signs of the issues listed on this page can be a sound buy but each one needs to be checked individually before you commit.
What are the most common problems with a used Mitsubishi Challenger?
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We've catalogued 10 known faults for the Mitsubishi Challenger, covering cooling, engine, and suspension. Two are written out in full on this page. The rest — with the symptoms to notice, what to inspect, and typical repair costs for each — are free once you create an account.
How much do repairs cost on a Mitsubishi Challenger?
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Most single repairs on the Mitsubishi Challenger fall between $400–$1,400 at NZ independent-workshop rates. Some of the 10 documented faults cost less and a few cost considerably more, and no one car needs them all. Knowing which ones to look for before you view is what lets you negotiate the price down or walk away.
Should I get a pre-purchase inspection on a Mitsubishi Challenger?
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Yes. A Mitsubishi Challenger inspection focused on its known weak points is the single best way to avoid an expensive mistake. KickTyres gives you a guided, model-specific inspection plus a market valuation and negotiation figure for $17.90 far less than the cost of missing one of the faults on this page.