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Mitsubishi1999–2015 Critical issues documented

Mitsubishi Challenger: common faults & what to check

Thinking about buying a used Mitsubishi Challenger (1999–2015) in New Zealand? We've documented 12 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. Every one is listed below with its symptoms and repair cost, and each has its own page with where to look and what to ask the seller. Free, no account needed.

Check this exact Mitsubishi Challenger

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  • Money owing
  • Reported stolen
  • Ownership history
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  • NZ owned and operated

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12

Documented faults

Critical

Most serious

$400–$1,200

Typical repair

7

Systems covered

Which Mitsubishi Challenger are you looking at?

3 generation variants documented. Pick the shape you recognise: the faults, the servicing and the timeline below all narrow to it. Free, no account needed.

Now narrow it to the engine

A 1.8 and a 2.4 of the same car do not fail the same way, so the faults below narrow to the engine as well as the year. Free, no account needed.

Which engine is in it? These cover every year of this model.

2.8L diesel (4M40)· 2.8 litre diesel3.5L petrol (6G74)· 3.5 litre petrol

Start your free check on this Mitsubishi Challenger

No plate needed. You get the risk score, the buyer's checklist and the guided inspection for the exact car you picked above — not the whole nameplate.

Mitsubishi ChallengerEngine not picked yet

Pick the engine above first: the Challenger came with 2, and without it the report has to show all of their faults. Pick the engine

Free. The paid plate check is separate, and stays optional.

Can't confirm for this car

Mitsubishi Challenger

Nothing has been narrowed yet, so nothing below is a claim about a particular car. Pick a year and an engine to see which faults apply.

Tell us the engine, or check the engine code on the car, before relying on this.

matched on no vehicle context

What to look out for

The checks worth doing on a Mitsubishi Challenger before you hand over any money. Every documented fault is listed below, each with its own page.

  • Serious issue

    Confirm timing belt replacement history with receipts or stamped service book.

    See why

    6G74 3.5L V6 Timing Belt Failure (Interference Engine)

    The 6G74 3.5-litre V6 petrol fitted to K96W Challengers is an interference engine with a rubber timing belt that requires replacement at 90,000 km intervals. Belt failure results in immediate piston-to-valve contact and complete engine destruction. The V6 belt and tensioner setup is expensive to replace but far cheaper than an engine rebuild. A significant proportion of used K96W Challengers on the NZ/AU market have unknown or undocumented belt histories.

    What you would notice

    • No warning prior to catastrophic failure if belt snaps
    • Rough running or misfire if belt has jumped timing
    • Complete engine failure if belt snaps at speed

    Typically $600–$1,200 to put right.

  • Serious issue

    Any vertical play in the lower ball joint indicates wear.

    See why

    Front Lower Control Arm Ball Joint Failure

    The front lower control arm ball joints on K96W Challengers are subject to premature wear, particularly on vehicles used off-road or where the ball joint boots have been damaged by stone strike or water ingress. A failed ball joint causes unpredictable steering and is a WOF failure item. Widely documented across Mitsubishi's K9x-series platform including Pajero Sport.

    What you would notice

    • Clunking noise from front suspension over bumps or during steering input
    • Vague or wandering steering feel
    • Pulling to one side under braking
    • Visible grease leakage from ball joint boot

    Typically $400–$950 to put right.

  • Costly issue

    With engine warm, inspect the injection pump body carefully with a torch for any wet oil or fuel film.

    See why

    4M40 2.8D Injection Pump External Seal Failure

    The Bosch-type injection pump fitted to the 4M40 2.8-litre diesel in K96W Challengers develops external seal and o-ring failures with age, allowing diesel fuel and pump lubricant to leak from the pump body and mounting area. This is a widely documented fault on 4M40-powered vehicles (also shared with Pajero) and is progressive — a minor seep can become a significant leak if ignored. Fuel contact with hot exhaust components is a fire risk.

    What you would notice

    • Diesel or oil smell in engine bay when hot
    • Visible wet staining or drips from injection pump body
    • Black oily residue accumulation around pump base
    • Potential smoke from engine bay if fuel contacts exhaust

    Typically $600–$2,200 to put right.

  • Costly issue

    Ask the seller for the service history and look for a dealer invoice or service stamp showing recall PRA 2016/15466 was done.

    See why

    Headlight and indicator switch can fail recall (PB and PC Challenger, 2010-2014)

    PB and PC Challengers were recalled in June 2016 (PRA 2016/15466) because the turn signal and lighting switch connectors can wear and collect oxidised dust, so the lights and indicators can fail. The VIN ranges cover nearly every PB and PC built. It applies to all engines. The fix was free at a Mitsubishi dealer.

    What you would notice

    • Headlights or indicators work only sometimes

    Typically $0 to put right.

See all 12 documented issuesEverything researched for the Mitsubishi Challenger, including 7 rated critical.
Depends on which engine this Mitsubishi Challenger has — 12Each of these is documented for one particular engine. Pick the year and engine above to see which of them apply.
Engine, transmission & cooling6

014D56 coolant loss and overheating - service campaign 020116 and replaced engines

diesel2009–2015CoolingRead the full fault: symptoms, where to look, what to ask the seller

024D56 timing belt and balance shaft belt — a snapped belt destroys the engine

diesel2010–2015EngineRead the full fault: symptoms, where to look, what to ask the seller

03Coolant loss, overheating and head gasket blow-by, service campaign 020116 (2.5 4D56 diesel, built before March 2014)

diesel2009–2014Engine
CommonEngine $2,200–$8,000 to fix

Can't confirm for this car

Mitsubishi machined the top face of the 4D56 cylinder block too roughly on engines built before 18 March 2014, so the head gasket never sealed properly against it and combustion pressure could push past into the coolant. In November 2014 Mitsubishi opened preventative service campaign 020116 for PB/PC Challengers with the 2.5-litre 4D56HP diesel, citing engines overheating from 'repetitive coolant evaporation' after high-load driving such as towing, and inadequate head gasket sealing at the upper block surface. Australian owner forums carry accounts of head gaskets failing on low-kilometre cars, including a 2014 build at 60,000 km with tracking marks visible between cylinders. The pattern is coolant that vanishes with nothing on the ground, then an overheat, then a bill that can run into a head skim or a new engine. Mitsubishi changed the machining process around 2014, so later cars are the safer buy.

A removed multi-layer steel head gasket held up, showing staining around the cylinder bore.Example of the part — not this vehicle

A used multi-layer head gasket. Discolouration between a cylinder and a water gallery is the tell.

John Furman · CC BY-SA 3.0 · Wikimedia Commons

Symptoms to notice

  • Coolant level falling with nothing ever visible on the driveway
  • Temperature gauge climbing when towing, on hills or on a hot day
  • Bubbling or gurgling in the coolant header tank with the engine running
  • White steam from the exhaust that does not clear once warm
  • Creamy or mayonnaise-like residue under the oil filler cap

What to check

  1. Check the coolant level in the header tank with the engine cold and ask the seller straight out how often they top it up — 'now and then' is the answer that matters here.
  2. Once the engine is properly cold, look at the underside of the oil filler cap for a creamy mayonnaise-like film, which points at coolant getting into the oil.
  3. With the engine idling and warm, look into the coolant header tank for a steady stream of bubbles rising through it, and sniff the tank for an exhaust smell.
  4. Take the car up a decent hill on the test drive, or ask to tow nothing but drive it hard for ten minutes, and watch the temperature gauge the whole way.
  5. Ask whether service campaign 020116 was carried out and whether the head gasket has ever been replaced, and ask for the invoice if it has.

Where to look: Cylinder head gasket between the head and the top face of the block; coolant header tank at the front of the engine bay

Parts involved: Head gasket.

Ask the seller

  • “How often do you top up the coolant?”
  • “Was Mitsubishi service campaign 020116 carried out on this vehicle?”
  • “Has the head gasket ever been replaced, or the head skimmed? Can I see the invoice?”
  • “Has this vehicle been used for towing?”

044D56 balance shaft belt shredding and taking the timing belt with it

The 4D56 runs a second, inner toothed belt for the balance shafts, sitting behind the main timing belt.diesel2009–2015EngineRead the full fault: symptoms, where to look, what to ask the seller

056G74 3.5L V6 Timing Belt Failure (Interference Engine)

Confirm timing belt replacement history with receipts or stamped service book.petrol1999–2009Engine
CommonEngine $600–$1,200 to fix

Can't confirm for this car

Unconfirmed. This entry does not match our record of which engines and years this model was sold with, and is awaiting review. Confirm it against the car before acting on it.

The 6G74 3.5-litre V6 petrol fitted to K96W Challengers is an interference engine with a rubber timing belt that requires replacement at 90,000 km intervals. Belt failure results in immediate piston-to-valve contact and complete engine destruction. The V6 belt and tensioner setup is expensive to replace but far cheaper than an engine rebuild. A significant proportion of used K96W Challengers on the NZ/AU market have unknown or undocumented belt histories.

Symptoms to notice

  • No warning prior to catastrophic failure if belt snaps
  • Rough running or misfire if belt has jumped timing
  • Complete engine failure if belt snaps at speed

What to check

Confirm timing belt replacement history with receipts or stamped service book. If no documentation, the belt must be treated as unknown and budgeted for immediate replacement. Also replace tensioner, idler pulleys, and water pump at the same time as they are driven by the same belt.

Where to look: Front of engine, under timing cover

Parts involved: Timing belt.

Ask the seller

  • “Can you provide documentation of timing belt replacement?”
  • “Were the tensioner, idlers, and water pump replaced at the same time?”
  • “What is the odometer reading at the last belt change?”

06Suction control valve on the Denso high-pressure pump — hard hot starting and surging

diesel2015EngineRead the full fault: symptoms, where to look, what to ask the seller
Electrical1

01Headlight and indicator switch can fail recall (PB and PC Challenger, 2010-2014)

Ask the seller for the service history and look for a dealer invoice or service stamp showing recall PRA 2016/15466 was done.2010–2014Electrical
CommonElectrical $0 to fix

Can't confirm for this car

PB and PC Challengers were recalled in June 2016 (PRA 2016/15466) because the turn signal and lighting switch connectors can wear and collect oxidised dust, so the lights and indicators can fail. The VIN ranges cover nearly every PB and PC built. It applies to all engines. The fix was free at a Mitsubishi dealer.

Symptoms to notice

  • Headlights or indicators work only sometimes

What to check

Ask the seller for the service history and look for a dealer invoice or service stamp showing recall PRA 2016/15466 was done. Give the VIN to a Mitsubishi dealer and ask them to check for open recalls before paying. Work the light stalk through every position and the indicators both ways, and check every lamp lights steadily. If a workshop inspection is possible: a Mitsubishi dealer can confirm from the VIN whether the recall work was completed.

Where to look: Steering column light and indicator stalk

Ask the seller

  • “Has the lighting switch recall been done?”
Body, brakes, suspension & interior4

01Front Lower Control Arm Ball Joint Failure

Any vertical play in the lower ball joint indicates wear.1999–2009Suspension
CommonSuspension $400–$950 to fix

Can't confirm for this car

The front lower control arm ball joints on K96W Challengers are subject to premature wear, particularly on vehicles used off-road or where the ball joint boots have been damaged by stone strike or water ingress. A failed ball joint causes unpredictable steering and is a WOF failure item. Widely documented across Mitsubishi's K9x-series platform including Pajero Sport.

The front wheel of a car splayed outward with the lower control arm hanging down after a ball joint separation.Example of the part — not this vehicle

A separated lower ball joint: the control arm has dropped and the wheel has splayed out under the guard.

Elfix · CC0 · Wikimedia Commons

Symptoms to notice

  • Clunking noise from front suspension over bumps or during steering input
  • Vague or wandering steering feel
  • Pulling to one side under braking
  • Visible grease leakage from ball joint boot

What to check

Any vertical play in the lower ball joint indicates wear. Also inspect the rubber boot for cracking or grease expulsion. This is a standard WOF inspection item. If a workshop inspection is possible: With vehicle on a hoist and wheels hanging free, grasp each front tyre at 12 and 6 o'clock and attempt to rock it.

Where to look: Front suspension, lower control arm, each side

Parts involved: Ball joint.

Ask the seller

  • “Have the front lower ball joints been inspected or replaced?”
  • “Has the vehicle been used heavily off-road?”
  • “Does the steering feel vague or make any clunking over bumps?”

02Front lower control arm weld failure - 2013 safety recall (PRA 2013/13840)

2011–2012Suspension
OccasionalSuspension $0–$900 to fix

Can't confirm for this car

In November 2013 Mitsubishi recalled 20,405 Australian vehicles - 17,540 Tritons and 2,865 Challengers - from the 2011 and 2012 model years built before 11 May 2012. The front suspension lower control arms had been improperly welded, and the recall notice warned that the weld could fail, at which point the vehicle would become unstable and pull sharply to one side of the road. The Challenger campaign is PRA 2013/13840. The repair is free at a Mitsubishi dealer, but a vehicle this old has usually changed hands several times and a good number were never presented, so on a 2011 or 2012 Challenger this has to be confirmed against the VIN rather than assumed. It costs nothing to check and it is the single highest-value phone call you can make about this car.

Symptoms to notice

  • Vehicle pulling to one side and needing constant steering correction to hold a lane
  • A clunk or a sudden shift felt through the steering when you go over a bump
  • Steering wheel not sitting centred while driving straight
  • Uneven or feathered wear on the front tyres
  • A wheel alignment that will not stay put

What to check

Write down the VIN from the base of the windscreen or the driver's door frame and have a Mitsubishi dealer confirm by VIN whether the 2013 lower control arm recall has been completed - it costs nothing and takes one phone call. Ask the seller for the recall letter or the dealer paperwork showing the work was carried out. On the test drive, find a straight flat road, briefly relax your grip on the steering wheel and see whether it tracks straight or wanders to one side. With the window down, roll slowly over a driveway lip or a speed bump and listen for a clunk from the front. Look at the inner and outer edges of both front tyres for uneven or feathered wear, which suggests the front end has not been right for a while. If a workshop inspection is possible: have a mechanic put it on a hoist and inspect the welds along both front lower control arms, and check the front suspension for play at the same time.

Where to look: The front suspension lower control arms - the large A-shaped arms running from the chassis out to the bottom of each front wheel hub, behind and below the front bumper on each side.

Ask the seller

  • “Has the 2013 lower control arm recall been carried out, and is there paperwork?”
  • “Does it pull to one side or need constant steering correction?”
  • “Has the front suspension or either control arm ever been replaced?”
  • “When was the last wheel alignment, and did it hold?”

03Power seat recline switch can jam on — seat motor and cushion can melt or burn (2013 recall)

In September 2013 Mitsubishi recalled Challenger 4WD XLS models built from 2010 to 2012 with powered front seats.2010–2013Interior
RareInterior $0–$900 to fix

Can't confirm for this car

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?”

04Tailgate gas springs can corrode and break, tailgate drops suddenly, safety recall PRA 2016/15767 (PB/PC Challenger)

On 12-13MY PB and 14MY PC Challengers, Mitsubishi found the end caps on the tailgate gas springs were not given enough anti-corrosion coating.2011–2014Body & Rust
OccasionalBody & Rust $0–$400 to fix

Can't confirm for this car

On 12-13MY PB and 14MY PC Challengers, Mitsubishi found the end caps on the tailgate gas springs were not given enough anti-corrosion coating. The end cap can rust and break, letting the tailgate fall suddenly onto whoever is standing under it. Mitsubishi recalled 5,924 Australian Challengers in December 2016 (PRA 2016/15767) and replaces both springs free of charge. The replacement springs are silver, so the original black ones are easy to spot.

Symptoms to notice

  • Tailgate will not stay up or drifts down
  • Rust on the ends of the tailgate struts
  • Tailgate drops without warning

What to check

  1. Open the tailgate fully and look at the two gas struts: silver struts mean the recall has been done, original dark struts with rusty end caps mean it has not.
  2. Check the tailgate stays fully up on its own without being held.
  3. Ask for paperwork showing the recall was completed at a Mitsubishi dealer.

Where to look: Rear tailgate, the two gas struts either side of the opening

Parts involved: Body corrosion.

Ask the seller

  • “Has the tailgate gas spring recall been done?”
  • “Do you have the dealer paperwork for that recall?”
Fluid leaks1

014M40 2.8D Injection Pump External Seal Failure

With engine warm, inspect the injection pump body carefully with a torch for any wet oil or fuel film.diesel1999–2009Fluid LeaksRead the full fault: symptoms, where to look, what to ask the seller

Mitsubishi Challenger faults in detail

Each of these has its own page: the symptoms, where to look, what to ask the seller and what the repair costs. Free, no account needed.

4D56 balance shaft belt shredding and taking the timing belt with itCritical · Engine4D56 coolant loss and overheating - service campaign 020116 and replaced enginesCritical · Cooling4D56 timing belt and balance shaft belt — a snapped belt destroys the engineCritical · Engine4M40 2.8D Injection Pump External Seal FailureMajor · Fluid LeaksSuction control valve on the Denso high-pressure pump — hard hot starting and surgingMajor · Engine

What these repairs cost on other cars

Some of the Mitsubishi Challenger’s documented faults are repairs other models share. Each page lists the documented NZ cost for every model it affects.

Other Mitsubishi models

Mitsubishi Outlander47 documented faultsMitsubishi Lancer39 documented faultsMitsubishi Pajero39 documented faultsMitsubishi Mirage11 documented faultsMitsubishi Colt10 documented faultsMitsubishi Evo X10 documented faults

Mitsubishi Challenger buyer questions

Is the Mitsubishi Challenger reliable?

Like any used car, it depends on the specific example and its service history. Across the 12 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?

We've catalogued 12 known faults for the Mitsubishi Challenger, covering cooling, engine, and suspension. All 12 are written out in full on this page, with the symptoms to notice, what to inspect, and typical repair costs for each. Free to read, no account needed.

How much do repairs cost on a Mitsubishi Challenger?

Most single repairs on the Mitsubishi Challenger fall between $400–$1,200 at NZ independent-workshop rates. Some of the 12 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?

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 $24.90 far less than the cost of missing one of the faults on this page.