2003 Mitsubishi Lancer Evolution Body & structure Problems

Corrosion on cross member

NHTSA ID

11517476

Incident

Mar 20, 2023

UPON INSPECTION OF THE UNDERCARRIAGE IN THE REAR, AREAS OF SEVERE CORROSION HAS DEVELOPED UNDERNEATH THE REAR ON THE ALUMINUM SUBFRAME BAR THAT HOLDS THE REAR DIFFERENTIAL AND OTHER SUSPENSION COMPONENTS IN PLACE SUCH AS THE REAR DIFFERENTIAL & LATERAL CONTROL BARS THAT CAN SURELY COMPROMISE THE CARS ABILITY TO DRIVE IF UNNOTICED. ADDITIONALLY THE FUEL LINES ALONG THE GAS TANK, AS WELL SURROUNDING SURFACES ON THE DRIVER SIDE REAR, HAVE DEVELOPED NOTICEABLE CORROSION AS WELL THAT IS ALSO PROVING TO BE A LARGE AREA OF CONCERN. I AM CERTAINLY CONCERNED FOR MY SAFETY WHEN OPERATING THIS AND THE VEHICLES ROAD WORTHINESS BECAUSE OF THESE AREAS. THIS VEHICLE IS BY NO MEANS HEAVILY MODIFIED AT ALL, THE VEHICLE IS NEVER OPERATED BEYOND ITS LIMITATIONS/AGGRESSIVELY AS IT'S ALWAYS BEEN GREAT FOR ME AS IS, AND IT RESEMBLES EXACTLY THE WAY IT DID WHEN IT LEFT THE FACTORY. SOURCING ORIGINAL AND DOT APPROVED REPLACEMENT PARTS HAS BECOME VERY DIFFICULT AND IT LEAVES ME AT A STANDSTILL. PLEASE IF THERE ISN'T SOME KIND OF ROAD WORTHY DIRECTIVE IN REGARDS TO THIS I BELIEVE THERE SHOULD BE BECAUSE IT CAN CERTAINLY COMPROMISE SAFETY FOR DRIVER IN COMMAND AS WELL AS OTHER DRIVERS ON THE ROADS. TO WHOM IT MAY CONCERN AND WHOMEVER READING THIS, I HOPE MY INFORMATION CAME OFF CLEAR AND IS CONSIDERED. I GREATLY APPRECIATE YOU TAKING THE TIME OBSERVE THIS AND MAKING A PROMINENT DECISION. I CAN PROVIDE ADDITIONAL PHOTOS AND VIDEOS UPON REQUEST AS WELL. THANK YOU FOR YOUR TIME.

NHTSA ID

11342164

Incident

Jul 29, 2020

Mileage

80,000 mi

SEVERE REAR FRAME RAIL UNIBODY RUST. SPECIFICALLY WHERE THE REAR ALUMINUM SUBFRAME MOUNTS TO THE BODY. MY VEHICLE, ALONG WITH THOUSANDS OTHER, HAVE SHARED SIMILAR RUST AND ROT FROM THE EXACT SAME LOCATIONS ON 2003-2006 MITSUBISHI LANCER EVOLUTIONS. ABSOLUTELY NO FRAME PROTECTION FOR THE STEEL BODY. THERE IS ALREADY A RECALL ON THE FRONT SUBFRAME FOR RUST THAT CAN ALLOW THE FRONT LOWER CONTROL ARM TO FALL OUT. THE SAME COULD HAPPEN TO THE REAR OF THESE VEHICLES WHERE THE ENTIRE REAR END/DRIVETRAIN AND SUSPENSION COULD FAIL AND FALL OUT, POTENTIALLY CAUSING A SEVERE SAFETY ISSUE. ANY PART OF THE US WHERE HIGH HUMIDITY/RAINFALL OR WHERE ROAD SALTS/SOLUTIONS ARE USED ACCELERATE THE CORROSION PROCESS. BEING A UNIBODY VEHICLE THIS IS A SERIOUS PROBLEM AND DESIGN FLAW. IT HAPPENS OVER TIME AND DOESN'T DISCRIMINATE TO CONDITIONS. HAPPENS ON BOTH DRIVER AND PASSENGER SIDES OF THE REAR FRAME LEGS WHERE THE SUBFRAME MOUNTS.

NHTSA ID

11340609

Incident

Mar 1, 2018

Mileage

100,000 mi

WHILE REPLACING FRONT SUB FRAME STRUCTURE UNDER RECALL FOR RUST AND CORROSION, RUST DAMAGE TO THE REAR STRUCTURE WAS NOTED BY DEALER. UPON FURTHER INSPECTION, THERE ARE HOLES IN THE REAR STRUCTURE AS WELL.

NHTSA ID

11083585

Incident

Apr 10, 2017

Mileage

145,000 mi

I HAD JUST ARRIVED FROM WORK AND PULLED-IN MY DRIVEWAY, I WAS IDLING MY CAR BEFORE SHUTTING OFF THE ENGINE. I THEN SWITCHED OFF MY HEADLIGHTS, BUT THE HEADLIGHTS STAYED ON. I THEN PROCEEDED TO TURN THE HEADLIGHT SWITCH ON, THEN OFF; AFTER SEVERAL ATTEMPTS THE HEADLIGHTS FINALLY SWITCHED OFF, BUT THEN, THE HEADLIGHTS, PARKLIGHTS, MARKERS AND EVEN THE LICENSE PLATE LIGHTS WOULD FLICKER UNTIL THE IGNITION WAS SWITCHED OFF AND PULLED OUT THE KEY, BUT JUST BEFORE THIS INCIDENT I USED MY WIPERS TO CLEAR MY WINDSHIELD OF RAIN/MIST WITH A ONE WIPE/MANUAL SWEEP AND THE WIPERS JUST SEEMED THAT IT DIDN'T WANT TO STOP WIPING UNTIL THE IGNITION WAS SWITCHED OFF AND THE KEY PULLED OUT. THIS IS THE FIRST INCIDENT AND IT WAS RAINING OR HAD JUST RAINED. THE DEALERSHIP THEN REPLACED BOTH LIGHT AND WIPER SWITCHES AFTER DETERMINING THAT THERE WAS A SHORT. THIS SEEMED TO ADDRESS AND CORRECT THE PROBLEMS. THEN ON APRIL 28, 2008 I HAD JUST ARRIVED AT WORK AND WAS IDLING MY CAR BEFORE SWITCHING THE IGNITION OFF, AS I SWITCHED OFF THE LIGHTS THE HORN STARTED GOING OFF CONTINUOUSLY. IF THE LIGHTS WERE LEFT IN THE ON OR PARK POSITION, THE HORN WOULD STOP, BUT WHEN THE LIGHT SWITCH WAS TURNED OFF, IT DIDN'T STOP GOING OFF EVEN WHEN THE IGNITION WAS OFF AND THE KEY PULLED OUT. IT ONLY STOPPED AFTER THE FUSE WAS PULLED OUT. AGAIN, THE WEATHER WAS RAINING OR HAD JUST RAINED. I THEN DROPPED OFF MY CAR AT THE DEALERSHIP AND THEY DETERMINED THAT WATER INTRUSION THROUGH THE DRIVER'S FRONT KICK PANEL TO JUNCTION BLOCK, INSTRUMENT HARNESS, FLOOR HARNESS AND CHASSIS HARNESS. CORROSION ON PINS AND CONNECTORS CAUSING FAILURES AND SHORTS TO ALL SYSTEMS. THEY HAD AN OUTSIDE VENDOR SEAL AROUND WIRING HARNESS BEHIND INNER FENDER WELL. AT THIS POINT NONE OF THE WIRINGS NOR HARNESS WERE REPLACED. I WAS INFORMED THAT THIS WOULD ALL BE CUSTOMER PAY AND NOT COVERED UNDER WARRANTY AS I HAVE EXCEEDED THE 3/36 WARRANTY PERIOD. WIPERS HORN AND REMOTE UN/LOCK DON'T WORK. *TR

NHTSA ID

10227112

Incident

Mar 11, 2008

Mileage

48,605 mi

PAINT ON MY 03 EVO BEGAN FLAKING OFF, ROCK CHIPS BY BOTH BACK PASSENGER DOORS, 24K MILES AND I HAVE TOO MANY ROCK CHIPS EVERYWHERE, MY 98 CAVALIER DOESN'T HAVE THIS MANY ROCK CHIPS. *JB

NHTSA ID

10150620

Incident

Feb 10, 2006

ROCK CHIPS BEHIND THE DRIVERS SIDE REAR DOOR. MANY LITTLE CHIPS RUNNING UP THE DOOR FRAME. THE CHIPS ARE IN THE CREASE OF THE DOOR JAMB. I CAN PROVIDE PICTURES. I TOOK THE CAR (2003 MITSUBISHI LANCER EVOLUTION) TO HALL MITSUBISHI IN NEWPORT NEWS VIRGINIA AROUND JANUARY OR FEBRUARY. THE SERVICE MANAGER SAID IT WAS ROCKS KICKED UP FROM THE ROAD AND DIRECTED ME TO CALL A TOUCH UP PAINT REPAIR SPECIALIST. I HAVE TALKED TO MANY OTHER LANCER EVOLUTION OWNERS AND SEEN FIRST HAND THAT ALMOST EVERY EVOLUTION HAS THIS PROBLEM. I CAN PROVIDE PICTURES OF THE AREA IN QUESTION. THE CHIPS ARE TINY, BUT THEY ARE IN A PLACE ON THE CAR THAT WILL BE VERY SUSCEPTABLE TO RUST. I STARTED NOTICING THE PROBLEMS ABOUT A MONTH AFTER I BOUGHT THE CAR. I BELIEVE THE PROBLEM IS CAUSED BY A IMPROPERLY ALIGNED REAR DOOR. SO FAR I HAVE ONLY NOTICED THE PROBLEM ON THE DRIVERS SIDE OF THE CAR. *AK

NHTSA ID

10066215

Incident

Sep 1, 2003

Mileage

500 mi

THERE ARE PITTED RUST SPOTS ON THE REAR DRIVERSIDE QUARTER PANEL. WHERE THE DOOR MEETS THE PANEL. ALSO THERE ARE SURFACE RUST ON THE REAR OF MY BUMPER OF MY CAR.*AK

NHTSA ID

10064065

Incident

Jan 7, 2004