2015 Mitsubishi Lancer Evolution

The Office of Defects Investigation (ODI) opened this investigation to determine if the failure of airbags to deploy during severe crashes, in certain vehicles, was the result of a safety related defect.  During the investigation a complex failure was studied that can result in non-deployment of subject vehicle air bags and other restraint system devices in severe crash events. The subject vehicles may be equipped with an airbag control unit (ACU) for the supplemental restraint system (SRS) Electronic Control Unit (ECU) manufactured by ZF-TRW.  The ECU receives signals from crash sensors mounted in the vehicle and deploys the vehicle air bags and seat belt pretensioners in accordance with manufacturer design specifications.  The ECU in the subject vehicles contains a model DS84 application-specific integrated circuit (ASIC) which controls the communication of the crash sensor signal, firing commands (i.e., when to deploy the airbag(s) and/or pretensioners), and fault information (e.g., diagnostic trouble codes). In September 2016, FCA announced recall 16V-668 for certain model year (MY) 2010 to 2014 Chrysler, Dodge and Jeep products manufactured with the subject ZF-TRW ACU.  In this recall, FCA discussed an EOS condition that resulted in a failure of the subject DS84 ASIC, which caused air bag non-deployment.  FCA noted that the defect condition had only been observed in vehicles equipped with sensor harnessing routed across the front of the vehicle.  Other FCA vehicles that also used the subject ACU, but were not equipped with cross-car harnessing, had not experienced EOS failures, despite similar time in service. During the course of this investigation, ODI sent two separate Information Request (IR) letters to six vehicle manufactures (including FCA, Hyundai, Honda, Kia, Mitsubishi, and Toyota) and one IR letter to ZF-TRW.  These IR letters resulted in ODI receiving comprehensive data from these manufacturers and suppliers. Studies of this data found that the DS84 ASIC does not have sufficient protection against negative electrical transients or electrical overstress (“EOS”) that can be generated in certain severe crashes.  An electrical transient occurs when the electrical power supplied to a circuit changes momentarily over a short duration of time.   In these severe crash cases, the crash sensors and other powered wiring can be damaged and short circuited so as to create a negative electrical transient of sufficient intensity and duration (that are outside the vehicle manufacturer's specification) to damage the ASIC before the restraint device deployment signal is received by the SRS ECU.  This damaged signal can lead to incomplete or nondeployment of the air bags and/or pretensioners.  Airbag non-deployment and/or lack of pretensioner operation can increase the risk or severity of injury in a crash.A total of 8 fatalities and 14 injuries were associated with known EOS events. The common element in all investigated manufacturers vehicles is the SRS ECU containing a DS84 ASIC manufactured by ZF-TRW.  The risk associated with the ASIC is equally shared among all OEMS involved in the investigation.  The actual real-world risk can be mitigated by other factors which were assessed by ODI during this investigation. The first mitigating factor involves protections built into the ACU design which protect the DS84 ASIC from damage.  There are multiple strategies and levels of protection employed by different OEMs that provide effective EOS mitigation.  The two most common strategies at the ACU level are circuit protection diodes on the remote senor signal lines, and current limiting resistors that protect critical components. The second mitigating factor is found at the vehicle level and involves the location and routing of the wires leading from the crash sensors to the SRS ECU.  If the wires are well protected in a crash and are not routed with other power wires carrying large currents, the risk for an EOS event is significantly reduced or eliminated. These design specific factors combine to produce a spectrum of risk for the vehicles equipped with ACUs using the DS84 ASIC.  Given the many of years of field exposure, it is possible to divide the subject population into two groups; vehicles which have experienced EOS events, and vehicles which have not experienced EOS field events. Four of the six OEMs involved in this investigation have experienced EOS field events on at least one of their models equipped with a DS84 ASIC.  All vehicle models (including the Toyota models identified in the Failure Report Summary of the opening resume for this investigation) with field events have been recalled.  In an abundance of caution, ODI kept this investigation open five years to monitor field performance and did not identify any field events on vehicles not included in existing safety recalls. Given the spectrum of risk identified in this investigation and that all vehicles with a demonstrated unreasonable risk have been recalled, ODI is closing this investigation. ODI is closing this investigation with the following manufacturer safety recalls: 16V-668, 18E-043, 18V-137, 18V-363, and 20V-024.  With the recall actions taken by the subject vehicle and equipment manufacturers, this investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exists on other model or model year vehicles outside of the recall scopes. The agency reserves the right to take further action if warranted by the circumstances.

TENSIONER BROKE RELEASING THE SERPENTINE BELT. LOST POWER STEERING, COOLING AND AC. CAR STOPPED IN THE MIDDLE OF THE ROAD. IMMOBILE. ENDED UP TAKING UR TO SHOP AND THEY FOUND THE CRACKED TENSIONER AND RUINED BELT THAT ONLY HAD ABOUT 10K MILES

NHTSA ID

11181255

Incident

Jan 1, 2019

Mileage

65,000 mi

CAR HAS ONLY BEEN DRIVEN JUST UNDER 6 MONTHS WITH NO ABUSE AND WITH JUST AT 10,000 MILES THE CLUTCH FAILED. THE DEALER AND MANUFACTURER CLAIM WEAR ITEM. IF THE CAR HAD 40,00 OR MORE MILES I MIGHT ACCEPT, BUT THEY BUILT A CAN WITH AN ENGINE THAT PRODUCES OVER 300 FT.LBS. OF TORQUE, AND APPARENTLY INSTALLED A CLUTCH AND PRESSURE PLATE THAT DOES NOT HAVE ADEQUATE CLAMPING AND HOLDING ABILITIES FOR THE ENGINE IN THE CAR. THE ARE CLAIMING WEAR ITEM AND WANT APPROXIMATELY $2,000.00 FOR THE REPAIR OF WHAT I BELIEVE TO BE A DEFECTIVE OR INTENTIONALLY INSUFFICIENT PART TO PROPERLY CONTAIN THE OUTPUT OF THE CARS ENGINE AND ARE PASSING THE COST ON TO THE BUYERS. THESE ARE ALSO NOT ENTRY LEVEL CARS AND ARE ADVERTISED AS HIGH POWER, PERFORMANCE CARS. CLUTCH BEGAN SLIPPING WHILE DRIVING THEREBY CREATING AN UNSAFE OPERATING CONDITION. AN EXTENDED WARRANTY WAS ALSO PURCHASED AND THE CLAIM IS BEING DENIED BY BOTH THE MANUFACTURE, AND THE ADD ON WARRANTY COMPANY AS WEAR ITEMS,

NHTSA ID

11043027

Incident

Oct 26, 2017

Mileage

10,000 mi

ALL WHEEL DRIVE NOT WORKING. FAILED WHILE DRIVING IN THE SNOW, SLIPPERY CONDITIONS. THERE IS A SERVICE BULLETIN ON THIS. THE AWD CENTER DIFF PUMP IS MOUNTED BEHIND THE REAR TIRE WHERE DEBRIS IS CONTINUALLY PRESENT. REPLACING THE PUMP IS NOT A PERMANENT FIX. *TR

NHTSA ID

10936224

Incident

Dec 13, 2016

Mileage

17,518 mi

This Technical Service Bulletin instructs the dealer to update the Hands Free Module software to improve the Bluetooth connection when certain devices are connected to Wi‐Fi.

Service Manual Revision - This Technical Service Bulletin provides the replacement procedure for the Differential Mount Bracket Bush of the Rear Axle Differential Carrier Assembly in the applicable Service Manual sections.

This is a Dealer Letter sent to dealers informing that Mitsubishi Technical Training has launched the 3rd quarterly technician quiz for 2023.

This Technical Service Bulletin provides service manual corrections and additional information for the transaxle assembly removal and installation of the roll stopper bracket.

This Technical Service Bulletin reviews the regulations that require a label showing the reduction in load carrying capacity be affixed to vehicles when the total net weight of accessories is more than 1.5 percent of the vehicle's gross vehicle weight rating (GVWR) or 100 lbs.

This Technical Service Bulletin provides instructions and material safety data sheets for removal of rap-film adhesive residue.