2015 MITSUBISHI I-MIEV

Symptoms: Hard brake pedal with little assist, Grinding or whining noise from under hood during braking, Brake warning light illuminated, Increased stopping distances

Fix: The electric vacuum pump (required since there's no engine vacuum) fails due to internal wear or moisture contamination. Replacement involves 2.5-3 hours labor to remove intake components and access the pump mounted near the brake booster. This is the subject of a NHTSA recall, but many units fail outside recall parameters.

Estimated cost: $800-1,400

Symptoms: Vehicle won't enter READY mode despite charged traction battery, Clicking from contactors but no startup, Dash displays 'CHECK EV SYSTEM' message, Remote key functions erratic or non-functional

Fix: The small 12V battery (NOT the main traction pack) powers computers and contactors. It drains quickly if the car sits unused, and the charging system doesn't always top it off properly. Dies typically at 3-5 years regardless of mileage. Replacement is straightforward—0.5 hours labor—but requires memory-saver to avoid module relearns.

Estimated cost: $200-350

Symptoms: Fast-charging stations fail to initiate charge, Error messages on DC fast charger screen, Level 2 AC charging works normally, Corrosion visible in CHAdeMO inlet pins

Fix: The DC fast-charge inlet contacts corrode from moisture intrusion or simply lose spring tension from repeated use. Repair involves removing the charge port assembly (1.5 hours), cleaning contacts with specialized solution, or replacing the entire inlet assembly if pins are damaged. Some techs retrofit with updated inlet seals.

Estimated cost: $400-900

Typical onset: 40,000-80,000 mi

Symptoms: Coolant smell in cabin, Wet carpet behind driver seat, Coolant level drops with no external leaks, Fogged windows that won't clear

Fix: The resistive cabin heater assembly (mounted under rear seat area) develops pinhole leaks in coolant passages. Access requires removing rear seat, interior trim panels, and carpet—4-5 hours labor. Aftermarket heater cores are scarce; most repairs use dealer parts. Coolant is EV-specific long-life formulation.

Estimated cost: $800-1,300

Symptoms: Reduced power in hot weather, CHECK EV SYSTEM warning during spirited driving, Coolant overflow reservoir overfills, Gurgling sounds from rear of vehicle

Fix: The rear-mounted electric motor and inverter share a cooling loop that's difficult to properly bleed. Air pockets cause localized overheating and power reduction. Proper bleeding requires a vacuum fill tool and specific procedure—1.5 hours labor. Often occurs after any cooling system service or if coolant level was allowed to drop.

Estimated cost: $150-300

Typical onset: 50,000-90,000 mi

Symptoms: Clunking over bumps at low speeds, Wandering steering feel, Excessive play during wheel shake test, Uneven front tire wear on inside edges

Fix: The front lower ball joints wear prematurely, likely due to the car's unusual weight distribution (batteries in floor). Not serviced separately—requires complete lower control arm replacement. 2.5 hours labor per side for arms, alignment, and test drive. OEM arms recommended; aftermarket quality is inconsistent.

Estimated cost: $600-1,000 both sides

Symptoms: Rapid or erratic range loss beyond normal degradation, Turtle mode engaging prematurely, Charging stops early before reaching full, Individual cell voltage spread exceeds 0.3V during diagnostic scan

Fix: The BMS loses calibration or individual cells drift, causing premature power limiting. Often corrected with a deep discharge/recharge cycle (3-4 hours to execute properly) and BMS reset. True cell failure requires traction battery module replacement—dealer-only job running $3,000-5,000 for parts alone. Most cases resolve with recalibration.

Estimated cost: $200-400 for recalibration