The 2005 Evo VIII is a legend with the bulletproof 4G63 engine, but turbocharged performance comes at a price—these cars are frequently modified, abused, and run hard. Even unmolested examples face transmissions that can't handle full power, cooling system fragility, and transfer case wear from aggressive launches.
5-Speed Manual Transmission Synchro Wear and Bearing Failure
Common · high severity
Typical onset: 60,000-90,000 mi
Symptoms: grinding into 2nd or 3rd gear especially when cold, difficulty downshifting, whining noise in gear that changes with speed, metallic debris in transmission fluid
Fix: The 5-speed is notoriously weak in higher-power applications and even stock cars see synchro wear from spirited driving. Rebuild with OEM or upgraded synchros requires full trans removal (6-8 hours labor), or swap to 6-speed if budget allows. Many cars have been grenaded by previous owners launching aggressively.
Estimated cost: $2,800-4,500
Transfer Case Rear Output Shaft Bearing and Seal Failure
Common · medium severity
Typical onset: 70,000-120,000 mi
Symptoms: whining or howling from center of car that increases with speed, gear oil leak at rear of transfer case, vibration during acceleration, AWD binding or jerking in tight turns
Fix: The rear output bearing takes abuse from hard launches and inadequate fluid changes. Requires transfer case removal and teardown (8-10 hours). Replace bearing, seal, and chain tensioner while you're in there. Use quality Mitsubishi Diaqueen fluid on reassembly or risk premature failure.
Estimated cost: $1,800-3,200
Crankshaft Position Sensor Failure Leading to No-Start
Occasional · high severity
Symptoms: intermittent no-start with cranking but no firing, stalling at idle then won't restart until cooled down, CEL with P0335 or P0340 codes, car dies while driving and coasts to stop
Fix: Heat-related failure of crank or cam position sensor causes sudden no-start conditions, often stranding owners. Sensor replacement is straightforward (1-1.5 hours) but diagnostic time can add up if issue is intermittent. Replace both sensors preventively if one fails—they're the same age and heat-cycled identically.
Estimated cost: $250-450
Turbocharger Compressor Wheel Damage from Intake Debris
Occasional · medium severity
Typical onset: 80,000-140,000 mi
Symptoms: loss of boost pressure, loud screaming or grinding from turbo, excessive blue smoke on acceleration, shaft play detectable by wiggling compressor wheel, oil consumption increase
Fix: TD05 turbos are stout but intake tract leaks or deteriorated air filter let debris chew compressor blades. Turbo replacement requires 6-8 hours including manifold removal, downpipe work, and oil/coolant line replacement. Upgraded units (16G, etc.) common at this point. Inspect intake tract thoroughly before new turbo install.
Estimated cost: $1,500-3,000
Front Lower Control Arm Bushing Deterioration and Ball Joint Wear
Common · medium severity
Typical onset: 60,000-100,000 mi
Symptoms: clunking over bumps from front end, steering feels vague or wanders, inner tire edge wear, popping noise during tight low-speed turns, visible bushing cracking or tearing
Fix: Factory bushings rot out from spirited driving and age, causing alignment issues and poor handling feel—critical on a performance car. Replace full arms with OEM or Whiteline units (2.5-3 hours per side). NHTSA recall 06V277000 addressed some early lower arm issues but bushings still wear normally. Get alignment immediately after.
Estimated cost: $600-1,200
Radiator and Intercooler Sprayer Line Leaks
Occasional · low severity
Typical onset: 80,000-120,000 mi
Symptoms: coolant smell but no visible leak on ground, slow coolant loss over weeks, coolant light illuminates intermittently, visible green staining on radiator core or frame rail, hissing sound after shutdown
Fix: The intercooler sprayer system lines and radiator hoses age-harden and crack, especially lower hose at radiator outlet. NHTSA recall 08V300000 covered some cooling hoses. Replacement is straightforward (1-2 hours) but requires system flush and refill with proper coolant. Inspect all coolant hoses at this age—they're original rubber.
Estimated cost: $300-600
Clutch Slave Cylinder Internal Seal Failure
Occasional · medium severity
Typical onset: 70,000-110,000 mi
Symptoms: clutch pedal slowly sinks to floor when held down, difficulty getting into gear with engine running, clutch engagement point changes or feels soft, brake fluid level drops in reservoir, clutch doesn't fully disengage causing gear grind
Fix: Internal seals in the clutch slave cylinder wear out causing hydraulic leak past piston. Replace slave cylinder and bleed system (2-3 hours). Cheap insurance to do clutch master cylinder at same time—labor overlap is minimal and they fail together. Use DOT 3 or 4 fluid, never silicone.
Estimated cost: $400-700
Owner tips
Change transfer case and rear differential fluid every 30k with Mitsubishi Diaqueen or equivalent—this prevents $3,000+ transfer case failures
Inspect turbo intake tract for cracks or loose clamps every oil change—a $5 clamp prevents a $2,500 turbo replacement
Avoid cars with intake/exhaust/tune mods unless you have receipts for supporting mods (fuel pump, injectors, dyno tune)—half-done builds grenade transmissions and motors
Factory timing belt interval is 60k—do it at 50k with water pump, tensioner, and cam/crank seals or risk interference engine damage
Budget $1,500/year for maintenance and repairs even on clean examples—these are high-performance machines, not appliances
Buy one if you're handy and understand what you're getting into—spectacular driving experience but prepare for $3k-5k in deferred maintenance on any used example, and verify it hasn't been modified and beaten.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
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AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE · 18V220000
2018-04-05 · EA15001
Mitsubishi Motors North America, Inc. (MMNA) is recalling certain 2004-2006 Mitsubishi Lancer vehicles that previously received a like-for-like passenger side frontal air bag inflator under recall 15V321 as interim remedy. Also recalled are 2004-2006 Lancer vehicles located in Guam or Saipan that previously received or never received a new inflator under 15V321 or 17V569. These passenger side frontal air bag inflators may be susceptible to moisture intrusion which, over time, could cause the inflator to explode in the event of an air bag deployment.
Consequence: In the event of a crash necessitating deployment of the passenger's frontal air bag, the inflator could explode with metal fragments striking the vehicle occupants potentially resulting in serious injury or death.
Remedy: MMNA will notify owners, and dealers will install a final replacement passenger side frontal air bag inflator, free of charge. The recall began on April 26, 2018. Owners may contact MMNA customer service at 1-888-648-7820. MMNA's number for this recall is SR-18-005.
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE · 17V569000
2017-09-14 · EA15001
Mitsubishi Motors North America, Inc. (Mitsubishi) is recalling certain 2004-2006 Lancer and Lancer Evolution vehicles and 2004 Lancer Sportback vehicles. These vehicles are equipped with a passenger side frontal air bag that may be susceptible to moisture intrusion which, over time, could cause the inflator to rupture.
Consequence: In the event of a crash necessitating deployment of the passenger's frontal air bag, the inflator could rupture with metal fragments striking the vehicle occupants potentially resulting in serious injury or death.
Remedy: Mitsubishi will notify owners, and dealers will replace the front passenger air bag inflator with a different inflator, free of charge. The recall began on October 12, 2017. Owners may contact Mitsubishi customer service at 1-888-648-7820. Mitsubishi's number for this recall is SR-17-001. Note: This recall supersedes recall 15V-321.
SUSPENSION:FRONT:CONTROL ARM:LOWER ARM · 16V458000
2016-06-23
Mitsubishi Motors North America, Inc. (MMNA) is recalling certain model year 2002-2007 Lancer, 2004 Lancer Wagon, 2003-2006 Lancer Evolution, 2003-2006 Outlander and 2007-2013 Outlander V-6 vehicles originally sold in, or ever registered in, Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Virginia, West Virginia, Wisconsin and the District of Columbia. In the affected vehicles, the front lower control arms may detach due to the front cross member corroding from salt water exposure such as from road salt use.
Consequence: A detached front control arm can result in the loss of control of the vehicle, increasing the risk of a crash.
Remedy: MMNA will notify owners, and dealers will inspect the front cross members. Depending on the level of existing corrosion, either a sealing/anti-corrosion agent will be applied or the front cross member will be replaced with a new one that has a sealing/anti-corrosion agent applied to it. These repairs will be performed free of charge. The recall began January 2017. Owners may contact MMNA customer service at 1-888-648-7820. MMNA's number for this recall is SR-16-003.
EXTERIOR LIGHTING:HEADLIGHTS · 09E025000
2009-05-11
DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
Consequence: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Remedy: DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON JULY 28, 2009. OWNERS MAY CONTACT DOPE, INC. AT 1-626-272-1798.
EXTERIOR LIGHTING · 06E064000
2006-07-17
CERTAIN TRADESONIC COMBINATION LAMPS SOLD AS REPLACEMENT LAMPS FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. COMBINATION LAMPS NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
Consequence: LACK OF AMBER SIDE REFLECTORS IN THE LAMPS WILL DECREASE LIGHTING VISIBILITY TO OTHER DRIVERS AND MAY POSSIBLY RESULT IN A VEHICLE CRASH.
Remedy: TRADESONIC WILL NOTIFY OWNERS AND REPLACE THE LAMPS FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING JULY 2006. OWNERS MAY CONTACT TRADESONIC AT 626-934-8884.
EXTERIOR LIGHTING:HEADLIGHTS · 06E023000
2006-03-13
CERTAIN ANZO COMBINATION HEADLAMP ASSEMBLIES SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES. SOME COMBINATION LAMPS ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS WHICH FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT."
Consequence: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH.
Remedy: ANZO WILL NOTIFY OWNERS AND REPLACE THE HEADLAMPS FREE OF CHARGE. THE RECALL BEGAN MAY 9, 2006. OWNERS MAY CONTACT ANZO USA AT 909-468-3688.
ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSES/LINES/PIPING/FITTINGS · 05V335000
2005-07-27
ON CERTAIN PASSENGER VEHICLES, THE TURBO CHARGER COOLANT HOSE WAS INCORRECTLY MANUFACTURED, AND MAY ALLOW COOLANT LEAKAGE.
Consequence: IF A LEAK OCCURS, DURING VEHICLE OPERATION WHEN THE MANIFOLD IS HOT, COOLANT MAY IGNITE AND CAUSE A VEHICLE FIRE.
Remedy: DEALERS WILL REPLACE THE TURBO CHARGER COOLANT HOSE FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 15, 2005. OWNERS MAY CONTACT MITSUBISHI AT 888-648-7820.
Performance
Horsepower
271hp
Torque
273lb-ft
0–60 mph
4.9sec
Quarter mile
13.4sec
Top speed
155mph
Fuel economy (EPA)
City
17mpg
Highway
24mpg
Combined
19mpg
Fuel
Premium Gasoline
Capability & size
Curb weight
3,263lb
EPA class
Compact Cars
Fuel economy figures are EPA data via fueleconomy.gov (median across matching trims). Performance figures are compiled estimates for the 2005 Mitsubishi Lancer Evolution 2.0L I4 Turbo 4G63 and can vary by trim.
🔧 Database maintained under the daily editorial review of Chris Hackleman · Master Technician · 20+ years and Jeff Moore · Master Lexus & Toyota Mechanic · 20+ years.