The 2006 Evo IX is a legendary AWD turbo sedan built for abuse, but the 4G63 engine and transmission demand respect. Most problems stem from modified examples or deferred maintenance, though even stock cars have weak points that emerge with mileage and spirited driving.
Transfer Case Rear Output Seal & Center Diff Pump Failure
Common · high severity
Typical onset: 60,000-90,000 mi
Symptoms: Grinding or whining from center of car during acceleration, Gear oil puddle under transmission/transfer case area, Loss of AWD or violent driveline shudder in turns, Check Engine Light with ACD/AYC fault codes
Fix: Transfer case must come out to replace rear seal and inspect center diff pump assembly. If pump is damaged, expect full transfer case rebuild or replacement. 8-12 hours labor depending on skill level and whether trans needs to drop.
Estimated cost: $1,800-3,500
Crankshaft Walk & Thrust Bearing Failure
Occasional · high severity
Typical onset: 80,000-120,000 mi
Symptoms: Metallic scraping noise at idle that changes with clutch engagement, Oil leaking from rear main seal area, Clutch pedal feel changes or clutch won't disengage properly, Vibration at idle that wasn't there before
Fix: The 4G63 thrust bearing wears and allows crank to walk forward into the clutch. Requires full engine removal, crank inspection, thrust bearing replacement, and often flywheel resurfacing. If caught late, crank needs machining or replacement. 20-25 hours for proper fix.
Estimated cost: $3,000-5,500
Camshaft Lifter Wear & Valve Train Noise
Common · medium severity
Typical onset: 70,000-110,000 mi
Symptoms: Loud ticking or tapping from valve cover, especially cold start, Noise persists after oil changes with correct weight, Loss of power at high RPM, Metal shavings in oil filter during changes
Fix: Worn cam lobes or collapsed lifters require head removal, cam replacement, and full lifter set. Often find scoring on cam journals. Head resurface recommended while apart. 12-16 hours labor plus machine work.
Estimated cost: $2,200-4,000
Lower Control Arm Bushing Failure
Common · medium severity
Typical onset: 50,000-80,000 mi
Symptoms: Clunking over bumps from front suspension, Steering wander or vague on-center feel, Uneven inner tire wear, Suspension feels loose or unsettled
Fix: Front lower control arm bushings are under-engineered for this car's performance envelope. Bushings tear and separate, requiring full arm replacement (bushings not sold separately by Mitsubishi). Alignment mandatory after. 3-4 hours labor for both sides.
Estimated cost: $800-1,200
Turbo Oil Feed Line Banjo Bolt Clogging
Occasional · high severity
Typical onset: null
Symptoms: Turbo whine or whistle changes tone under boost, Blue smoke from exhaust especially after idle, Loss of boost pressure, Turbo failure with shaft play
Fix: The restrictive banjo bolt filter screens on the turbo oil feed line clog with debris, starving the turbo bearings. Caught early, clean screens and replace feed line. If turbo is damaged, expect replacement. 6-8 hours with turbo R&R.
Symptoms: Grinding or resistance going into 2nd gear, especially when cold, 3rd gear pops out under deceleration, Hard to downshift quickly into 2nd, Gear oil has metallic sheen or glitter
Fix: The 5-speed's 2nd and 3rd synchros are weak points, especially in cars that saw track use or aggressive driving. Requires transmission removal and full rebuild with synchro replacement. 10-14 hours labor plus rebuild parts.
Estimated cost: $2,000-3,500
Harmonic Balancer Separation
Occasional · high severity
Typical onset: 90,000-140,000 mi
Symptoms: Severe vibration at idle that worsens with RPM, Visible wobble of crank pulley when engine running, Serpentine belt shredding or coming off, Rough idle and accessory drive noise
Fix: Rubber ring separates from outer pulley, causing violent imbalance. If caught before pulley comes apart completely, it's a straightforward replacement. If it grenades, expect collateral damage to belt, tensioner, and possibly oil pump drive. 2-3 hours labor.
Estimated cost: $400-800
Owner tips
Change oil every 3,000-4,000 miles with quality synthetic — the 4G63 turbo is oil-sensitive and short intervals prevent lifter and turbo issues
Inspect transfer case fluid every 15,000 miles; dark or metallic fluid means pump or seal trouble is starting
Replace turbo oil feed line banjo bolt screens preventively at 60k miles — $50 insurance against $2,500 turbo replacement
Avoid cars with modifications unless you have full documentation of tuning and supporting mods — most failures trace to boost without fueling
Budget $1,500-2,000 annually for maintenance and deferred items on any used Evo — these are 20-year-old performance cars now
Buy one if you can verify maintenance history and accept that ownership costs rival German sports sedans — when maintained, they're bulletproof, but neglect kills them fast.
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.
AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE · 16V334000
2016-05-23 · EA15001
Mitsubishi Motors North America, Inc. (MMNA) is recalling certain model year 2006-2007 Lancer and Lancer Evolution vehicles manufactured June 29, 2005, to June 19, 2007, equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules, and used as original equipment or replacement equipment. In the event of a crash necessitating air bag deployment, these inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.
Consequence: An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.
Remedy: MMNA will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge. The recall began on July 19, 2016. Owners may contact MMNA customer service at 1-888-648-7820. MMNA's number for this recall is SR-16-002.
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.
Performance
Horsepower
286hp
Torque
289lb-ft
0–60 mph
4.8sec
Quarter mile
13.4sec
Top speed
155mph
Fuel economy (EPA)
City
17mpg
Highway
23mpg
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 2006 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.