The 2005 Endeavor with the 3.8L V6 suffers from catastrophic engine failures due to piston ring/cylinder bore issues and transmission fluid cooler leaks that destroy the 4-speed automatic. These are budget-killing problems that often total the vehicle.
Piston Ring Failure / Cylinder Bore Scoring (3.8L V6)
Common · high severity
Typical onset: 80,000-140,000 mi
Symptoms: Excessive oil consumption (quart per 500-1000 miles), Blue smoke on startup or acceleration, Low compression readings on multiple cylinders, Check engine light with misfire codes, Knocking or rattling from engine under load
Fix: Piston rings lose tension and cylinder bores score due to material/design flaw. Requires complete engine rebuild or used/reman engine replacement. Rebuild: 18-24 hours labor. Engine swap: 14-18 hours including fluids and ancillaries.
Estimated cost: $3,500-6,500
Transmission Oil Cooler Internal Leak
Common · high severity
Typical onset: 70,000-120,000 mi
Symptoms: Transmission slipping or delayed engagement, Pink or milky fluid in radiator or transmission pan, Overheating transmission (burnt smell), Erratic shifting or loss of gears, Strawberry milkshake appearance in coolant reservoir
Fix: Internal cooler in radiator fails, allowing coolant and ATF to mix. Destroys transmission and contaminates cooling system. Requires radiator replacement, transmission rebuild or replacement, full cooling system flush. Total repair: 12-16 hours labor.
Estimated cost: $3,000-5,000
Rear Transmission Mount Failure
Common · medium severity
Typical onset: 60,000-100,000 mi
Symptoms: Clunking during acceleration or deceleration, Vibration at idle in gear, Excessive drivetrain movement when shifting, Visible tear or separation in rubber mount
Fix: Rear trans mount tears due to weight of 4-speed auto and V6 torque. Straightforward replacement but requires supporting transmission. 1.5-2 hours labor.
Estimated cost: $180-320
Ignition Coil and Spark Plug Tube Seal Failure
Occasional · medium severity
Typical onset: 50,000-90,000 mi
Symptoms: Misfire codes (P0300-P0306), Rough idle or hesitation, Oil pooling in spark plug wells, Hard starting when engine is hot
Fix: Valve cover spark plug tube seals leak oil into wells, fouling plugs and killing coils. Replace valve cover gaskets, tube seals, spark plugs, and failed coils. 3-4 hours labor for thorough job.
Estimated cost: $450-750
Brake Master Cylinder Failure
Occasional · high severity
Typical onset: 80,000-130,000 mi
Symptoms: Brake pedal slowly sinks to floor when held, Soft or spongy pedal feel, Loss of braking power, No external fluid leaks visible, Brake fluid level drops without visible leak
Fix: Internal seals fail in master cylinder (recall-related issue in some cases). Must replace master cylinder and bench-bleed, then bleed entire system. 2-3 hours labor including bleeding.
Estimated cost: $350-600
Front Wheel Bearing Failure
Occasional · medium severity
Typical onset: 70,000-110,000 mi
Symptoms: Grinding or humming noise that changes with speed, Noise increases during turns (load-dependent), Wheel wobble or play when jacked up, ABS light may illuminate
Fix: Hub bearing assemblies wear prematurely, especially in AWD models. Replace complete hub assembly per side. 2-2.5 hours labor per side.
Estimated cost: $280-450
Fuel Filler Neck Corrosion/Rust
Occasional · low severity
Symptoms: Fuel smell near rear of vehicle, Check engine light with EVAP codes, Difficulty filling tank (nozzle clicks off), Visible rust on filler neck at body connection
Fix: Filler neck rusts through in rust-belt areas or humid climates. Replace filler neck assembly. 1.5-2 hours labor including tank strap access.
Estimated cost: $250-450
Owner tips
Check for engine oil consumption immediately on any used purchase—burn test with 500-mile interval checks before major mileage
Inspect coolant and transmission fluid for cross-contamination (pink/milky) at every oil change—catching cooler leak early saves transmission
Budget $4,000-6,000 for inevitable engine or transmission failure if buying high-mileage—these are when-not-if issues
Avoid models with incomplete maintenance records; religious oil changes delay but don't prevent piston ring failure
Hard pass unless under $3,000 and you're handy with engine swaps—the 3.8L engine and trans cooler failures are financial sinkholes that exceed vehicle value.
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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FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP · 10V065000
2010-02-25 · PE09056
MITSUBISHI IS RECALLING CERTAIN MODEL YEAR 2004-2010 ENDEAVOR VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF 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 WASHINGTON D.C. COLD STATES INCLUDE NORTH DAKOTA, SOUTH DAKOTA, NEBRASKA, KANSAS, OKLAHOMA, COLORADO, WYOMING, MONTANA, IDAHO, WASHINGTON, OREGON, AND UTAH. ADJOINING STATES INCLUDE ARKANSAS, TENNESSEE, AND NORTH CAROLINA.
IN SEVERE CORROSIVE ENVIRONMENTS WHERE ROAD SALTS ARE FREQUENTLY USED IN WINTER VEHICLES MAY BE EXPOSED TO ROAD DEBRIS (MUD) MIXED WITH ROAD SALT. THIS MATERIAL CAN BECOME TRAPPED BETWEEN A REINFORCING BRACKET AND THE FUEL FILLER PIPE, POTENTIALLY CAUSING CORROSION. OVER TIME, CORROSION COULD CREATE A LEAK IN THE FUEL FILLER PIPE THAT COULD RESULT IN A FUEL LEAKAGE WHEN FUELING THE VEHICLE.
Consequence: FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy: DEALERS WILL REPLACE THE FUEL FILLER PIPE WITH A NEW IMPROVED PART FREE OF CHARGE. THE SAFETY RECALL IS EXPECTED TO BEGIN ON OR BEFORE JULY 5, 2010. OWNERS MAY CONTACT MITSUBISHI AT 1-800-222-0037.
MITSUBISHI IS RECALLING 45,988 MY 2005-2007 ENDEAVOR, GALANT, ECLIPSE COUPE, AND MY 2007 ECLIPSE SPYDER VEHICLES. THE BRACKET THAT IS THE ATTACHMENT POINT FOR THE LEFT REAR FUEL TANK MOUNTING STRAP MAY HAVE BEEN IMPROPERLY FORMED DURING A METAL STAMPING PROCESS. THE PROCESS MAY HAVE CAUSED THE METAL TO HAVE A SPLIT IN THE AREA WHERE THE BOLT THAT HOLDS ONE OF THE TWO FUEL TANK STRAPS TO THE UNDERSIDE OF THE VEHICLE IS LOCATED. IN THE EVENT THE FUEL TANK IS FULL AND THE VEHICLE IS SUBJECT TO A SEVERE COLLISION, THE BRACKET MAY BREAK AND ALLOW THE FUEL TANK TO DROP DOWN, POSSIBLY CAUSING A FUEL LEAK.
Consequence: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.
Remedy: DEALERS WILL INSPECT TO SEE IF THE LEFT REAR FUEL TANK STRAP MOUNTING BRACKET HAS SPLITTING BEYOND A SPECIFIC LIMIT. VEHICLES
WITH MODERATE TO SEVERE SPLITTING WILL BE REPAIRED USING A REINFORCEMENT CAP, A SPECIAL STRUCTURAL ADHESIVE, AND A RIVET TO REINFORCE THE FUEL TANK MOUNTING BRACKET. THE RECALL BEGAN ON SEPTEMBER 20, 2008. OWNERS MAY CONTACT MITSUBISHI AT 1-800-222-0037.
ELECTRICAL SYSTEM:IGNITION · 08V139000
2008-03-26 · PE08006
MITSUBISHI IS RECALLING 120,000 MY 2004-2006 ENDEAVOR PASSENGER VEHICLES. DURING VEHICLE USE, THE IGNITION KEY INTERLOCK CABLE (WHICH IS A COMPONENT OF THE INTERLOCK SYSTEM) MAY ALLOW THE INTERLOCKING CAM TO FALL FORWARD AND ALLOW THE IGNITION KEY TO BE REMOVED FROM THE IGNITION SWITCH WHEN THE GEARSHIFT MECHANISM IS NOT IN THE PARK POSITION.
Consequence: IF THE DRIVER DOES NOT SHIFT TO PARK BEFORE REMOVING THE KEY AND FAILS TO ENGAGE THE PARKING BRAKE, THE VEHICLE COULD ROLL AND A CRASH COULD OCCUR.
Remedy: DEALERS WILL INSPECT AND CORRECT THESE VEHICLES FOR THE REPORTED CONDITION. THE RECALL WILL BEGIN ON JULY 7, 2008. OWNERS MAY CONTACT MITSUBISHI AT 1-888-648-7820.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:CALIPER · 06V068000
2006-03-09
ON CERTAIN SPORT UTILITY VEHICLES, THE MATERIAL USED TO MANUFACTURE THE FRONT DISC BRAKE CALIPERS MAY BE BRITTLE DUE TO IMPROPER METALLURGY.
Consequence: THIS COULD CAUSE FRACTURE OF THE BRAKE CALIPER AND SUBSEQUENT UNEXPECTED PARTIAL LOSS OF BRAKING FORCE, WHICH COULD RESULT IN A VEHICLE CRASH.
Remedy: DEALERS WILL INSPECT AND REPLACE THE FRONT BRAKE CALIPER IF NECESSARY FREE OF CHARGE. THE RECALL BEGAN ON APRIL 10, 2006. OWNERS MAY CONTACT MITSUBISHI AT 1-800-222-0037.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:MASTER CYLINDER · 05V409000
2005-09-15
ON CERTAIN PASSENGER VEHICLES EQUIPPED WITH ANTI-LOCK BRAKES, THE BRAKE MASTER CYLINDER, WHICH CONTROLS THE FLUID PRESSURE TO THE VEHICLE'S BRAKES, MAY ALLOW BRAKE FLUID TO BYPASS INTERNALLY DURING STOPPING.
Consequence: THIS MAY RESULT IN A PARTIAL LOSS OF BRAKING, INCREASED STOPPING DISTANCES, AND COULD LEAD TO A VEHICLE CRASH.
Remedy: DEALERS WILL REPLACE THE BRAKE MASTER CYLINDER. THE RECALL BEGAN ON OCTOBER 3, 2005. OWNERS MAY CONTACT MITSUBISHI AT 1-800-222-0037.
PARKING BRAKE · 05V069000
2005-03-02
ON CERTAIN SPORT UTILITY VEHICLES, THE PARKING BRAKE PEDAL CABLE LOCK NUT MAY NOT HAVE BEEN TIGHTENED TO THE PROPER TORQUE SPECIFICATION. THE LOCK NUT MAY LOOSEN AND COME OFF, WHICH WILL REDUCE THE EFFECTIVENESS OF THE PARKING BRAKE.
Consequence: THIS CONDITION COULD ALLOW THE VEHICLE TO ROLL IF THE TRANSMISSION IS NOT PLACED INTO THE "PARK" POSITION AND THE VEHICLE IS PARKED ON A SLOPE, THUS RAISING THE POSSIBILITY OF A CRASH.
Remedy: DEALERS WILL INSPECT AND TIGHTEN THE PARKING BRAKE CABLE LOCK NUT, IF NECESSARY FREE OF CHARGE. THE RECALL BEGAN FEBRUARY 24, 2005. OWNERS MAY CONTACT MITSUBISHI AT 1-800-222-5500.
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