Common problems · 1994–2007
Delica Space Gear problems: 8 things to check
The problems owners and specialists flag most on the Mitsubishi Delica Space Gear, the repairs they end up doing and what those cost, plus the years and recalls to watch. Sourced, not scraped.
Delica Space Gear problems to check before you buy
- Crawl under it with a flashlightRust is the van-killer. One Delica Canada owner photographed it on the frame rails, under the battery compartment, in the hole in front of the battery tray, along the seam back to the firewall and behind the rear bumper where the spare sat. Another warned that rebuilding a rotten L400 cost so much time and money he'd never do it again.
- Look up, tooOwners warn about the roof and the windshield surround. Crystal Lite Roof vans are said to be prone to rust and electrical problems, and one owner was quoted about $1,000 for windshield-frame rust repair.
- Confirm it's actually 4WDRear-drive Space Gears exist (PA, PB and PC codes). A 4WD van has a Super Select lever and a chassis code such as PD6W, PE8W, PD8W, PF6W or PF8W. Match the code on the frame number to the engine before you pay.
- Cycle the Super SelectShift through 2H, 4H, 4HLc and 4LLc on loose ground. A front-wheel light that keeps flashing usually means a sticking vacuum solenoid pair or a seized front-diff actuator; a flashing centre-diff light points to the transfer-case position switches.
- Cold-start a diesel yourselfArrive early so the seller can't pre-warm it. Hard starting points to glow plugs or the glow-plug controller, and smoke can be a clogged EGR, injectors or an injection pump that's on its way out. The early mechanical pump is the one owners say leaks.
- Check the cooling system and headAn owner told Field Mag that overheating and cracked heads are common on L400s. Look for coolant loss, bubbles in the reservoir and white smoke, and ask whether the van has ever overheated. A Delica Canada member advises crack-testing the head if the gasket has gone.
- Test the automatic properlyDrive it until it's warm and make sure it shifts through all four gears. A van that holds third and flashes the neutral light has dropped into limp mode, which can be a sensor fault or a failing transmission.
- Ask how it got hereGet the export certificate, the import paperwork and the build month. In the US the 25-year clock starts at the build date, and RHD insurance and registration rules vary by state and province.
The repairs Delica Space Gear owners end up doing
| REPAIR | SYMPTOMS | DIFFICULTY | TIME | COST |
|---|---|---|---|---|
| Fix flashing Super Select lights (vacuum solenoids and front actuator) | The green front-wheel lights on the Super Select display keep flashing in 2H, or the van won't fully engage or release 4WD. A flashing yellow centre light is a different fault. | 2 / 5 | ≈ 1–3 hours | Often just cleaning; solenoids and hoses if not |
| Replace the front lower ball joints | Clunks over bumps, play at the knuckle, torn boots. Lifted vans wear them faster, and Delica Canada members warn that a lift adds strain. | 3 / 5 | ≈ Half a day | FEBEST joints were about $19 each in 2016, plus shipping |
| Rebuild the brakes with Montero calipers and pads | Pulling, sticking or seized rear calipers (a common Delica Canada thread), or a failed safety inspection. | 2 / 5 | ≈ 2–4 hours | Parts-store calipers and pads |
| Replace CV boots (and consider manual hubs) | Grease on the inside of the wheel, a torn or slipped inner boot, clicking at full lock. One Expedition Portal owner had a CV joint break and lose a ball bearing. | 3 / 5 | ≈ Half a day per side | Boot kits are cheap; a used axle from an importer if a joint has failed |
| Clean and check the EGR (4M40) | Black smoke, rough running, carbon build-up in the intake. | 2 / 5 | ≈ 1 hour | A gasket or two |
| Fix a leaking 4M40 injection pump | Diesel weeping around the pump, hard or rough cold starts, irregular shifting on automatics, smoke. | 4 / 5 | ≈ 6–8 shop hours to remove and refit (one Calgary quote), plus bench time | Calgary owners were quoted CA$1,600–1,800 in 2016, including removal |
| Head gasket on the 6G72 V6 | Bubbles in the coolant reservoir, coolant loss, overheating, white smoke. | 4 / 5 | A multi-day job | Gasket kit plus a timing belt; machine-shop work if the heads are warped |
| Stop the frame rust | Scaling on the frame rails, rear axle and driveshaft; bubbling around the battery tray and rear bumper. | 2 / 5 | ≈ A messy day, then yearly | A Fluid Film kit with gun and two gallons came to about CA$230 for one owner |
Each repair links to a step-by-step guide with tools, part numbers and where to buy the parts.
Owner questions about Delica Space Gear reliability
How bad is the rust?
Bad enough to end a van. Owners watch the frame rails, the battery-tray area, the firewall seams, the rear bumper, the roof and the windshield surround. Undercoat as soon as you buy it, and every year after that.
SOURCE · DELICA CANADA · JDMBUYSELLTake the printable Delica Space Gear inspection checklist: every check on this page plus the model-specific ones, on one sheet. Get the checklist →
Sourced from owners, specialists and factory documents; full sources are on the Delica Space Gear guide. Verify torque figures and procedures against the factory service manual (disclaimer).