BOXY TRUCKS
Common problems · 1982–91

1st Gen Pajero / Montero problems: 8 things to check

The problems owners and specialists flag most on the Mitsubishi Pajero / Montero (First Generation), the repairs they end up doing and what those cost, plus the years and recalls to watch. Sourced, not scraped.

Read the full 1st Gen Pajero / Montero guideSpecs & fluids

1st Gen Pajero / Montero problems to check before you buy

  1. Rust: windshield frame, roof and floorsBring a Trailer's 1989 Raider showed corrosion on the bonnet, the windshield surround and the roof, and its 1988 Montero Sport had corrosion and failing clearcoat. Check the windshield frame, the roof gutters, the floors, the rear wheel arches and the chassis rails.
  2. Steering linkageEvery first-generation chassis code is on Mitsubishi's pitman-arm notice. Check for play and inspect every ball-joint boot. A cracked boot means the joint needs replacing.
  3. Listen for chain rattle on the 2.6The 4G54 runs a timing chain and a balance-shaft chain. A rattle at cold start means a chain-and-guide job, so budget for both chains.
  4. Test the hubs and 4WDEngage 4H and 4L on gravel. The automatic hubs should lock and release cleanly. A truck that's been driven in 4WD on pavement may have a stressed driveline.
  5. Check the paperwork and the odometerTwo of the BaT trucks we read about had odometer problems: a Raider with a Carfax mileage inconsistency and a Montero Sport issued 'Not Actual Mileage' titles several times. Pull a history report.
  6. Know which engine and rear suspension you're gettingA 'V6' grille badge marks the 3.0. Leaf-sprung and coil-sprung rear ends take different parts. Any diesel in the US is a later import, so check its paperwork.
  7. Run the VIN for recallsUS recalls include front seat-belt buckle buttons (95V103: 1986–91 Montero and 1987–89 Raider), throttle icing on 1989 trucks (89V030 for the Montero, 89V027 for the Raider) and a leaking oil-pressure sender on 1984 Monteros (84V098).
  8. Budget for the small stuffBaT sellers regularly list air conditioning that doesn't work, a missing headliner, and replaced fuel pumps, shocks, wheel cylinders and power-steering lines. Most are simple fixes that add up.

The repairs 1st Gen Pajero / Montero owners end up doing

REPAIRSYMPTOMSDIFFICULTYTIMECOST
Inspect the pitman-arm ball joint and steering bootsWander, play at the wheel, or split ball-joint boots. Mitsubishi Japan's notice lists every first-generation code (L041G–L149G). It warns that on old, hard-used trucks with integral ball-nut steering, a corroded pitman-arm ball joint can break and cause loss of steering.2 / 5≈ 1–2 hoursFree to inspect; a pitman arm or ball joints if worn
Timing and balance-shaft chains (2.6 4G54)A chain rattle from the front of the engine, worst at cold start. The 4G54 has Mitsubishi's 'Silent Shaft' twin balance shafts, and aftermarket timing kits for the Montero's 4G54 include two chains, tensioners and guides.4 / 5≈ A weekendA two-chain kit plus gaskets
Fuel pump, filter and the 'won't stay running' fixHard hot starts, stumbling or dying under load. Several Bring a Trailer sellers list a replaced fuel pump and filter in recent work on 2.6 Raiders and Monteros.2 / 5≈ 1–3 hoursA pump, a filter and hose
Set the front ride height at the torsion barsA nose-down stance, or one front corner lower than the other. Like every Pajero up to 1999, the first generation has double-wishbone front suspension on torsion bars.2 / 5≈ 1 hour plus an alignmentFree to adjust
Rear drum brakes and wheel cylindersA spongy pedal, fluid on the inside of the rear tyre, or pulling under braking. US Raiders and Monteros on Bring a Trailer have front discs and rear drums, and one seller replaced the wheel cylinders along with the shocks and idler arm.2 / 5≈ 2–3 hoursWheel cylinders, shoes and hardware
Check the automatic locking hubs and part-time 4WD4WD that won't engage or won't release. US trucks have automatically locking front hubs as standard. Mitsubishi says the first generation's part-time system binds ('tight-corner braking') if you use 4WD on dry pavement.2 / 5≈ 1–2 hours to check; longer to rebuild a hubFree to check
Fix oil leaks: valve covers, intake gasket and oil-pressure senderOil on the exhaust manifolds, a burning smell after a drive, or wet patches under the engine. Bring a Trailer sellers list new valve cover gaskets and an oil-pressure sender on a 1989 Raider V6, and new valve cover and intake gaskets on a 1990 Montero 3.0. A 1988 Montero Sport 2.6 sold with an oil leak noted. Mitsubishi recalled 1984 Monteros (84V098) because the oil-pressure sender could leak oil.2 / 5≈ 2–4 hours for valve covers or a sender; longer for an intake gasket or front sealGaskets and a sender are cheap; labor is the bill
Rust repair: windshield frame, roof and floorsBubbling paint along the windshield surround, roof gutters and hood, and soft spots in the floors and rear arches. Bring a Trailer's 1989 Raider showed corrosion on the hood, windshield surround and roof. Its 1988 Montero Sport had corrosion and failing clearcoat.4 / 5≈ A weekend for surface rust; much longer if panels need cutting outFrom a can of primer to a body-shop bill

Each repair links to a step-by-step guide with tools, part numbers and where to buy the parts.

1st Gen Pajero / Montero recalls and service bulletins

Check any VIN for open recalls at nhtsa.gov/recalls ↗, or see the recall tracker.

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Take the printable 1st Gen Pajero / Montero 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 1st Gen Pajero / Montero guide. Verify torque figures and procedures against the factory service manual (disclaimer).

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