BOXY TRUCKS
Common problems · 1991–99

2nd Gen Pajero / Montero problems: 8 things to check

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

Read the full 2nd Gen Pajero / Montero guideYears to avoidBiggest tireSpecs & fluids

2nd Gen Pajero / Montero problems to check before you buy

  1. Ask for the timing-belt receiptOn the V6s and the 4D56 the belt is a scheduled part, and owners say the 3.5 doesn't survive a snapped belt. Australian owners use about 100,000 km. With no proof, price in a belt, tensioner, idlers and water pump. The 4M40 uses a chain.
  2. Look hard at the V6 cooling systemCheck for milky oil, coolant loss and a temperature gauge that wanders. ExplorOz mechanics describe the V6 Pajeros as prone to head gaskets and say the heads crack. A combustion-leak test before purchase costs very little.
  3. Blue smoke on the overrunWorn valve stem seals are a known V6 complaint. One Australian owner says they 'normally need replacing at 200,000 km', and Montana Montero has a video on why Monteros burn oil. Watch the exhaust after a long idle and on the first blip of the throttle.
  4. Exercise the Super Select leverOn loose ground, go through 2H, 4H, 4HLc and 4LLc. The lights should stop flashing once each mode engages. A light that keeps flashing, or a front axle that won't engage, points to the vacuum system. Owners say the system misbehaves on trucks that rarely use 4WD.
  5. Check the steering linkageMitsubishi's pitman-arm notice covers every second-generation code, the Evolution included. Feel for play at the pitman and idler arms and inspect every boot. A cracked boot means the joint needs replacing.
  6. Measure the front ride heightTired torsion bars leave the nose low, and a bull bar makes it worse. Uneven ride height side to side or a nose-down stance means the bars need adjusting or replacing.
  7. Rust in the sills and chassisSteven Taylor's Mk2 Pajero video shows sill replacement and chassis welding on a 2.8. BaT's 1998 Montero needed its underside treated. Probe the sills, the rear chassis rails and the spring mounts.
  8. Run the VIN for recallsUS recalls include the 1998–2000 NADI driver airbag (20V035000), cracking front brake hoses on 1992–94 trucks (96V143), chafing brake lines on 1997–98 trucks (98V220) and a loose crank-pulley bolt on 1992–96 3.0s (00V311001). In Australia, NL airbag trucks are being bought back.

The repairs 2nd Gen Pajero / Montero owners end up doing

REPAIRSYMPTOMSDIFFICULTYTIMECOST
Timing belt, tensioner and water pump (6G72 3.0 / 6G74 3.5)Usually none before it fails. A whirring from the belt area can mean an over-tight belt or a failing idler. Australian owners change it about every 100,000 km and warn that the 3.5 has no valve clearance if the belt breaks, while the 3.0 does. Treat those as owner reports and check your engine.3 / 5≈ A long dayAustralian owners quoted about A$650–1,000 in 2006, the top figure including a water pump
Cure a flashing 4WD light (front axle engagement)The Super Select lights keep flashing after you select 4H, or the front axle never engages. Owners say the system 'sometimes plays up if not used very much'.2 / 5≈ 1–3 hours to diagnose and fixUsually a vacuum solenoid or hose; parts plus your time
Inspect the pitman-arm ball joint (Mitsubishi's procedure)Steering play, a clunk through the wheel, or a split ball-joint boot. Mitsubishi Japan warns that on old, hard-used trucks with integral ball-nut steering, corrosion and wear can break the pitman-arm ball joint and cause loss of steering. Every second-generation chassis code, the V55W Evolution included, is on its list.2 / 5≈ 1–2 hoursFree to inspect; a pitman arm or boots if worn
Reset or upgrade the front torsion barsThe nose sits low. One ExplorOz contributor says many high-mileage Pajeros 'almost look like they're sitting on the front bump stops.' A heavy steel bull bar makes it worse.2 / 5≈ 1 hour to adjust; half a day to replace the barsFree to adjust; uprated bars and rear coils as a kit
V6 head gasket replacement (and do it properly)Coolant loss, milky oil on the dipstick or under the filler cap, overheating. One NJ 3.0 owner on ExplorOz had replaced the head gasket twice in about three years. Mechanics in that thread say the V6s have a weak spot for head gaskets and that the heads 'do crack a fair bit'.4 / 5≈ 2–3 daysParts plus machine-shop crack test and skim
Replace the front brake hosesCracked, chafed or weeping front hoses. NHTSA recall 96V143 says the wheel-side front hoses on 1992–94 Monteros could crack at full steering lock and full suspension travel. Recall 98V220 covers 1997–98 front brake lines chafing through at the inner-fender pass-through.2 / 5≈ 1–2 hoursA pair of hoses and a bottle of DOT 3
Replace the V6 valve stem seals (blue smoke)A puff of blue smoke at start-up or after a long idle, smoke on the overrun, and oil use with no external leaks. Worn valve stem seals are a known V6 complaint. One ExplorOz owner says they 'normally need replacing at 200,000 km', and another warns that when they wear out it means 'a lot of smoke or [an] expensive repair'.4 / 5≈ A weekend with the heads onA seal set is cheap; the labor isn't. Cheapest when the heads are already off
Sill and chassis rust repairBubbling at the sills and rear wheel arches, flaking chassis rails and soft spring mounts. Steven Taylor's Mk2 Pajero video shows sill replacement and chassis welding on a 2.8, and BaT's 1998 Montero needed its underside treated.4 / 5≈ A weekend to several, depending on what you findFrom a can of cavity wax to a fabrication bill

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

Years with known problems

YEARSFLAGWHAT TO KNOW
1998BewareExport and Gulf trucks get the 'blister' wide-fender facelift; airbags standard on 3.5 models in those markets. Beware the NADI driver airbag: 1998–2000 US Monteros are under recall 20V035000 for a new inflator, and in Australia Mitsubishi is buying back NL Pajeros built 31 May 1996 to 30 September 2000 because no replacement exists

Every 2nd Gen Pajero / Montero model year, with the best ones to buy →

2nd Gen Pajero / Montero recalls and service bulletins

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

Going to look at one?

Take the printable 2nd 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 2nd Gen Pajero / Montero guide. Verify torque figures and procedures against the factory service manual (disclaimer).

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