Common problems · 1999–2006
3rd Gen Pajero / Montero problems: 8 things to check
The problems owners and specialists flag most on the Mitsubishi Pajero / Montero (Third Generation), the repairs they end up doing and what those cost, plus the years and recalls to watch. Sourced, not scraped.
3rd Gen Pajero / Montero problems to check before you buy
- Ask for the timing-belt receiptBoth US V6s use belts, and owners on Expedition Portal call them interference engines. One owner quotes the manual at 105,000 miles for 2001–2006 Monteros. If there's no proof, budget for a belt, tensioner, pulley, water pump and seals; owners quoted $700 at an independent shop to about $1,400 at a dealer.
- Test the brakes cold, and listen for the boosterThird-gen trucks use a hydraulic brake booster (HBB) with an accumulator. Recalls covered the accumulator in the US (01V254001), Australia and Hong Kong. Listen for an ABS-pump noise or tone, and check for a hard pedal on the first stop after the truck has been parked. One 2002 owner paid about $2,000 to replace the whole HBB system.
- Look under it for oil and ATF cooler leaksOwners on Expedition Portal chase leaks from the engine-oil and transmission-cooler hoses where they run along the frame and join the oil pan and cooler. Bring a Trailer's 2001 Limited had its oil-cooler lines replaced before sale.
- Cycle the Super Select leverGo through 2H, 4H, 4HLc and 4LLc on loose ground. CarsGuide's expert says a flashing 4WD light on these trucks usually points to the front-diff actuation system: solenoids, vacuum lines, actuator or diff sensor. BaT's 2001 Limited needed new transfer-case switches.
- Feel for driveline clunkAustralian NM owners report a clunk when going from off-throttle to on-throttle. One dealer replaced the diff centre and drive rods, which only helped a little. Owners say it didn't get worse with mileage, but factor it into the price.
- Check rear ride heightSeveral NM/NP owners on ProductReview say the rear sags with age, and an ExplorOz owner scraped the side steps and towbar until he fitted a 40 mm ARB kit. Look for a nose-up stance and worn rear bushings.
- Identify the engine, and don't expect a ladder frameJDMBUYSELL warns buyers that there's no separate chassis, that the 4M41 uses a chain while the V6s use belts, and not to accept a common-rail claim on a 1999 diesel without proof. Check the chassis code on the plate.
- Run the VIN for recallsUS recalls include the brake-booster accumulator (01V254001, 2001–02), a fuel-tank leveling valve that can leak (04V319000, 2002–04), and label campaigns. In Australia, REC-003136 covers 13,488 NM/NP trucks for the same accumulator.
The repairs 3rd Gen Pajero / Montero owners end up doing
| REPAIR | SYMPTOMS | DIFFICULTY | TIME | COST |
|---|---|---|---|---|
| Timing belt, tensioner and water pump (6G74 3.5 / 6G75 3.8) | Usually none before it fails. Owners on Expedition Portal call both US V6s interference engines and quote the manual's 105,000-mile interval for 2001–2006 Monteros. On a 2001 NM, an Australian owner's tensioner disintegrated at about 110,000 km. | 3 / 5 | ≈ 10+ hours for a first-timer | Owners quoted about $700 (independent) to $1,400 (dealer) for the full job |
| Diagnose the hydraulic brake booster (HBB) and accumulator | A hard pedal or slow brake assist on the first stop after the truck has been parked, an ABS-pump noise, or a warning lamp or buzzer. The US, Australian and Hong Kong recalls say a faulty accumulator can leak its nitrogen charge. A 2002 Limited owner on Expedition Portal had intermittent ABS tones, then a total loss of boost and a seized pump motor that drained the battery. | 3 / 5 | ≈ 1 hour to check the recall; half a day to replace parts | Recall work is free; one owner paid about $2,000 for a complete HBB system |
| Replace leaking oil and ATF cooler hoses | Oil or ATF drips under the engine, wet hoses along the frame, a low transmission level. Owners trace leaks to the joints at the oil pan and the oil cooler, and one found a line that had chafed on the frame. | 2 / 5 | ≈ 2–4 hours | OEM hoses, copper washers and fluid |
| Cure a flashing 4WD light (Super Select II) | The 4WD indicator keeps flashing after you shift, or the front axle won't engage. | 2 / 5 | ≈ 1–3 hours to diagnose | Usually a solenoid, hose, switch or sensor |
| Chase the on/off-throttle driveline clunk | A heavy clunk from the driveline when you go from off-throttle to on-throttle. NM owners on ExplorOz report it from about 50,000–60,000 km, and say Mitsubishi called it a known issue with no fix at the time. | 2 / 5 | ≈ 2 hours to inspect | From a grease gun to diff mounts and bushings |
| Refresh tired rear springs, shocks and bushings | A sagging rear, scraping side steps or towbar, and a floaty or clunky rear end. Several NM/NP owners say the rear sags with age, and one ExplorOz owner fixed scraping with a 40 mm ARB lift. | 3 / 5 | ≈ half a day | Springs, shocks and bushings, plus an alignment |
| Replace the starter motor | Clicking or slow cranking with a good battery. Starters are the most common complaint in ProductReview's NM/NP owner reviews; one owner says they 'started to go like hot cakes'. | 2 / 5 | ≈ 1–2 hours | A starter and an hour or two |
Each repair links to a step-by-step guide with tools, part numbers and where to buy the parts.
Years with known problems
| YEARS | FLAG | WHAT TO KNOW |
|---|---|---|
| 2001 | Recall | First US model year: Montero XLS and Limited, LWB only, 3.5 V6 (200 hp). Consumer Reports rates the Limited 'Not Acceptable' in June. US recall 01V254001 for the brake-booster accumulator (2001–02). Kleinschmidt wins the Dakar |
| 2002–2004 | Recall | US recall 04V319000: fuel-tank leveling valve can leak when parked nose-up with a full tank |
Every 3rd Gen Pajero / Montero model year, with the best ones to buy →
3rd Gen Pajero / Montero recalls and service bulletins
- Hydraulic brake booster accumulator can leak ↗ 2001–2002 · NHTSA 01V254001An improperly made accumulator can lose its nitrogen charge, causing a noise from the dash and delayed brake assist after the truck has been parked. Dealers fitted an improved accumulator. Australia's REC-003136 covers 13,488 NM/NP Pajeros for the same part.
- Fuel tank leveling valve may leak ↗ 2002–2004 · NHTSA 04V319000With a full tank, parked nose-up on a slope, expanding fuel can get past the leveling valve and leak onto the ground. Dealers replace the valve.
- Tire and loading label capacity weights wrong ↗ 2004 · NHTSA 04V095000The label's capacity figures were wrong and could lead owners to exceed GVWR; replacement labels were mailed.
- Bilingual airbag warning labels too small ↗ 2001–2004 · NHTSA 04V428000Removable English/Spanish airbag labels on the dash and visor didn't meet FMVSS 208 size rules.
- Owner's manual missing tether-strap headrest instructions ↗ 2001 · NHTSA 04V067000The manual didn't explain headrest adjustment when fitting a child-seat tether, as FMVSS 225 requires.
- Passenger-side exterior mirror non-compliant ↗ 2001 · NHTSA 00V123002Some passenger mirrors didn't meet FMVSS 111; dealers replace the mirror.
- Hydraulic brake booster: spilled fluid can damage the pump motor ↗ · Mitsubishi HBB notice (reported by JDMBUYSELL; six chassis codes)Spilled brake fluid entering the pump motor caused malfunction and weak assist. Wipe up spills, never wash them away with water, and have a warning lamp, buzzer or poor braking checked with Mitsubishi's tester.
Check any VIN for open recalls at nhtsa.gov/recalls ↗, or see the recall tracker.
Owner questions about 3rd Gen Pajero / Montero reliability
Is it the Montero that failed Consumer Reports' rollover test?
Yes. In 2001 CR rated the Montero Limited 'Not Acceptable' after its test truck tipped up on two wheels in eight of nine runs at 36.7 mph or faster in a short-course avoidance manoeuvre. Mitsubishi disputed the method and quoted NHTSA's view that CR's test had no scientific basis, and Mitsubishi quoted a static stability factor equal to a three-star NHTSA rating.
SOURCE · ROCKCRAWLER · DESIGN NEWSTake the printable 3rd 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 3rd Gen Pajero / Montero guide. Verify torque figures and procedures against the factory service manual (disclaimer).