Symptoms
Bubbling 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.
The fix, step by step
- Get the truck on stands, wash the underside and scrape off loose underseal.
- Probe the sills, the rear chassis rails and the spring mounts with a pick or screwdriver.
- Surface rust can be ground or blasted back, treated, primed and painted.
- Holed sills have to be cut out and replaced with new sections: weld-through primer on the joint faces, short stitch welds, then seam sealer and paint.
- Rotten chassis or spring-mount metal is structural and is a job for a fabricator.
- Finish by spraying a cavity coating inside the sills and rails.
Tools & part numbers
- Jack stands
- pick or screwdriver
- angle grinder
- MIG welder
- panel clamps
- seam sealer
- cavity-spray wand.
Where to buy the parts
Weld-through primerEastwood ↗Amazon ↗
Internal frame and cavity coatingEastwood ↗Amazon ↗
Body parts and seals, 1995 Montero 3.0RockAuto ↗Amazon ↗
Hunting a used or discontinued part? Search eBay Motors for Mitsubishi Pajero / Montero (Second Generation) parts →
Rated for a competent home mechanic with a decent tool kit. Confirm torque figures, fluids and procedures against the factory service manual for your VIN, support the truck on stands rather than a jack, and work at your own risk (disclaimer). Some parts links are affiliate links, which pay us a small commission at no cost to you.