1995 Mitsubishi Montero Problems

What owners report

Owners of this model year most often describe the crankshaft pulley bolt coming loose or breaking, which throws the belts, takes away power steering assist, and can stop the engine; many say their vehicle was excluded from the related recall by VIN or after the recall period ended. A second common theme is oil use and smoke traced to valve guides or a porous head. Smaller groups describe rear axle housing welds cracking and front-end steering that wanders or separates at a tie rod. Reports span a wide mileage range, so many of these are age- and wear-related rather than early failures.

1. 1
   Engine cooling

   Crankshaft pulley bolt breaks or backs out

   Mentioned in 25 of 59 sampled complaints

   Owners describe the bolt holding the crankshaft pulley shearing or loosening while driving, after which the pulley wobbles or falls off and the belts are thrown. The immediate effect reported is loss of power steering assist, dash warning lights, and in some cases the engine shutting down, with drivers saying they had to force the vehicle to the shoulder. Several report a mechanic confirming the broken pulley bolt, and a number state their vehicle was excluded from recall 00V311001 by VIN or that the repair was declined because the recall period had passed. Reported from around 70,000 miles up to roughly 215,000 miles, often at ordinary road and highway speeds.

   Recall 00V311001

   What to check: Ask whether recall 00V311001 was completed and whether the pulley bolt was actually replaced rather than only inspected; listen for belt squeal or a wobbling pulley at idle.

   2 excerpts from owner complaints in NHTSA records

   “The crankshaft pulley bolt has broken 3 times in 2003 while driving. Powersteering is lost and the last time car died while driving.the previos owner fixed it on feb.7, 2003. It broke while my husband was on the freeway may 15th, 2003 and then it broke again sept.4,2003. There is a recall on this bolt for the Montero 3.0 l engine and the galant same year. Why no recall on the Montero 3.5 l? No fatalities this time.”

   NHTSA complaint #10040987, filed 2003-09, 70,000 miles

   “Vehicle experienced a problem with the crankshaft pulley. This problem is the same as the Montero sport which is under re-call. This vehicle does not apply under the re-call because of the VIN# and vehicle identification. Provide further details.”

   NHTSA complaint #10055780, filed 2004-01, 149,000 miles
2. 2
   Engine cooling

   Excessive oil use and smoke from worn valve guides

   • 7 complaints (8%)
   • median 100,000 mi at 8.8 yrs old (3 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 1999–2008

   Complaints describe adding oil far more often than expected, smoke from the tailpipe on first acceleration, and oil use that some owners measured as most of a crankcase between changes. Dealers cited valve guides sitting too low and letting oil onto the valves, valve stem seals, or a porous head casting; one owner reported an external leak traced to a porous head. Owners say they were often told the consumption was normal and were offered no assistance. Appears from roughly 88,000 miles up to about 150,000 miles, during normal driving and on start-up.

   What to check: Check the oil level and watch for blue-grey smoke at start-up or under acceleration; ask how often oil is added between changes and whether the head or valve guides have been serviced.

   2 excerpts from owner complaints in NHTSA records

   “Dt: the caller said smoke came out of tail pipe when vehicle first accelerated. He had to put oil in the vehicle more often than normal. Dealer told him vehicle idled too slowly, and that oil was getting on the valves, causing the smoke. He was told the guides were dropping too low, and that was letting the oil leak onto the valves. Dealer and manufacturer offered no help for free.”

   NHTSA complaint #10137207, filed 2005-09, 88,000 miles

   “Vehicle was at a complete stop, consumer noticed smoke coming from the engine. Consumer checked under the hood and notice a oil leak. Consumer had vehicle serviced by the dealership, who indicated that the porous head caused the engine leak. Please provide more details. Ts”

   NHTSA complaint #10001165, filed 2002-12, 100,000 miles
3. 3
   Suspension

   Rear axle housing weld cracks and leaks

   • 5 complaints (6%)
   • median 154,500 mi at 18.2 yrs old (2 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2001–2019

   Owners report gear oil leaking from the rear axle housing where the tube is welded, with the crack running partway around the housing. In the more advanced cases described, the weld separates, the wheel tilts, and the assembly loses its fluid, damaging bearings and gears; one dealer quoted replacement of the whole axle assembly. Complaints say the problem was found after noticing a strange feel from the rear of the vehicle or oil on the ground. Reported between about 109,000 and 200,000 miles, typically noticed during or after ordinary driving.

   What to check: Look for oil weeping or a seam crack along the rear axle tube welds and check the differential fluid level; ask whether the axle assembly has been replaced or rewelded.

   2 excerpts from owner complaints in NHTSA records

   “Right rear axle housing weld id cracked where it was welded from the factory. It is leaking gear fluid from the crack. It goes about 3/4 the way aound the axle. I was driving and I felt a strange feeling in the rear of the Montero check3d it and fould whwere it is seperatedat the weld, like it was not positioned correctly in the welding jig.”

   NHTSA complaint #11191255, filed 2019-03, 200,000 miles

   “I have a 1995 Montero sr and while I was driving on the highway I smelled oil and when I stopped to check it the rear driver side tire caved in and oil was all over the ground what's left of it any way , the weld on housing the axle assembly was broke any how I tow it home and check it to find out that the teething on the axle inside is gone the fact there is no oil and the seal and the bearing inside the housing is gone , so I called the dealer and told me there is nothing they can do but to change the axle assembly for about little over …”

   NHTSA complaint #10228691, filed 2008-05, 109,000 miles
4. 4
   Steering

   Steering wander and tie rod separation

   • 13 complaints (15%)
   • median 170,735 mi at 10.9 yrs old (2 state mileage, few)
   • 5 mention a crash, fire or injury
   • filed 1996–2007

   Complaints describe the vehicle drifting left and right on the road and needing constant correction, with one owner reporting repeated dealer visits without a fix. Others describe an inner tie rod coming apart, which produced an immediate loss of steering control, and in those cases both tie rods were replaced. One complaint describes the steering wheel locking up before a crash, and another describes steering loss after the pulley failure counted under the pulley bolt issue. Reported from roughly 100,000 to 110,000 miles, during normal driving and low-speed turns.

   What to check: Have the front end checked on a lift for play in the inner and outer tie rods and ask about alignment history; a test drive should track straight without constant correction.

   2 excerpts from owner complaints in NHTSA records

   “My vehicle is wondering on the road so bad that it has became a safety issue for me and my family. I cann't get the dealer to do any thing about it. My vehicle is drifting on the road some time to the right and some time to the left. I have had this problem for the past 15 months. I have taken to the dealer more than 15 times, I have spent my money and time and I'm getting no where. Please help me! I will porvide this vehicle for any kind of testing. I have searched and found out that this porblem has caused accidents in the past with injuries. …”

   NHTSA complaint #701550, filed 1998-12

   “While driving 52 MPH, the driver started to hear drilling sounds/vibration from the front of the vehicle. Then without any warning he couldn't control the vehicle because the steering wheel locked up. Tried to put on brakes, nothing happened. The vehicle began to flip and spin and was involved in a crash. Neither air bags deployed. Six (6) injuries and one (1) fatality.”

   NHTSA complaint #830559, filed 1999-06

Buying note. On a vehicle this old, condition and service history matter more than the badge: confirm the crankshaft pulley bolt and belts have been addressed, check oil consumption and rear axle seepage, and inspect the front end for tie rod play before buying.

Summary written with AI from a sample of 59 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.