1997 Mitsubishi Montero Problems

What owners report

Owners of this model year most often describe two kinds of trouble: an accessory drive pulley and crankshaft bolt that comes loose and shears off, taking power steering and charging with it, and brake problems ranging from pulsating rotors and sticking calipers to chafed front brake lines. Many reports come from vehicles with well over 100,000 miles, and several owners describe the pulley failure as sudden, with no warning, mid-drive or right after starting the engine.

1. 1
   Engine cooling

   Crankshaft pulley bolt shears, losing power steering

   • 9 complaints (14%)
   • median 156,000 mi at 11.5 yrs old (5 state mileage, few)
   • filed 2002–2011

   Owners describe the crankshaft pulley bolt coming loose or shearing off, sometimes repeatedly after repairs. When it lets go, the accessory belt stops driving the power steering pump and alternator, so steering effort increases sharply, dash lights come on and the battery stops charging; several complaints note a loud clanking from the front beforehand or none at all. Repair estimates in the complaints run from a pulley and bolt replacement to a replacement harmonic balancer and, in one case, the engine. Some owners say the dealer declined coverage because the vehicle was not included in a related campaign. Reported from about 60,000 to 270,000 miles, increasingly in the higher-mileage reports and often during normal low-speed city driving or right after startup.

   What to check: Inspect the crank pulley and bolt area for looseness, wobble or fresh wrench marks, and ask for service records showing whether the bolt was replaced and re-torqued. Start the engine and watch the belt run true with the A/C and lights on.

   2 excerpts from owner complaints in NHTSA records

   “1997 Mitsubishi Montero crankshaft pulley came loose three times which created no power steering and no charging of the battery purchased new crankshaft pulley but did not help the third time installed a lock washer on the bolt and re torqued to spec last week.”

   NHTSA complaint #10320369, filed 2010-03, 156,000 miles

   “1997 mitsubish Montero 3.5 liter automatic- crank shaft bolt has come out on 5 separate occasions and has cost over $3000 to have it replaced. The inside of the crankshaft where the bolt goes is completely stripped to the point I now have to replace the engine. This is not an isolated issue as this appears to be an inherent problem with all years of monteros. There should be a recall for this and Mitsubishi should cover the cost for there negligence.”

   NHTSA complaint #10396534, filed 2011-04, 270,000 miles
2. 2
   Brakes

   Pulsating or fading brakes, warped rotors, leaking lines

   • 11 complaints (17%)
   • median 110,500 mi at 8.0 yrs old (1 states mileage, few)
   • filed 1998–2004

   Complaints describe brake pedal pulsation at speed that returns after rotor resurfacing or replacement, and pedal fade or a pedal that sinks toward the floor. Owners also report brake fluid leaks from front lines routed near the A/C lines, and ABS activation on wet pavement that they say locked the wheels or made the vehicle skid. Dealers in the complaints resurfaced or replaced rotors, replaced the master cylinder, or could not explain why the rotors kept warping. Reported across a wide mileage range, with several owners noting front rotor work within the first 10,000 miles and repeat visits every few thousand miles afterward.

   Recall 98V220000

   What to check: A recall addressed front brake lines chafing through the inner fender opening; confirm by VIN whether that work was done and look for hand-bent or scuffed lines near the A/C lines. Drive at highway speed and brake firmly from higher speed to feel for pulsation.

   2 excerpts from owner complaints in NHTSA records

   “I've had same problems with my brakes twice now. My brakes pulsate at higher speeds. I've had my rotors resurfaced twice.(1) at 34,000 miles & (2) at 58840. The warranty the dealer ship gives me is 3 month or 3000 miles for pulsating, even if I were to buy new rotors. I' ve had to recently replace my right back shoe because it was rubbuing metal on metal but my left side was perfectly fine. They could'nt give me an explanation why. I'm tired of paying $ 500 for the same problem year after year. …”

   NHTSA complaint #714359, filed 1999-11

   “1. Brake light came on and has stayed on for a couple of days. Car was checked out and estimated charges for repairs to front brake, including new rotor, would be $1000. I was not aware of the recall for 1997 monteros in regard to brake lines. 2. Service engine soon comes on at random and only goes off when the battery is unhooked and rehooked or replaced.”

   NHTSA complaint #10090429, filed 2004-09, 110,500 miles
3. 3
   Electrical system

   Electrical faults: no-start, alarm and window glitches

   • 8 complaints (13%)
   • median 103,250 mi at 7.6 yrs old (4 state mileage, few)
   • 3 mention a crash, fire or injury
   • filed 1997–2014

   Owners report intermittent no-start conditions traced to blown main fuses, battery drain, or an alarm that sounds on its own and door locks that cycle repeatedly. Others describe windows that tilt and leave a gap, warning lights that stay on at random, and a computer replacement that did not resolve a power-loss and no-start complaint. One owner reported chafed vanity mirror wiring that sparked and smoked at the sun visor. Reported from about 75,000 to 172,000 miles, often described as intermittent and worsening over time.

   What to check: Check that every warning lamp behaves correctly at key-on, test the windows, locks and alarm several times, and look for spliced or chafed wiring at the sun visor and under the dash. Ask whether the vehicle has sat with a battery drain.

   2 excerpts from owner complaints in NHTSA records

   “In early 2003 I purchased a 1997 Mitsubishi Montero full SUV. In april 2003 my girl friend was driving the car one day , when it just broke down on her .hen she turned the key to start the car you could hear the engine, but the car would not start.I got it towed,and my mechanic looked at it and said one of the main fuse (mfi-multi fuel injection) had blown. He replaced the fuse and the car was fine, two weeks later it happened again , so he replaced the fuse and I took it to the dealer. …”

   NHTSA complaint #10080813, filed 2004-07

   “1 - this just started happening, no accident or misuse. 2 - vehicle will not start at times and must keep turning ignition, eventually it stats. (changed battery, terminals, wires, etc, with no affect) alarm goes off sporadically or sets on it's own. Door locks unlock, then immediately lock back. Windows are not going up correctly and are tilting slightly causing a small air leak on both front windows. All problems are annoying but I can still get from point a to point b. This happens every day.”

   NHTSA complaint #10081177, filed 2004-07, 75,000 miles

Buying note. On a vehicle of this age, service history matters more than the report itself: ask specifically about the crank pulley bolt and front brake line work, since both are recurring themes in owner complaints. A pre-purchase inspection by a mechanic familiar with these trucks, plus a highway test drive for brake pulsation and steering shake, will tell you more than a walk-around.

Summary written with AI from a sample of 48 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.