Summary
The Mitsubishi Montero has 15 recalls spanning 1990 to 2004, with the most serious being a driver airbag inflator defect on 1998-2000 models where moisture absorption can cause the inflator to rupture and send metal fragments into the cabin, or leave the airbag underinflated in a crash.
The 2004 model year has a compliance recall involving an incorrect tire and loading information label that could cause owners to overload the vehicle beyond its rated weight capacity. The 2002 model year carries two fuel system and one brake-related recall: when a full tank is parked nose-up on a slope and ambient temperatures rise, fuel can expand past the tank leveling valve, leak onto the ground, and ignite if a heat or spark source is nearby. Separately on 2002 models, a brake booster accumulator can leak pressurized nitrogen over time, which causes an unusual noise from the left side of the dashboard when braking and can reduce initial brake boost assist.
The 2001 model year has a passenger-side exterior mirror that does not meet federal rearview mirror standards, narrowing the driver's side view, and an owner's manual that omits step-by-step instructions for adjusting the headrest when installing a child safety seat tether, which could leave the seat inadequately secured in a crash.
For 1997 models, the front brake lines can develop small holes where they pass through the inner fender, leaking brake fluid and reducing braking performance. The 1994 model year has front lower brake hoses that can crack and lose fluid, impairing braking, and an accessory cargo mat that prevents the folding third-row seats from latching fully, raising the risk of ejection in a crash.
Going back further, 1992 models have two issues: front wheel-side brake hoses that can crack under full steering lock combined with full suspension travel, leaking fluid and reducing braking effectiveness, and a crankshaft pulley bolt that can loosen and let the pulley fall off, cutting power steering assist. The 1990 model year has a front seatbelt buckle whose plastic release button can break and shed pieces into the buckle mechanism, preventing the belt from functioning properly in a crash.
