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Mitsubishi Pajero Problems & Known Issues

The most common Mitsubishi Pajero problems ranked by severity — what to watch for, what it costs to fix, and what happens if you ignore it.

Generations

Gen2 — Second Generation
1991–1999
2.5 TD, 2.5 TD, 2.8 TD, 2.8 TDi
Gen3 — Third Generation
2000–2006
2.5 TDi, 2.5 TDi, 2.8 TDi, 2.8 TDi, 2.8 TDi

Top issues to watch for

The most serious Mitsubishi Pajero problems ranked by severity. We track 5 known issues — here are the ones you need to know about first.

Dangerous
Chassis and subframe structural corrosion
Gen2, Gen31991–200680k–200k miles
The Pajero's ladder-frame chassis and mounting points for suspension and subframe components are highly susceptible to corrosion, particularly around the rear spring hangers, shock absorber mounts, and chassis rails. The combination of exposed chassis construction and inadequate factory protection leads to severe weakening of load-bearing areas. This affects the vehicle's fundamental structural integrity and is a major safety concern.
What happens if ignoredStructural failure can occur without warning, potentially causing loss of control or component detachment while driving. Repair requires extensive welding work often exceeding the vehicle's value. Many examples become economically unrepairable once corrosion reaches advanced stages.
Independent garage
£1,500–£5,000
Specialist
£2,000–£6,000
Parts only
£300–£800
Dangerous
Steering system excessive wear and play
Gen2, Gen31991–2006120k–200k miles
The steering rack and associated linkages on the Pajero suffer from premature wear, creating excessive free play at the steering wheel. MOT data shows steering play failures at 86.5 times the fleet average, with ball joint wear at 34.2 times average. The combination of heavy vehicle weight, off-road use history, and inadequate sealing of steering components leads to accelerated deterioration. This represents a serious safety hazard as steering response becomes unpredictable.
What happens if ignoredComplete loss of steering control can occur without warning. Vehicle may become impossible to control in emergency situations. Complete steering rack replacement typically required rather than component repair.
Independent garage
£400–£800
Specialist
£600–£1,200
Parts only
£200–£500
Major
Wheel bearing failure
Gen2, Gen31991–2006100k–200k miles
Wheel bearings on the Pajero fail at 14 times the fleet average according to MOT data, with 1,685 recorded failures. The heavy vehicle weight combined with off-road use puts excessive stress on the bearing assemblies. Poor sealing allows contamination to enter the bearings, accelerating wear. Both front and rear bearings are affected, with failure typically occurring between 100,000-150,000 miles.
What happens if ignoredComplete bearing failure can cause wheel detachment and loss of vehicle control. Continued driving on worn bearings will damage the hub assembly and brake components, significantly increasing repair costs.
Independent garage
£200–£400
Specialist
£250–£500
Parts only
£80–£200
Major
Brake line corrosion and failure
Gen2, Gen31991–200680k–200k miles
Brake pipes and flexible hoses corrode at 5.4 times the fleet average on the Pajero, with 5,014 MOT failures recorded. The exposed brake line routing and inadequate protection from road salt and debris leads to perforation of steel brake pipes. Flexible brake hoses also deteriorate due to age and exposure. This creates a direct safety hazard through potential brake system failure.
What happens if ignoredComplete brake failure can occur without warning if brake lines rupture. Even minor leaks reduce braking efficiency and can lead to brake fade. Repair involves replacement of corroded sections and full system bleeding.
Independent garage
£150–£400
Specialist
£200–£500
Parts only
£50–£150

1 more known issues tracked

Including wear items, electrical niggles, and generation-specific problems.

MOT failure hotspots

Based on DVSA MOT test data. These are the items where the Mitsubishi Pajero fails at a significantly higher rate than the average car.

Free play in the steering, measured at the rim ...
Steering · 120-150k miles
MOT failure rate: 77x the fleet average
Sample: 1,344 tests
Track rod ends worn
Steering · 100-120k miles
MOT failure rate: 59x the fleet average
Sample: 163 tests
Fixings missing or insecure
Bodywork · 150k+ miles
MOT failure rate: 29x the fleet average
Sample: 904 tests
Structural corrosion
Bodywork · 80-100k miles
MOT failure rate: 27x the fleet average
Sample: 173 tests
Obligatory rear fog lamp missing, or a front or...
Lights & Electrics · 150k+ miles
MOT failure rate: 27x the fleet average
Sample: 1,246 tests
ABS fault
Bodywork · 120-150k miles
MOT failure rate: 26x the fleet average
Sample: 274 tests

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Related

Mitsubishi Pajero reliability FAQs

What are the most common problems with the Mitsubishi Pajero?

The Mitsubishi Pajero has 5 known issues across 3 severity levels. The most serious are: Chassis and subframe structural corrosion, Steering system excessive wear and play.

Is the Mitsubishi Pajero reliable?

The Mitsubishi Pajero has 2 dangerous and 2 major known issues. Most can be avoided with a thorough pre-purchase check and full service history.

How much does it cost to fix Mitsubishi Pajero problems?

Repair costs range widely. The most significant issue (Chassis and subframe structural corrosion) costs £1,500–£5,000 at an independent garage. Minor issues can be under £200. Always get a full inspection before buying.

Which Mitsubishi Pajero generation is most reliable?

The Gen2 (1991–1999) has the fewest dangerous issues (2). However, condition and service history matter more than generation — a well-maintained earlier car can be more reliable than a neglected newer one.