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2002 Mitsubishi Montero Recalls, Problems & Maintenance

The 2002 Mitsubishi Montero has no open NHTSA recalls. Owners report 8 recurring issue clusters, led by “Premature brake rotor and pad wear.” Mitsubishi publishes short, conservative intervals: oil every 7,500 miles normal / 3,750 severe, and — unlike many rivals — an explicit CVT fluid replacement schedule rather than a 'lifetime fill' claim. Read the severe-service column honestly: stop-and-go city trips, short hops, and hot climates all qualify, and they describe how most Mirages actually live. The 10-year/100,000-mile powertrain warranty stays intact only with documented on-schedule service.

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No open recalls on file. NHTSA lists no unrepaired safety recalls for this year, make and model. A recall can be issued at any time, and a specific car can still have one open — check yours by VIN at nhtsa.gov/recalls.

Known issues & problems for this vehicle

What drivers and federal regulators have officially reported about the 2002 Mitsubishi Montero.

Reported to NHTSA

Premature brake rotor and pad wear

SERVICE BRAKES, HYDRAULIC

6 NHTSA complaints · 2002-08 → 2010-04

“THE BRAKES NEED TO BE REPLACED ON A REGULAR BASIS DUE TO A FAULTY SYSTEM. THE ROTORS WEAR DOWN EVERY TIME AND MUST BE REPLACED. I HAVE BEEN DRIVING AUTOS FOR OVER 50 YEARS AND HAVE NEVER EVER HAD A PROBLEM LIKE THIS”
— Owner report, NHTSA ODI #10313426
“ROTORS AND PADS NEEDED TO BE REPLACED ON ALL 4 MECHANISMS DUE TO EXCESSIVE WEAR AND GRINDING SOUND. VEHICLE HAS BEEN BACK TO DEALERSHIP IN JANUARY, FEBRUARY, AND MAY 2002. PLEASE DESCCRIBE DETAILS. *AK”
— Owner report, NHTSA ODI #8016729
“REAR ROTORS AND BRAKE PADS NEEDED TO BE REPLACED DUE TO PREMATURE WEAR, PER DEALERSHIP.*AK”
— Owner report, NHTSA ODI #10033688

Read all complaints on NHTSA →

Frame and undercarriage rust

STRUCTURE

5 NHTSA complaints · 2013-04 → 2016-02

“FRAME AND UNDERCARRIAGE ROT/RUST. WAS TOLD BY ONE SHOP ABOUT IN 2013 THAT I HAD ALOT OF RUST ON THE FRAME WHEN THEY REPLACED MY RUSTED BRAKE LINES”
— Owner report, NHTSA ODI #10651571
“THE CONTACT STATED THAT DURING A ROUTINE INSPECTION, THE CONTACT WAS ADVISED THAT THE FRAME WAS ROTTING AND THERE WERE TWENTY TWO INCH-LONG FRACTURES FOUND IN THE FRAME. A DEALER WAS NOTIFIED BUT OFFERED NO ASSISTANCE. THE VEHICLE WAS NOT REPAIRED”
— Owner report, NHTSA ODI #10511130
“I TOOK MY TRUCK FOR A FRAME INSPECTION, FRAME WAS REND ENDEARED UNSAFE AND RUSTED ALL THE WAY THROUGH. BODY & ENGINE ARE INTACT. NEW FRAME IS 10,000.00. THE MECHANIC TOLD ME THEIR WERE NUMEROUS COMPLAINTS ABOUT THIS YEARS FRAME. HE SAID THE METAL WAS DIPPED CORRECTLY”
— Owner report, NHTSA ODI #10825482

Read all complaints on NHTSA →

Tire blowout while driving

TIRES

5 NHTSA complaints · 2002-08 → 2003-04

“BRIDGESTONE, DUELER HT-689, P265/70R16, DOT # ELLJJNM3701, ORIGINAL EQUIPMENT ON A 2002, MITSUBISHI, MONTERO WITH 11400 MILES. PASSENGER'S SIDE REAR TIRE BLEWOUT AT 65-70 MPH. *AK *YH”
— Owner report, NHTSA ODI #8015687
“THE DRIVER'S SIDE REAR TIRE DISINTEGRATED, WHICH ALMOST CAUSED THE CONSUMER TO LOSE CONTROL OF THE VEHICLE. *JB”
— Owner report, NHTSA ODI #10015165
“WHILE DRIVING AT 30 MPH AND WITHOUT WARNING FRONT PASSENGER SIDE TIRE BLOWOUT. PLEASE PROVIDE THE SIZE AND DOT#. DEALER NOTIFIED. TX”
— Owner report, NHTSA ODI #10001690

Read all complaints on NHTSA →

Hydraulic brake booster accumulator noise and brake loss

SERVICE BRAKES, HYDRAULIC

60 NHTSA complaints · 2005-02 → 2018-06

“THE HYDRAULIC BRAKE ACCUMULATOR FAILED AT 65,000 MILES. I HEARD A NOISE FROM THE LEFT SIDE OF THE DASH BOARD AND STOPPED AT MY LOCAL MECHANIC. HE DIAGNOSED THE PROBLEM AND TOLD ME I SHOULDN'T DRIVE IT UNTIL IT IS REPAIRED. HE ALSO SAID THERE WAS A RECALL, NHTSA ID 01V254001”
— Owner report, NHTSA ODI #10199672
“WHILE DRIVING 50 MPH, THE VEHICLE MADE A CHIRPING SOUND. THE BRAKES FAILED TO RESPOND AND THE BRAKE PEDAL TRAVELED TO THE FLOORBOARD. THE VEHICLE WAS TOWED TO THE CONTACT'S HOME. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED”
— Owner report, NHTSA ODI #10981628
“THE ACCUMULATOR THAT IS INSTALLED ON THE HYDRAULIC BRAKE BOOSTER IS MAKING AN ABNORMAL NOISE, THAT CAN BE HEARD FROM INSIDE THE TRUCK, AND I KNOW THIS TYPE OF TRUCK HAD A RECALL A FEW YEARS AGO ( NHTSA # 01V254001), SO I TOOK IT TO THE DEALER THIS MORNING, JUST TO BE TOLD THAT”
— Owner report, NHTSA ODI #10160966

Read all complaints on NHTSA →

Horn and alarm sounding without driver input

ELECTRICAL SYSTEM, AIR BAGS

10 NHTSA complaints · 2007-02 → 2024-04

“DURING COLD WEATHER (APPROXIMATELY 20 DEGREES C AND BELOW) THE HORN STARTS BLOWING AND WON'T TURN OFF UNLESS THE BATTERY IS DISCONNECTED OR THE CAR INTERIOR HAS WARMED UP. THE ONLY WAY I HAVE TO PREVENT THE HORN FROM COMING ON IS TO KEEP THE HORN/AIR/BAG ASSEMBLY WARM”
— Owner report, NHTSA ODI #10181825
“AGING OF THE COSMETIC VINYL COVERING ON STEERING WHEEL THAT COVERS AIR BAG MODULE WILL CONTRACT TOO MUCH IN COLD WEATHER, APPROXIMATELY 40 DEGREES F OR LOWER CAUSING CAR HORN TO GO OFF EVEN WITHOUT ENGINE RUNNING”
— Owner report, NHTSA ODI #10653550
“THE HORN SOUNDS FOR NO REASON, WHEN THE TEMPERATURE DROPS BELOW 55DEGREES. I MUST REMOVE THE FUSE TO SILENCE IT. IT IS STATE REQUIRED SAFETY EQUIPMENT. I CONTACTED THE LANCASTER, PA MITSUBISHI DEALER BUT THEY WON'T REPLY”
— Owner report, NHTSA ODI #10421099

Read all complaints on NHTSA →

Air bags not deploying in a crash

AIR BAGS

15 NHTSA complaints · 2002-07 → 2015-11

“I WAS A PASSENGER IN A 2002 MITSUBISHI MONTERO AND WE WERE HIT HEAD ON DOING 40+ ON THE HIGHWAY. NEITHER FRONT AIRBAG DEPLOYED. I FRACTURED MY HUMOROUS REQUIRING SURGERY FOR THE INSTALLATION OF HARDWARE TO MEND THE BONE. *TR”
— Owner report, NHTSA ODI #10239122
“MY FAMILY AND I WERE INVOLVED IN A FOUR-CAR PILE UP. WE REAR-ENDED A 4RUNNER AT 45 MPH AND THE FRONT AIR BAGS NEVER DEPLOYED. HUSBAND HAS SEVERE BACK TROUBLE AND I SUFFER NECK AND SHOULDER PAIN. *NM”
— Owner report, NHTSA ODI #10182309
“WHILE DRIVING 35 MPH, THE CONTACT'S WIFE REAR ENDED ANOTHER VEHICLE. THE FRONT AIR BAGS FAILED TO DEPLOY. THE SEAT BELT DID NOT RETRACT AND SHE LUNGED FORWARD INTO THE STEERING WHEEL. HIS WIFE SUSTAINED MINOR INJURIES TO HER ARM, FACE, AND CHEST”
— Owner report, NHTSA ODI #10202910

Read all complaints on NHTSA →

Crankshaft pulley bolt failure

ENGINE AND ENGINE COOLING

3 NHTSA complaints · 2008-01 → 2021-08

“CRANSKHAFT BOLT SHEARED OFF WHILE DRIVING AT HIGHWAY SPEEDS CAUSING LOSS OF POWER STEERING ON ICY ROADS. THE INCIDENT ALSO CAUSED DAMAGE TO THE CRANKSHAFT SENSOR, HARMONIC BALANCER, AND TIMING BELT”
— Owner report, NHTSA ODI #10214082
“I was driving home from work, and all the sudden i couldn't steer. I had no steering, Lost power to vehicle and battery light came on. Wasnt sure what happened, looked under the hood and noticed belts were off”
— Owner report, NHTSA ODI #11427619
“I WAS DRIVING HOME FROM WORK AND NOTICE MY TRUCK HAD DIED WHILE SLOWING TO MAKE A RIGHT TURN AT A LIGHT..NOTICED THE BRAKE AND BATTERY LIGHT CAME ON...I RESTARTED THE CAR THEN TRIED TO MAKE A QUICK LEFT ON MY STREET AND COULDN'T STEER MY CAR...I HAD TO USE ALL MY STRENGTH TO”
— Owner report, NHTSA ODI #10510149

Read all complaints on NHTSA →

Fuel tank leak

FUEL SYSTEM, GASOLINE

4 NHTSA complaints · 2004-12 → 2010-08

“THE CONTACT NOTICED A FUEL LEAK WHILE SHE WAS ADDING FUEL TO THE VEHICLE. SHE TOOK THE VEHICLE TO A MECHANIC WHO DIAGNOSED THE FAILURE AS THE FUEL STORAGE TANK”
— Owner report, NHTSA ODI #10349049
“I STARTED TO SMELL GAS WHEN NEAR THE MONTERO. I THOUGHT IT WAS ANOTHER RECALL NOTICE ABOUT A VALVE SEALING BUT IT GOT WORSE, AND I STARTED NOTICING A GAS PUDDLE UNDER THE MONTERO”
— Owner report, NHTSA ODI #10253184
“THE CONSUMERS VEHICLE WAS INCLUDED IN RECALL /FUEL LEAKAGE. HOWEVER, THE VEHICLE STARTED TO LEAK GAS ONCE AGAIN. THE CONSUMER TOOK THE VEHICLE IN AGAIN FOR THE SAME RECALL. THE VEHICLE IS IN THE REPAIR SHOP NOW. *JB THE VEHICLE IS STILL LEAKING GAS, WHICH CAUSED IT STALL. *SC”
— Owner report, NHTSA ODI #10105501

Read all complaints on NHTSA →

Issues on other model years

Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 20, 2026. Investigation data refreshed Sep 20, 2026.

We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.

Raw data + downloads for this vehicle →

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter

Every 7,500 mi

Replace every 7,500 miles normal / 3,750 severe. Mirage's 1.2L three-cylinder holds barely over 3 quarts — small sumps punish stretched intervals. 0W-20 on most recent models.

Estimated cost — typical U.S. ranges

Dealer

~$120–$160

Shop

~$85–$115

DIY

~$25–$55

Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.

CVT Fluid

Every 60,000 mi

Mitsubishi schedules CVT fluid replacement — commonly every 60,000 miles normal / 30,000 severe (check your year's table). Use only the specified CVT fluid (J4/CVTF-J4 family); generic ATF destroys the belt-and-pulley unit.

Estimated cost — typical U.S. ranges

Dealer

~$360–$500

Shop

~$255–$355

DIY

~$80–$180

CVT fluid is manufacturer-specific and pricey — do NOT substitute conventional ATF.

Tire Rotation

Every 7,500 mi

Rotate with every oil change. Light Mirages are easy on tires but the economy-focused OEM rubber wears fast when neglected.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Often free at the shop where you bought the tires — worth asking before paying.

Brake Inspection

Every 7,500 mi

Inspect pads, rotors/drums, and lines at each service — Mirage G4 retains rear drums, which need periodic adjustment checks.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.

Brake Fluid

Every 30,000 mi

Replace every 2-3 years per the schedule. Cheap job, big ABS-unit insurance.

Estimated cost — typical U.S. ranges

Dealer

~$180–$200

Shop

~$125–$140

DIY

~$10–$25

DOT 3 or 4 — match the cap. Vacuum bleeders make this a one-person DIY.

Important maintenance

Keeps your vehicle running smoothly and efficiently

Spark Plugs

Every 60,000 mi

Iridium plugs commonly every 60,000 miles on the Mirage's 3A92 and Lancer's 4B11 — verify your year's table, as some engines list up to 105,000.

Estimated cost — typical U.S. ranges

Dealer

~$285–$390

Shop

~$200–$275

DIY

~$25–$100

Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.

Engine Air Filter

Every 15,000 mi

Mitsubishi's schedule replaces the engine air filter every 15,000 miles — shorter than most brands, and a 5-minute DIY on the Mirage.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

5-minute job on most cars; the airbox lid usually has clips, no tools needed.

Drive Belt

Every 60,000 mi

Inspect from 60,000 miles and replace on cracking. The Mirage's single serpentine belt also drives the A/C — a failure strands the car's accessories at once.

Estimated cost — typical U.S. ranges

Dealer

~$195–$235

Shop

~$135–$165

DIY

~$20–$50

DIY-friendly if you can reach the tensioner. Inspect for cracks rather than swap on a strict mileage interval.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Cabin Air Filter

Every 15,000 mi

Replace every 15,000 miles, behind the glovebox. Often skipped at quick-lube visits — worth checking if airflow feels weak.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.

Coolant Replacement

Every 60,000 mi

First change around 60,000 miles, then roughly every 30,000-45,000 per the schedule. Mitsubishi long-life coolant or equivalent OAT for your year.

Estimated cost — typical U.S. ranges

Dealer

~$285–$330

Shop

~$200–$235

DIY

~$25–$60

Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.

Battery Test & Service

Every 25,000 mi

Test annually after year 3. Small-battery economy cars have little reserve — the first cold snap finds a weak one.

Estimated cost — typical U.S. ranges

Dealer

~$225–$390

Shop

~$160–$280

DIY

~$130–$250

Most auto-parts stores test and install batteries free with purchase. Skip the dealer markup.

Fatal crash history & reported problems

Occupant deaths in fatal crashes (FARS)

161 crashes 1990–2024

How the 161 occupant deaths break down

96

driver deaths

65

passenger deaths

161

occupant deaths

Crash years covered: 1990–2024 This model year first appears in 2001 crashes. Older models have had more years on the road to appear in these crashes, so a higher count here does not by itself mean a vehicle is less safe.

FARS counts every occupant death in a fatal crash, whatever the cause — it does not mean the vehicle was at fault or defective. Counts are not adjusted for how many of each vehicle are on the road. How to read this number

FARS 2024 data is an annual report file. NHTSA revises these records when the final file is published, so this count can change.

Why we show driver deaths too

Every vehicle has exactly one driver seat, so driver deaths line up fairly when you compare one model to another. Occupant deaths include passengers, so a three row SUV can show a higher number than a two seat car simply because it carries more people.

Both figures are plain counts, not rates. A rate would need to know how many of each vehicle are on the road, and that registration data is not public, so we do not publish rates or scores of any kind.

IIHS publishes driver death rates using this same driver only idea, paired with a registered vehicle years denominator we do not have. Their rates and these counts answer different questions, so do not read either number here as a safety rating.

Owner-reported problem signals

Separate from the federal fatality data above: complaints owners filed with NHTSA about this year and model. These are reports of problems, unverified, and are counted here only as signals.

24

complaints mentioning a crash

1

complaints mentioning a fire

Reviewed known issues for this vehicle

Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.

How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.

This maintenance schedule for the 2002 Mitsubishi Montero reflects Mitsubishi's published service intervals. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.

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