The safest way to drive the Khandala Ghat is to let the engine and gearbox do the braking on the descent, keep a generous gap to the vehicle ahead, and treat the climb as hard work for the cooling system. Use the same gear going down that you would use going up, avoid resting your foot on the brake pedal, and stop at the first safe spot if you smell something hot or see the temperature gauge rising. Most hill-road breakdowns trace back to two things: brakes that have been overheated by constant light pressure, and engines that have been run too hot in slow traffic.
The road you are dealing with
The Bhor Ghat, widely called the Khandala Ghat by drivers heading towards Mumbai, is a roughly 10 km section of the Mumbai–Pune Expressway between Lonavala and Khalapur. The older national highway (NH 48) climbs the same escarpment and merges with the expressway near Khandala. The descent toward Khalapur is steep enough that speed limits have been set specially for it. As reported in 2025, cars were limited to 60 km/h on the ghat stretch and heavy vehicles to 40 km/h on the downhill, with the heavy-vehicle limit under review. Cameras enforce these figures, and a first speeding offence was reported to carry a fine of ₹2,000. Check the signs on the day, since limits can change.
In a car, 60 km/h is not a target to hit. On a wet evening with trucks in the left lane, the right speed is simply the one at which you can stop comfortably in the distance you can see.
Going down: protecting the brakes
Brake pads and discs convert movement into heat. Held lightly for a long time, they get hot enough to lose grip, a problem usually called brake fade. In older cars with damp or old brake fluid, the fluid itself can heat up and give a soft, sinking pedal. Several habits help.
- Select a low gear before the descent starts. In a manual car, second or third gear is typical for a steep section; check your handbook. In an automatic, use the manual mode, the L, 2 or 3 position, or paddle shifters if the car has them.
- Brake firmly and briefly, then release, instead of dragging the pedal for a kilometre.
- Never coast in neutral or with the engine off. Without the engine you lose engine braking, and the power steering and brake booster assistance drop away.
- Leave space. Trucks come downhill slowly, and a sudden stop by one in front of you leaves very little time.
Warning signs of overheated brakes include a sharp burning smell, a pedal that feels spongy or travels further than usual, and braking that seems weaker than normal. If it happens, drop to a lower gear, ease off the pedal in short pumps, and stop as soon as it is safe. Let the brakes cool for a long while before continuing, and have them checked afterwards. Brake fluid absorbs moisture over time, and most manufacturers recommend replacing it every two to three years, so look at your own service schedule.
Going up: protecting the engine
The climb is where cooling systems are tested. Engine speed, load, air-conditioning and outside temperature all rise together, and in a queue there is little airflow through the radiator.
- Watch the temperature gauge. A needle that moves beyond its usual mid-point deserves attention.
- Switch the air conditioning off for the steepest section if the gauge rises, and turn the cabin heater to maximum, which draws heat out of the engine.
- In a manual car in a jam, avoid slipping the clutch for long periods. A burning smell from the clutch is a sign to stop and rest.
- If the temperature warning appears, stop at the first safe point, switch off, and wait. The radiator cap should not be opened while the engine is hot because the coolant is under pressure. Let it cool for at least half an hour, and then check the reservoir level.
Topping up with coolant or clean water to reach a garage is a short-term fix. A car that overheats once on a climb usually has a reason: low coolant, a weak radiator fan, a worn thermostat, a blocked radiator or a failing water pump. If it recurs, the cause needs to be found. The pre-trip checks in the weekend drive checklist include the coolant and oil levels that prevent many of these cases.
Symptom table
| What you notice | Likely cause | Immediate response |
|---|---|---|
| Sweet smell, steam from bonnet | Coolant loss or overheating | Stop, switch off, do not open the bonnet or cap until cooled |
| Burning smell, pedal feels soft | Brakes overheated | Lower gear, short firm braking, stop at a safe spot |
| Acrid, rubbery smell on climb | Slipping clutch | Stop and let it cool; avoid holding on the clutch in queues |
| Power loss on the climb | Fuel, air or turbo problem; heat soak | Pull over safely and call for help if it does not recover |
| Steering heavy after engine stalls | Power assistance lost | Brake steadily, steer firmly to the side, hazards on |
Rain, mist and visibility
Low cloud often sits over the ghat in the wet season, and visibility can drop quickly. Use dipped headlights and fog lamps only where visibility is truly poor. Brake earlier than you would on dry road, and keep wipers and washer fluid in good condition. In heavy rain, the ghat has seen landslides: in early July 2026, Lonavala recorded roughly 670 mm of rain in 24 hours, and slips were reported in the Bhor Ghat section along with disruption to the expressway. Pay attention to official weather warnings and traffic advisories before leaving. The monsoon car care checklist covers wipers, tyres and brakes in more detail.
If it goes wrong on the ghat
The same rules apply as on any part of the expressway: get to the left, hazards on, people behind the barrier, then call. The expressway breakdown guide sets out the sequence and the numbers. A tow from this stretch is rarely short, and it is worth reading the towing guide in advance so you know what to ask.
Frequently Asked Questions
What is the speed limit on the Khandala Ghat?
As reported in 2025, cars were limited to 60 km/h on the ghat section of the expressway and heavy vehicles to 40 km/h on the downhill, with a revision for heavy vehicles under consideration. Always follow the signs.
Which gear should I use going down?
A low gear that holds the car at a steady, controlled speed without constant braking. In many manual cars this is second or third, and in automatics a manual mode or L, 2 or 3 position. Check your handbook.
Is it safe to turn off the air conditioning on a climb?
Yes. It reduces load on the engine and cooling system, and it is a sensible step if the temperature gauge is rising. Running the cabin heater at full also helps draw heat away.
What does brake fade feel like?
The pedal feels soft or goes lower than usual, braking feels weak, and there may be a hot, acrid smell. Drop to a lower gear, brake in short firm applications, and stop at a safe place to let the brakes cool.
Can I add water to an overheated engine?
Only after the engine has cooled and the cap can be opened safely. Pouring cold water onto a hot engine or opening the cap early can cause injury or damage. Coolant is better than plain water as a long-term fill.