If your car develops a fault on the Mumbai–Pune Expressway, keep it rolling to the far left shoulder while you still can, switch on the hazard lights, get everyone out on the left side and behind the guardrail, and call 112 or the control-room number printed on the expressway signboards. Do not stand between the car and traffic, do not try to repair anything in a live lane, and do not accept help from strangers who stop beside you. The road is built for sustained speed, and the real danger after a breakdown is not the car but the traffic arriving behind it.
What makes this road different from an ordinary highway
The Yashwantrao Chavan Mumbai–Pune Expressway is run by the Maharashtra State Road Development Corporation (MSRDC). It runs for roughly 94 km with three lanes in each direction, and it has been fully open since 2002. Pedestrians, bicycles, two-wheelers, three-wheelers, tractors and bullock carts are not permitted. MSRDC states that stopping vehicles on the expressway is not permitted, which is why a driver who is in trouble must treat the shoulder as a last resort and not as a convenient parking place.
Speed limits on the road have been reported as 100 km/h for cars and 80 km/h for heavier vehicles on the flat sections, with a lower limit of 60 km/h for cars through the ghat stretch between Lonavala and Khalapur. These figures have changed over time, so read the signs. Cameras and toll-plaza timing are used to enforce them, and speeding on the ghat section in particular has generated a steady stream of e-challans.
The first sixty seconds
- Notice early. A warning light, a pull to one side, a vibration or a sudden loss of power rarely requires an instant stop. Ease off, signal left and work your way across lanes. A car that rolls to the shoulder is far safer than one that dies in the middle lane.
- Hazard lights on. Turn them on as soon as you decide to leave the lane, not after you stop.
- Get as far left as you can. Aim to stop with the whole car beyond the white edge line. Turn the front wheels towards the left so the car rolls away from the carriageway if it is hit.
- Handbrake on, engine off, unless smoke or a burning smell suggests the engine itself is the problem, in which case switch off and leave the car at once.
Getting people out safely
Everyone should leave through the left-side doors, take phones, and move well behind the guardrail or up the embankment, away from the road. Children and pets go first. Keep the group together and facing the traffic rather than turned away from it. One person should stay near the car only if there is a safe barrier to stand behind. If you carry a reflective warning triangle, place it well behind the car only if you can do so without walking along the live carriageway, and never on a bend where you would need to step into traffic.
At night or in rain, wear something reflective or hold up a phone torch so approaching drivers see people, not only a dark car. In heavy rain or fog it is usually better to stay behind the barrier and keep clear of the shoulder altogether.
Who to call
| Situation | First call | Notes |
|---|---|---|
| Injury, fire or serious danger | 112 (national emergency number) | Say you are on the Mumbai–Pune Expressway and give the direction and the nearest km marker or exit |
| Ambulance only | 108 (Maharashtra's emergency ambulance number) | Also reachable through 112 |
| Breakdown with no injuries | The control-room number on expressway signboards, or your insurer's assistance line | Save these before the trip, as signal can be patchy in the hills |
| National highway stretches such as the old road through Khandala | NHAI's 1033 helpline | Meant for national highways; the expressway is a state road run by MSRDC |
Share your location by WhatsApp or a map link as well as describing it, since the same view of fields or hillside can describe fifty kilometres of road. Exits on the route include Kon, Chowk, Khalapur, Kusgaon and Talegaon, and the km markers by the roadside help a dispatcher find you.
Common faults and what they mean on this road
| Problem | What to do |
|---|---|
| Flat or burst tyre | Hold the wheel firmly, ease off the accelerator, brake gently, and steer onto the shoulder. Changing a wheel next to fast traffic is risky; see the flat tyre guide before deciding to do it yourself. |
| Temperature gauge climbing | Switch off the air conditioning, turn the cabin heater on full to shed heat, and stop at the first safe point. Do not open the radiator cap while hot. |
| Fuel exhausted | Stay out of the car, call for help, and do not walk along the road to find fuel. Diesel cars may need bleeding afterwards. |
| Battery or electrics dead | Hazards may fade, so use a phone torch and stay behind the barrier. |
| Smoke or fire | Everyone out and away immediately, then call 112. Do not open the bonnet. |
Tunnels and the Missing Link
A 13.3 km bypass between Khopoli and Kusgaon, with two tunnels and two viaducts, opened to traffic in May 2026 as part of the expressway. MSRDC has said that stopping is not permitted on it, that details of vehicles that do stop will be shared with the highway police, and that the tunnels and bridges are under round-the-clock camera watch. The road was shut for a time in July 2026 after a landslide, and rules about which vehicles may use it have been reported to differ from the older ghat section. Check MSRDC's latest announcements before you travel. If you break down inside a tunnel, switch on the hazard lights, call 112, and follow the signs and any announcement. Do not attempt repairs there.
What not to do
- Do not push the car along the carriageway.
- Do not cross the expressway on foot, even to reach a petrol station or food stop on the other side.
- Do not accept a rope tow from a passing vehicle; see how towing is arranged for safer options.
- Do not pay large sums to anyone who appears at the roadside uninvited.
If the breakdown turns out to be the result of a crash, the steps in the guide to dealing with an accident apply as well. And if you are worried about the climb itself, the ghat driving guide covers how to avoid the faults that cause most hill-road trouble.
Frequently Asked Questions
Can I stop on the Mumbai–Pune Expressway if I need a rest?
No. MSRDC says stopping vehicles on the expressway is not permitted. Use the rest areas and food courts reached through the exits and plan breaks around them.
Is 1033 the number to call on the expressway?
1033 is the NHAI helpline for national highways. The expressway is a state road run by MSRDC, so use the control-room number on its signboards, or call 112 in an emergency.
Should I put a warning triangle behind my car?
Only if you can do it without walking in traffic. Safety comes first, so move yourself behind the barrier and keep the hazard lights on.
Will I be fined for stopping on the shoulder in a real breakdown?
The rule is aimed at casual stops such as photo breaks. We did not find a published penalty schedule for genuine breakdowns, so report the stop to the control room straight away so that a patrol knows it is a fault.
What if my phone has no signal?
Stay behind the barrier and wait for the next patrol, or move to a spot with signal only if it can be done safely. Another driver may also call for you, but do not leave the car's side of the barrier to wave down vehicles.