Pajero Gen 2 restoration - Page 2





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  1. #21
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    Default Re: Pajero Gen 2 restoration

    Here is a photo of my installed upper ball joint.

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    Basically first fill the rubber boot with black CV grease. Then slide it onto the groove at the flange with the bolts. Then put the steel ring on the shaft with the lip facing to the rubber and slide it into the rubber boot. Make sure the steel ring's lip seats nicely into the rubber boot opening. Then add a tint bit of grease to the bottom of the steel ring and rubber boot and slide the rubber washer onto the shaft seating it against the steel ring. The grease ensures that the rubber washer remains in place. Now lift the wishbone and insert the shaft into the top opening of the arm.

    Make sure you have the LH and RH ball joints fitted to the correct side! Here are the part numbers from my notes.

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  3. #22
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    Default Re: Pajero Gen 2 restoration

    so the rubber ring seal is between the control arm and the rubber boot

    thank you
    Pajero Gen2 1996 2.8TDi LWB

  4. #23
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    Default Re: Pajero Gen 2 restoration

    Quote Originally Posted by hogbeast View Post
    so the rubber ring seal is between the control arm and the rubber boot

    thank you
    Yes, that is how installed mine after figuring the sequence out.

  5. #24
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    Default Re: Pajero Gen 2 restoration

    I have some time on my hands since I could not fly to New Zealand and now had to move back into my own home. So ... some more photos!

    Here is the front differential and side shaft tubes all redone and ready for installation.

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    Installed with a lot of help from SWAMBO ...

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    Wishbones and hub installed on both sides.

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    Brake rotor and calipers installed, side shafts shimmed and nut tightened to an almighty torque.

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  6. #25
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    Default Re: Pajero Gen 2 restoration

    Torsion bars cleaned and acid primed. These were really filthy and rusted, but with some love, they are as good as new!

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    Ready for installation ..

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    All installed and my nightmare began ...

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    Someone in the past made white markings to indicate the location of the teeth of the torsion bars in the holder. Alas, these were in the wrong location and I had to find the correct location by assembling torquing checking ride height and undo and redo four times before I found the sweet spot with the correct lift I wanted.

    All installed and all nuts and bolts torqued.

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  8. #26
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    Default Re: Pajero Gen 2 restoration

    When I rebuilt the power steering box, I had to undo this nut with the two slots.

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    The official spanner is this one, but alas none could be found where I live.

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    So I made my own from a sledge spanner and two high tension bolts the ends which I shaped to rectangles to fit into the slots.

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    And I could set the play on the pinion.

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  10. #27
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    Default Re: Pajero Gen 2 restoration

    I am absolutely loving your work. This is fantastic. How long did you have to wait for parts for Mitsubishi?

  11. #28
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  12. #29
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    Default Re: Pajero Gen 2 restoration

    Live and learn! I never knew the Gen2 had torsion bars up front! A system I quite love.
    We can't change the wind but we can set our sails

  13. #30
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    Default Re: Pajero Gen 2 restoration

    Quote Originally Posted by KylePajero View Post
    I am absolutely loving your work. This is fantastic. How long did you have to wait for parts for Mitsubishi?
    Thanks @KylePajero!

    The SA parts were about 10 days and the parts ordered from Spain were in Germany after three days where I collected them. That was last year, things might have changed now ...

  14. #31
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    Default Re: Pajero Gen 2 restoration

    Quote Originally Posted by MariusFourie View Post
    Love your work!
    Clean, precise, methodical.

    May it reward you many times over.
    Thanks @MariusFourie. That is the only way to work IMHO... one tip and old guy gave me when I was young is to sit and plan your job and the pack out all the tools for the job. That way you will make sure you think every step through before starting. Wise words, many times rewarded.

  15. #32
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    Default Re: Pajero Gen 2 restoration

    So ... today is day 8 of lockdown and I need to tackle the front shocks issue.

    When I installed the brand new front shocks, I saw that the rubbers immediately failed when I tightened the shaft nuts.

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    I was not a happy chappy so I wrote to the company and they took a while to respond. Just before lockdown started a small box with new replacement rubbers were personally delivered by their local representative. In the week my wife went shopping and came back saying that the Pajero is making a terrible clacking noise from the front.

    I looked this morning and alas, the bottom bushes of the shocks were gone! That after not even doing 150km ...

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    Aha, I thought, but I have a box of rubbers fresh from the factory, waiting to be installed. So I have now just opened the box and this is what I found.

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    Four rear bottom bushes and four front bottom bushes. Where the heck are the top rubbers? And why four of each, do they expect these not to last once again?

    So I will strip the shocks out and see what I can do today. I will also write and email to the representative and ask to make this thread known to the factory. Not good marketing in my books.

  16. #33
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    Default Re: Pajero Gen 2 restoration

    So onto getting the shocks fixed. The other shock also lost its bottom rubber, no wonder the wife was so worried. Must have been a terrible clanking noise!

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    LH shock and its rubbers packed out.

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    Someone at the shock company needs to go back to Polymer Engineering 101. I do not know how you can design a polymer and not know how about polymer hysteresis. The rubber or in this instance an elastomer simply stayed deformed ... ai.

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    Because using a nyloc nut is a waste of time in the 4x4 world (it will not stay in place and you will loose the shock absorber), I put the nut in the lathe and turned the nylon section away. In reality a nyloc nut is only a half nut with some nylon on top kept in place by crimping the nut's top sleeve over the nylon bit. So there I have a usable half nut.


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    Cleaning the round edge of the bottom sleeve, and applying some soap, I could easily press the new bottom bushes in.

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    I dug out the old top rubbers I kept when I replaced the Kubu shocks a few years ago and installed the shocks and locked the two half nuts in place with some Locktite. Amazing that even after doing almost 80k of off-road travel these rubbers are in pristine condition! Someone passed Polymer Engineer 101 with flying colours.

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    All installed and torqued.

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    I could not understand why the top wishbone shaft's bolts are indicated in the manual to be installed with the bolt heads on the shock side. This way round you cannot torque the nuts as you cannot get access from the engine side and you have to torque the head side which will give you a wrong torque setting. I therefore installed the bolts with the head on the engine side which made torquing easy. Anyway, now I understand. My way results in the bolt's thread end rubbing against the shock's rubber boot ... My solution was to cut a piece of plastic tubing, round the edge on a wire wheel in stick it over the end. Let's see how this works!

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  17. #34
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    Default Re: Pajero Gen 2 restoration

    One lesson learned is to fix a leaking brake fluid circuit as soon as you notice it.

    The clutch master cylinder was slowly leaking and I did not want to touch it before I had the service kit. So this became one of the items I tackled during the restoration process.

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    So I set out to strip the whole assembly after removing it from the vehicle. I must say, I am struggled to get my body and hands in the cramped space. Not designed for Boere to work on!

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    Stripped and time to clean

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    The service kit came with new washers, clips, bushes, rubbers and seals. It took a lot of time to derust and clean the firewall and repaint it. Then it was derusting and repainting the pedal assembly. After a few days of work, mostly watching stuff drying, I could assemble it and install the whole lot.

    Done ..

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    At the same time I serviced the slave cylinder which was also leaking. This was a bit of a nightmare as the person working on the slave cylinder before me stripped the pipe's nut where it enters into the slave cylinder. I tried for two days to get it loose to no avail. I ended up cutting the pipe and then I could get the slave cylinder out. This meant I had to get a new pipe made up and replace the old one. What a nightmare. It took a morning to get the old pipe out and a WHOLE day with the help of a friend to get the new pipe installed. There is simply no space to work and get the mountings undone and fastened. A few cut fingers and many new swear words later, the new pipe was in place.

    The new shiny pipe installed.

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    And screwed into the master cylinder.

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    I also had a new teflon pipe made up to run from the steel pipe to the slave cylinder as the old one was on it's last legs.

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    The repainted and refurbished slave cylinder installed.

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    Basically I redid the whole clutch hydraulic circuit. Bleeding was simple and took a few minutes. No leaks anymore and the clutch works well! No, the wet is some oil I washed from the engine. Need to find that very slow oil leak ..

    In the end, I now can sleep well knowing that I do not permanently have to check the clutch's reservoir and top it up.
    Last edited by mygoggie; 2020/04/05 at 01:07 PM.

  18. #35
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    Default Re: Pajero Gen 2 restoration

    Well done on your great work, love those 90s SUVs.

    I hope those HDP shocks serve you well.

    Mine didn't last long.

    Plain Safari much better , lasted ages .

    A case of false progress, where the new all singing all dancing product is worse than the original products it replaces .

  19. #36
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    Default Re: Pajero Gen 2 restoration

    Quote Originally Posted by tashtego9 View Post
    Well done on your great work, love those 90s SUVs.

    I hope those HDP shocks serve you well.

    Mine didn't last long.

    Plain Safari much better , lasted ages .

    A case of false progress, where the new all singing all dancing product is worse than the original products it replaces .
    Thanks for the heads-up. I will keep an eye on these, but I think you are correct. Next project is to build my own compressed air based shocks as there is air onboard now.

  20. #37
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    Default Re: Pajero Gen 2 restoration

    Come Sunday I decided I want to complete the wiring for the second battery system and heavy duty DC outlets on the Paj. The main motivation was to enable me to put a battery charger on the vehicle without hooking it to the battery and leaving the bonnet open. Long time ago I designed the DC bus layout that looks something like this.

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    So Sunday afternoon I set out to find a place to locate the fuse blocks. It took a while and one night to sleep on it and on Monday I made the final decision to mount it just to the rear of the battery on the sidewall. There were a few holes fitted with weldnuts available which made the choice a good solid one.

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    Because the surface is not level I decided to mount the fuse blocks on a backing plate. I had some left over extruded fibreglass sheeting from my biogas and water purification skid projects (read more here) and decided to use it. I first made a cardboard template to match the area, allow a cutout for the little vehicle plate and locate the holes.

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    Then it was onto cutting the plate and drilling the mounting holes.

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    The fused boxes layed out and their mounting holes marked out on the plate.

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    All mounted and screwed together.

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    I installed a rivnut in the top hole as it had no weldnut installed.

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    Backing plate with fuse blocks mounted.

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    One and a half day's work later, the fuse boxed are all wired up.

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    View from the top with new battery clamps modified to fit the Paj cables.

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    This afternoon was spent installing the two T-junction boxes in the passenger's foot well.

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    All done and tidied up.

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    Why do you always use so many tools even for a small job like this?

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    The Anderson plug at the front of the Paj I installed a while back while repairing frond end damage when a truck reversed into me. This is the plug I aim to use when trickle charging the battery.

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    The one in the rear I did at the same time.

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    So it was time to move onto installing the Anderson plug at the gear lever console.

    Soldering the Anderson plug pins. I packed some fire bricks in the footwell to protect the carpet from the hot air.

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    Both soldered onto the wires.

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    And the plug installed.

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    I need to bulkhead mount the plug so I need to fit the plug to a angle plate with a lip that screws onto the front surface and be covered with a faceplate. For the angle plate I will use some aluminium I found after cleaning and packing the garage up for the big move that never happened.

    First step is to make the faceplate from the same extruded fibreglass. Marked out and cut.

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    And more or less finished. Tomorrow I will drill the mounting holes and make the angled plate. First need to get some sleep!

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  22. #38
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    Default Re: Pajero Gen 2 restoration

    This morning was spent shopping for groceries. Nobody in the mall and everybody scared of each other! Scary to see ...

    Anyway, all groceries disinfected and packed away so I could move onto finishing the central console Anderson outlet project.

    Cover plate completed and test fit.

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    The aluminium plates I made today. Actually went very quickly.

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    Fitted in the console. I could not unscrew the cigarette lighter outlet and I was too lazy to remove the console, so I swapped the cap screws for SS self taper screws until I need to wire up some switches in the console.

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    Looks good to me! Now I can scrub all the dust away and clean up.

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  23. #39
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    Default Re: Pajero Gen 2 restoration

    And there we are! Charging of the battery without opening the bonnet!

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  25. #40
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    Default Re: Pajero Gen 2 restoration

    Looking good!

    I would like to know if the fuses to your starting battery are necessary when using a trickle charger to keep only the one battery charged?
    Mitsubishi Pajero 3.2 D-ID GLX LWB

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