Pajero Gen 2 restoration

[mygoggie]

I think 24-130 is just a drawing reference number.

Most likely you have the V5M31 tranmission as fitted to the 4M40 diesel.

To split the boxes the shifter on the back of the main geabox selector shaft must be removed. This is fixed to the shaft with a pin which must be punched out. Not easy but I believe it is possible by working from the top of the box after removing gear levers.

Attachment 592643

I have the workshop manual for this transmission if you would like me to post it here.

Regards

Thanks for this lead! I actually checked last night if I have that manual and missed it. Here is the page I have on the TC. Would you mind checking if it is the same? AFAIK this is a Borg Warner 302008 transfer case also used in the Dodge Ram-50.

[MysteriousEngine]

Yes, page 22C-7-1 is identical.

Have attached complete manual.

Regards

[mygoggie]

Yes, page 22C-7-1 is identical.

Have attached complete manual.

Regards

Thanks a mill!

[mygoggie]

I managed to get a quote from the stealers for the clutch and TC chain. 10k per item ... And then 30 days wait.

I managed to find an Exedy clutch kit from Abes for R2.7k. AFAIK this is the OEM clutch for Mitsubishi. Ordered and paid.

I am still looking for a Transmission jack to get the whole train of TC + Gearbox onto the ground.

[mygoggie]

Seals I managed to find from a local seal supplier. OEM at R20 per seal vs R140 at stealers.Bearings more or less sorted with SKF. I just need to strip the TC to get access to the roller bearings.TC chain I have received confirmation from BMG that they can assist. Should be less than the R10k from the stealers.Let's see!

[gazza1210]

Learning a great deal from this thread! Keep it up!

If you're battling for part numbers and/or detailed diagrams then this link should be very helpful.... gives all OEM part numbers etc. I usually copy the part numbers from the diagrams then google for prices and availability.

https://www.megazip.net/zapchasti-dlya- ... fl6-164993

[MariusFourie]

Check my signature for pajero files

[mygoggie]

And a PHC Valeo clutch arrived .... not what I asked for. Not a happy chappy.

[mygoggie]

I had some time to get the transmission train removed. What a job if you are alone.

I will post a lot of pictures for you following the thread.

Question I have:

The input shaft to the gearbox is quite worn where the pilot bearing seats. The pilot bearing wobbles on the shaft. When mounted in the pilot bearing the shaft wobbles as you can see by the alu dust the splines have eaten from the housing.

Is this worn area on the shaft repairable?

[Kalahari Vegmot]

I had some time to get the transmission train removed. What a job if you are alone.

I will post a lot of pictures for you following the thread.

Question I have:

The input shaft to the gearbox is quite worn where the pilot bearing seats. The pilot bearing wobbles on the shaft. When mounted in the pilot bearing the shaft wobbles as you can see by the alu dust the splines have eaten from the housing.

Is this worn area on the shaft repairable?

I guess it *could* be possible to have it spray welded..?

[jelo]

Are you saying the input shaft wobbles?

[mygoggie]

Are you saying the input shaft wobbles?

Yep, because there is so much play inside the bearing.

[jelo]

Yep, because there is so much play inside the bearing.

I'd say you'd need to address the bearing issue, and then knowing your skills, I'd turn the shaft down and put a bronze bush over the end.........

[mygoggie]

I'd say you'd need to address the bearing issue, and then knowing your skills, I'd turn the shaft down and put a bronze bush over the end.........

I am replacing the bearings yes. I looked at the loads on the shaft and I can get away with turning the shaft down and press fit (hot + cold process) a sleeve over the shaft end and then machine this down for a final slide fit in the bearing.

So it is onto stripping the gearbox. Just need to finish stripping the transfer case.

[MysteriousEngine]

Glad you are making good progress.

I will shortly have to do a gearbox removal and overhaul job on a V5MT1 box which is making serious bearing noises in all gears except 4th. This indicates a layshaft (or input shaft) bearing problem, probably a spun bearing since the noise suddenly got much worse.

I found a useful write-up for V5M31 overhaul here but you are probably already past that stage.

In this case, removal was with a pallet jack and a couple of old tyres for cushioning.

"...the way i did it was to drive the car up on 4 car ramps, then i put a pallet jack under the gearbox (in from the front of the car) and simply jacked the tolley up to take the weight of the gearbox and just pushed forward. it came straight out."



Regards

[mygoggie]

Can someone ID the gearbox + transfer case for me from these numbers? I think it is a V5MT1-6 (Super Select RHD) unit and not as previously thought a V5M31 unit.

[MysteriousEngine]

The V5MT1 can be identified by the cast iron main gearbox housing and the reverse gear cover plate for the power take off, just as in your pic.
So yes, I would say that's a V5MT1, (the 'T' denotes Truck).
Download the factory manual to make sure, or I can repost it here.

Regards

[GaryFrank]

I’ve got an 4x4 auto-box in my spares corner....30-40LE. Got a lefty front prop.

[jelo]

I’ve got an 4x4 auto-box in my spares corner....30-40LE. Got a lefty front prop.

Does it need a TCU?

[mygoggie]

The V5MT1 can be identified by the cast iron main gearbox housing and the reverse gear cover plate for the power take off, just as in your pic.
So yes, I would say that's a V5MT1, (the 'T' denotes Truck).
Download the factory manual to make sure, or I can repost it here.

Regards

Thanks for the feedback.

The "power take off" you mentioned. Please elaborate a bit more.

I do have the factory manual for this box. Thanks!