Pajero Gen 2 restoration

[jelo]

PTO: an optional power port usually adjacent to the front propshaft pinion shaft. You can drive external items like winches and pumps. Mostly unused these days but a clever bloke can have a gear cut and fit a shaft with bearing.

[mygoggie]

PTO: an optional power port usually adjacent to the front propshaft pinion shaft. You can drive external items like winches and pumps. Mostly unused these days but a clever bloke can have a gear cut and fit a shaft with bearing.

I never realised the gearbox has a PTO outlet. I see you can buy the bolt on unit from China and it is well rated by the AUZ guys. Vely intelesting.

[GaryFrank]

Does it need a TCU?

Nope.... was connected to a 4y motor....I’ve still got the adaptor & TC (as it came outta the Vehicle)

[jelo]

Nope.... was connected to a 4y motor....I’ve still got the adaptor & TC (as it came outta the Vehicle)

Probably won't fit the Pajero then.

[mygoggie]

Can anyone please check and let me know what direction the rear propshaft on the Gen 2 turns?

Thanks!

I really really need to post the hundreds twenty four onety photos I have taken so far on getting the gearbox and TC stripped.

[mygoggie]

I am making progress with finding a solution for the propshafts!

After giving up on anyone willing to help me I met Dawie Coetzee of Coetz Parts online. After a few emails he sent me this ...






Now I need to find someone to machine the splined sleeve yoke and fit a flange to it. I also need to make a plan to bolt/lock the sleeve onto the output shaft so that the spline in the shaft can accommodate the movement.

[EtienneB]

PLEASE don't snap change from 1st to 2nd when you're in a dice. That pencil is not gonna make it.

[jelo]

Now I need to find someone to machine the splined sleeve yoke and fit a flange to it. I also need to make a plan to bolt/lock the sleeve onto the output shaft so that the spline in the shaft can accommodate the movement.

So you need a Slip Yoke Eliminator?

How many teeth and what diameter on that output?

[MariusFourie]

Why not tripod CV joints?

[mygoggie]

So you need a Slip Yoke Eliminator?

How many teeth and what diameter on that output?

No, you do not get a SYE for this gearbox. I can have the splined shaft and the sleeve bolted together with a centre bolt to create one.

However for this I need a splined sleeve with a flange like this. This one is from a 2006 Pajero 3,2D front propshaft with a CV.





The number of splines are 26, the OD of the sleeve is 39,7mm and the ID between splines is 29,3mm. See below.

[mygoggie]

Why not tripod CV joints?

No idea why Marius. If you know of a brand + part number that can work, please let me know. So far only Dawie Coetzee has been willing to help me with this problem and he said for a 4x4 a double cardan is the correct way to go. He said that propshaft CVs tend to loose the protecting rubber and then the CV lasts a few minutes.

[mygoggie]

I took this in to Loftie Dysel in PE this morning and he said no issue to fix. Hard chrome the area and the turn it to size. Works out a tad more than a grinding and sleeving operation and is the correct way of fixing the issue.

Let's see what it looks like when done.

[jelo]

The number of splines are 26, the OD of the sleeve is 39,7mm and the ID between splines is 29,3mm. See below.

1 9/16" and 1 5/16" ?

http://driveshaftparts.co.za/index.p...ry&path=20_125

http://driveshaftparts.co.za/index.p...roduct_id=3623

Seems to be in stock.

[mygoggie]

1 9/16" and 1 5/16" ?

http://driveshaftparts.co.za/index.p...ry&path=20_125

http://driveshaftparts.co.za/index.p...roduct_id=3623

Seems to be in stock.

Wow, thanks for this. I will get the exact dimensions as this state 39mm OD whereas I need a 39,7mm OD. The oil seal is exactly 39,7mm ID so the sleeve OD must match.

[jelo]

Then look at this, should be the same as the early Paj and the Galloper were the same vehicle:

http://driveshaftparts.co.za/index.p...roduct_id=1575

[mygoggie]

Then look at this, should be the same as the early Paj and the Galloper were the same vehicle:

http://driveshaftparts.co.za/index.p...roduct_id=1575

This one is not stocked ...

[jelo]

This one is not stocked ...

Frok

[grips]

Why not tripod CV joints?

Tripod CV joints are low velocity joints. Won`t work on a prop shaft.

[mygoggie]

Tripod CV joints are low velocity joints. Won`t work on a prop shaft.

Thanks for the feedback @grips. After a bit of reading it also appears that tripod joints have a much smaller functional angle of rotation.

[mygoggie]

I see a Spicer 2-3-8731X slip yoke can work if I can get the flange made up and welded to the yoke. Alternatively get the yoke to fit directly into the double cardan joint. I will ask on Monday ...