Mitsubishi KM100 transfer cases

[alanc]

Hi,
Help please.
I am trying to get an understanding of the versions of early KM100 transfer cases.
I have only got access to an NA Pajero and an SD L300 for now and wondered if anyone else had noticed these early short TCs under Tritons and 88 to 92 Delicas. The 92 Delica that I saw had an extremely short fixed yoke version.
I am hopefull that as engines became larger then the TC was upgraded to larger input / output shafts and internals.
The cases I have are 24 tooth 60 deg fine spline( quite puny) and I wonder whether anyone has seen a 23 tooth course spline version. The later V6(around 92) pajeros had a larger TC with the 23 spline shaft.
Can anybody add to this please?
Al.

[Bitsamissin]

Hi Alan, I got your email but I will reply to you here so the tech imfo can stay in this forum.
I have never seen or heard of a KM100, they must be a very early t/case, most early Paj's have the KM145 (manual), KM148 (auto) all 4 cylinder.
V6's have the V5MT1 (manual) or VA4AW2 (early auto V6) and VA4AW3 (later auto V6).
I can tell you this that the auto t/case has a coarse 23 spline, 31.5mm diameter input gear and this is the same for all Pajero 2.6 & 3.0 V6 auto's.
I haven't got a manual input gear with me, call Mark Hardman he has my spare V5MT1 5sp and the t/case gears out of a 92 super select box I'm sure he would give you the measurements over the phone.
But the manual input gear is smaller than the auto by a considerable margin.
The 4 cylinder t/case is virtually identical to the 3.0 V6 except for chunkier gears and they are a very compact unit the 3.0 V6 super select t/case runs the same gears as the earlier V6 but is 4" longer due to the centre diff/viscous coupling assembly. The super select t/case also has a much beefier chain.
The super select 3.5 V6 t/case is a much larger case than the 3.0 V6 with different gears I don't know if the input shaft is the same size or not.
All Pajero t/cases run a slip yoke front & rear propshaft.
If your powering up I really wouldn't worry too much about the input gear the t/case chain is probably the weak point there has been 200+ HP turbo 2.6 Paj's running around for years without any major t/case drama's
Hope this helps.

Frank.

[alanc]

Frank,
Have you been a help? You bet.
All the little bits of info that I have got, some true some not , have been cleared up in seconds.
Over the weekend I went looking for Pajeros and found an 89 V6 LWB and a 93 V6 SWB. As you said both had the small case.
Since I was having another input shaft made anyway then I would prefer the larger spline version.
What chance that the 23 spline mitsubishi is the same as the 23 spline NP231 Jeep for which there is an extremely short shaft already available?
My conversion is 3.8 GM V6 with 4L60E. I have it solved with adapter and 24 T spline shaft but want heavier bits in the middle of the instalation.
Thanks again for your help.
Regards, Al.

[Bitsamissin]

Alan, I think there is a very good possibility that the 23 spline input gear of a NP231 will fit a Mitsu output shaft from an auto tranny. The auto tranny for Jeeps are actually made by Mitsubishi for Chrysler. Some of the Yanks looked at grafting the NP231 to a Mitsu gearbox to improve low range gearing. Marks 4wd Adaptors makes the 24 spline output shaft I believe and I remember Mark Hardman showing me your original email about this issue.
Also the 23 spline input gear from the auto t/case is 3mm longer than the 24 spline manual version. The extra length is so it can slide into the lip seal at the rear of the auto tranny the manual is sealed internally around the output shaft.
Let me know how you go with the NP231 (if you go this way) if it does fit it's big news for the Mitsi guys.

Frank.