Gen 1 3.5L V6 conversion and TT build up

[iwan]

hi guys..
i recently owned a LWB Gen 1 pajero which was my late father's. to keep the memories fresh, i decided to refresh the old car. it now has 2.5" body lift and about 2" suspension lift with 33" MTs. brought the car to the jungle twice and felt underpowered in hill climb and having trouble getting out of mud holes. my father had the engine changed to a 2.0 sohc non-intercooled turbo to save fuel as this was his weekend ride to the orchard. the original engine was the 2.6 4G54 carbie.




now that i'm mixing with some hardcore offroaders (these people participates in Malaysian RFC) i want to build my pajero so that the only weak point is the driver.. here's what i have in mind..a manual 5sp 3.0 twin turbo V6 with a super select gearbox. i'm trying to keep everything inside the mitsu circle. i went through the 'tech database' and search what's possible for this build. i can get most of these parts from local wreckers.

but i need your help to list the right parts for me and get me on the right path. here's what i understood. the transmission should come from the Gen 2 3.5 6G74 as this is the one rated with 300Nm engine. next, the front and rear axle should also comes from either the Gen 2 3.5 6G74 or 2.8TDi 4M40 because these has 8" front diff and 9.5" rear diff. please correct me if i'm wrong.. and to what trouble will i come across to succesfully make this happen.

your help is highly appreciated..most pajeros here in malaysia followed the 1jz or 2jz route and i haven't heard from anywhere there's a manual 5sp 3.0 V6 twin turbo pajero around..

[fondente]

Hi.. may be the 3.0v6 turbo cames from the mitsu gto.
Mitsu never produced a Pajo with v6 turbo engine... only diesel are fitted with it.
The 3.5/2.8 gearbox won't fit on a 3.0 engine.

I think you could find a 3.5 dohc (206 hp) or a 3.5 sohc (194hp)

[steverisingsun]

Hi.. may be the 3.0v6 turbo cames from the mitsu gto.
Mitsu never produced a Pajo with v6 turbo engine... only diesel are fitted with it.
The 3.5/2.8 gearbox won't fit on a 3.0 engine.

I think you could find a 3.5 dohc (206 hp) or a 3.5 sohc (194hp)

The 3.5 and 3.0 gearbox bolt pattern is the same

[iwan]

Hi.. may be the 3.0v6 turbo cames from the mitsu gto.
Mitsu never produced a Pajo with v6 turbo engine... only diesel are fitted with it.
The 3.5/2.8 gearbox won't fit on a 3.0 engine.

I think you could find a 3.5 dohc (206 hp) or a 3.5 sohc (194hp)

of course, that's the plan. the engine will come from a gto.

[iwan]

Hi.. may be the 3.0v6 turbo cames from the mitsu gto.
Mitsu never produced a Pajo with v6 turbo engine... only diesel are fitted with it.
The 3.5/2.8 gearbox won't fit on a 3.0 engine.

I think you could find a 3.5 dohc (206 hp) or a 3.5 sohc (194hp)

The 3.5 and 3.0 gearbox bolt pattern is the same

thank you for that confirmation. this is a good start for my build. i believe that would be the V5M31 gearbox; i'll try to source for manual gearbox before resorting to autos. less electronics, less worrying during offroading.

what about swapping the front axle to the 8" diff? is it a direct bolt or will drive shaft length be a problem?

[NJV6]

The 3.5 and 3.0 gearbox bolt pattern is the same

Are you sure?

[fondente]

3.0 gearbox don't fit on a 3.5 engine....
Ok.. I think everything can be done.. so you can fit everything... but starting a new project I'd find the best components to put together without losing too many time in adjusting...

bye

[iwan]

Ok.. I think everything can be done.. so you can fit everything... but starting a new project I'd find the best components to put together without losing too many time in adjusting...

yeah..you got a point there. so i guess i will be stuck with the V5MT1 transmission. how about the front and rear axle? it would be great if somebody has the measurement and dimension for the front 3.5/2.8TDi axle..would like to know just how much trouble it gonna cost me.

[iwan]

The 3.5 and 3.0 gearbox bolt pattern is the same

Are you sure?

came to think of it, there's quite a number of 3000GT in the US swapped their 6G72TT block with Pajero's 3.5 6G74 block. and, from where i read, this owner had it written down quite neatly and not mention about troubles bolting the original 3000GT gearbox to the 3.5 force-fed engine..except for the 3000GT transfer case that hit the 6G74 oil pan.

read it here

also, i read from here, it's easier to use 3.0V6 front diff, but my question is, are they the same for manual and auto?

[BORN2RUN]

intrestin....hmmm sumfin to think bout later on....thanks

[Spicoli]

If you swap to the gen 2 suspension your wheel track will increase by i think 2 or 3in, probly a plus for what you plan on doing.

Best route for all the axle/drive train swappage would probly be a complete parts rig. Here in the states the SR or Cold weather package meant you got the big axles and air locker in the back. Definite benefit of upgrading to the gen 2 stuff is that there all high pinion axles.

The twin turbo route has about been discussed to death here in the States never seen it have seen a few Ruskies and Japanese folks do it but cant get much detail most of them dont speak English but very impressive pictures

Good luck with this project

[iwan]

well..been a while since i updated my thread. after making further research, i think i'll drop the 3.0 GTO engine swap and proceed with whole 3.5 system. i have located a v45w 3.5 dohc 5sp manual halfcut with 157K mileage on the meter.

the plan is to do a complete drivetrain swap from the 3.5..drive it for sometime before turbocharging it. this is going to be a long term project and i'll update it from time to time. the main reason i dropped the 3.0 GTO engine swap idea is that it doesn't have good cost to benefit ratio. after spending some money just to buy the 6G72TT engine, i'll be limited to certain amount of boost and can't push the engine further because it has weak internals. there will be more money involved to get it reliable. 3SI has got 6G74 forged pistons and rods for force fed applications and it costs me almost the same for the the 6G72 TT GTO engine. bigger displacement 3.5 engine, forged pistons and rods..what else can go wrong for the engine build? to add more to this, 6G74 engine already has forged steel crankshaft built to it.

i'll be off to the chop shop tomorrow with my mechanic to check the halfcut out. hopefully it will start with no problems and doesn't exhibit any ridiculous engine noises.. i'll post more as i advance..

[Spicoli]

Glad to hear your trying something new/different!

Get us lots of pictures please unless we see pictures, it never happened

Best of luck with!!!!!

[WACKO]

if you can speak japanease or know someone that can, these guys may be worth contacting... seem to have done a few turbo pajs and various other conversions..

http://translate.google.com/translate?h ... %26hl%3Den

[iwan]

wacko,
i saw the WDEC link from the website you posted. i had the link for sometime and that actually light the bulb over my head to go down this route.

here it is.
http://translate.google.com/translate?j ... l=ja&tl=en

really envy the engine works. also from RPW website, i read that their using two GT28 and achieve full boost at around 3000rpm.

spicoli,
you are going to get lots of them! i'll post some of pics tonite.

[iwan]

these are some pictures i got when me and my mech were inspecting the halfcut. got a video of it as well. i'll get more pictures of it when it arrives to the workshop. i'm really a happy bunny now..after 2months of search.


quite clean from here..


dont know why, it looks really good from this angle..


the dash..halfcut comes with a box of tissue..


157K on the odometer..

http://www.youtube.com/watch?v=ROJrVI2o0d0

[WACKO]

that is a very cool link... added that to my favorites so i dont lose it.
looks like they made 2 pajs up... and at least one of them was originally an evo, theres a pic of the rear shock and its independant.. if they turboed both then id say the evo is 6g74TT MIVEC.... mmmmmmmmmm

and looks like you scored yourself everything you need for your conversion.. well done.. keep it coming.

[iwan]

If you swap to the gen 2 suspension your wheel track will increase by i think 2 or 3in, probly a plus for what you plan on doing.

how exactly can i achieve this? what i meant was which parts can be swapped without any hassle and which that need some modification to it?

i plan to keep the leaf springs because it's illegal to tamper with the chasis here in malaysia. no way i can get rear-coiled conversion registered. however, i can change the rear axle to fit the 3.5's.

i'd appreciate if you could provide me some links (about gen 2 front suspension swap) for me to read on, even better if any of you guys could explain and list them here..

thanks!

[Spicoli]

Havent done it myself, but on 4x4wire.com there has been a few guys primarily on SWB gen1's swap the complete gen2 drive train in. Seems pretty straight forward from what ive read/heard. Trickiest part is finding the right torsion bars. Outside of that everything bolts in from what I remember.

[iwan]

found it..just to keep the topic reachable, i post a link here. let me go thru it 1st.. my mech workshop is pretty much occupied now..will have to wait for the swap.

[iwan]

while waiting for my mech to finish up the cars in his workshop before i can send mine in, i send her to customize front and rear bumpers and also rock sliders. okay.. here's some pictures of the front bumper..this is not a finished product. what is not captured are the sliders..and rear bumper.







more pictures tomorrow.. :cheers

[iwan]

okay..bumpers and sliders completed. i bought shackles to be installed on the front and rear bumper but the guy forgot to install them. i'll come back to them..

[Spicoli]

Nice front bumper, mounting a winch to its gonna be breeze!!!! Gotta feeling doing the corner wrap around piece with that big of tube was a bitch tho.

Also love the WARN mudflaps

[iwan]

thanks man.. i brought it straight to the cashier once i spotted it. about the front bumper, as i ask some of my buddies, they question the durability of the front bumper mounting points. they're all bolted using stock locations and nuts which is not too strong.. mann, i may have to get another one. $#!7..

anyway, the paj will be in workshop for engine conversion next week..i hope.

[nervis]

Iwan, the ends of the front/rear bar are cast steam pipe bends, just cut to the desired length and wended on.

Damn nice work I must say!

[Spicoli]

Cast steam pipe you say eh?

Cant imagine case would be an ideal material to use on a bumper. Since it doesnt like being hit very much.

[iwan]

okay..some updates. for the last 2days, i was working on the donor vehicle, stripping parts down, wiring and just about everything from the halfcut.

some pictures..

radiator and condenser removed, all wire loom detached from cabin..prior lifting the cabin.


lifted the cabin a couple of inches and found brake lines still attached.


























by the end of the operating hours, the exhaust pipe, brake calipers, steering assembly were removed. now that stripping of the halfcut is done, i think it is almost time for my old pajy to enter the 'operation theater'.

[iwan]

does anyone knows whether the gearbox cross member from the Gen2 will bolt up to my Gen1? it will be a huge savings on time and cost if it would..

[Spicoli]

Nice work Iwan!!!! I love seeing updates to this thread

I doubt the crossmembers will seeing as how there different transmissions but cant honestly say yes or no.

I remember you saying your hoping to build this and possibly compete in the Malaysian RFC. Not very fimiliar with the event but..... If your really interested there was a guy here in the states that managed to put 2 transfer cases behind his stockish pajero. If your interested I can dig up the link for ya.

Best of luck with this build Iwan. Looking forward to seeing it completed.

[iwan]

Nice work Iwan!!!! I love seeing updates to this thread

I doubt the crossmembers will seeing as how there different transmissions but cant honestly say yes or no.

I remember you saying your hoping to build this and possibly compete in the Malaysian RFC. Not very fimiliar with the event but..... If your really interested there was a guy here in the states that managed to put 2 transfer cases behind his stockish pajero. If your interested I can dig up the link for ya.

Best of luck with this build Iwan. Looking forward to seeing it completed.

thanx man i'm already half-leg knee-deep in, i don't see why i should turn back. anyway Malaysian RFC is the rainforest challenge. i'm not too serious in participating is RFC, but any challenging mud trail is fine by me.. by the way, what's the need for 2 transfer cases?