Pajero Solid axle swap and other modifications

[monmendoza]

@love_mud - Thanks, I will take that into serious consideration. What they did actually was weld the panhard mount into the chassis. Your panhard mount definitely looks much better and more professional looking.

I also have the exhaust system replaced today. Well it was really old
and rusted with many holes in it so I decided to replace it with a new one which is less restrictive and straight through in design. When I looked at the underchassis components of the Pajero, I noticed that it was properly designed and they put a lot of attention to details. Its a + for me. I never had a Pajero before even if I have many other 4x4. Makes me think of buying another pajero. I also cannot say with a definite answer If I gained a few horses but my feeling is that It is easier for me to rev higher now than before. I like the results of free flowing exhaust. Time to buy K&N free flowing intake.


Here is the picture of the old exhaust system .


I bought a resonator, a straight through muffler a flexible conduit
and aluminized pipes.


Here is the after installation
The flexible coupling and the resonator


The muffler


The tail end



Mates, I am also thinking of buying the extra low tc gears from Mark4wd as stated in the Tech bible. I know that some of the members of our forum
have replaced their standard TC gears with them. Please comment
on their performance and reliability. If you think your opinion is confidential, I would really appreciate you give me a pm. Many thanks in advance.

[Bitsamissin]

The gears make a huge difference offroad and so far have proven to be ultra reliable. I've had the 2.85's in a 3.0 V6 and 3.15's in a 3.5 V6 = fantastic.
They are actually made from superior material than the factory gears.
So far there are around 70 sets out there in use for over 6 years now and no reported issues only questions about the install on some models.

[M1S3RY]

I've had the gears for a few months now and all i can say is they have totally transformed the car, in a good way, especially if you have 33"+ tyres..

[monmendoza]

Thanks Frank and Mist3ry for your inputs.
I have been trying to contact Mark4wd but I havent gotten a reply yet.
I would like to try it out too. How hard is it to install, if you have a 4x4 mechanic to help you? Are there any special tools requirement? For a normal install, can it be done in half a day? Tia .

[monmendoza]

I have bought the 2.84 low gears from Marks4wd.com but have not installed it yet.
I have the ARB front and rear lockers by the distributor in the Philippines but there seems to have a problem with the front differential so I decided to bring it back to a mechanical shop.

I have also completed the fender flares for it. Looks nice.
Here are the latest photos:







The pajero is currently in a mechanical shop. The ring and pinion is to be reset because of too much play and some bearings needs to be replace.

I will probably install the low TC gears by middle of November.

[88mitsu]

Where are the flares from? Jeep CJ?

[monmendoza]

Where are the flares from? Jeep CJ?

No, they are custom fabricated. They are made of fiberglass.

[Guy]

Where are the flares from? Jeep CJ?

No, they are custom fabricated. They are made of fiberglass.

Hope you still have the mould fiberglass and big hits (even rocks etc) being flung up from the tyres can take a large toll .

Could you make a new set of ABS plastic ?

[monmendoza]

The Pajero was delivered by 199ORH yesterday. They did a fantastic job!

While before the pajero death wobbles at 60kph or less, and wiggles violently,
now, I was able to run it at 110kph and I even released the steering wheel
without any drift. Here is what they did.

Before:



After:



You will see a very big difference in the angles from before to after.

The coil spring mountings were also strengthened to ensure it will not unseat itself
during rugged trailing.



The front shocks mount was increased.



The folding shackles were removed because it doesnot do what it is supposed to do:

before:



After:



Here is another picture of before:



The steering set-up was converted into high-steer. Ball joints were replaced with brand new units
from Mitsubishi Canter trucks which are widely available and more heavy duty.

Rear shocks angle were changed ad shocks replaced with longer ones made by Rancho.

before:



after:

oops I forgot to take a picture.

Steering damper location and mounting changed:
before:


After:





There are still many things that needs to be done that has nothing to do with its running performance
but nevertheless essential like the aircon, wipers, leaking window gaskets, repainting, change oil, stereo
keyless entry etc..
but I am already relieved that It is now performing as it should be. I really thought that my Pajero
would end up as junk. It is now 2 years since I started my Pajero project. Of course
more than 1 year was also wasted because I was busy with my job.


to be continued......

[MogLux]

I love this thing, you are thinking out side the norm.... Keep it up.
those flares look fantastic.

[RO8M]

I also love the look.

Are you concerned at all about damage to the body (or indeed the rod) of the steering damper?

[monmendoza]

Thanks Ro8M & Macarthur

@Ro8m. there is a space between the body and steering damper. It won't hit the body
or the pumpkin.

I am having the aircon fix by next week. I also plan to have some body panels, specially
the roof painted.

[RO8M]

Thanks Ro8M & Macarthur

@Ro8m. there is a space between the body and steering damper. It won't hit the body
or the pumpkin.

I am having the aircon fix by next week. I also plan to have some body panels, specially
the roof painted.

I was meaning damage from rocks etc.

[monmendoza]

your right Ro8m, A large potruding rock would probably damage the damper and or the
pumpkin. Would an aluminum cover help? How do people install an aluminum cover?
Most solid axle front rigs i see don't have them.

[monmendoza]

Started painting the pajero yesterday.





BTW I also bought a low transfer case gears fro the Pajero from
Marks4WD last year but never got to install it because of the still
death wobble problems, now I plan to install it. I have the
instruction sheet but I don't have pictures or videos of the
installation. Is there anywhere in the net that has a more detailed
instruction sheet or video. Any help would be very much
appreciated. Thank you in advance.

[monmendoza]

Last week started with the repainting of the Pajero.
Hopefully to finish by next week. Primer is now being
applied.

[monmendoza]

I decided to make the silver color of the Pajero a little
darker than the previous color.



I also asked the fabricator to do me a railing for the back of the
Pajero.





The rollbar temporarily removed.




Here is my Pajero and Feroza being repainted.





to be continued.....

[hasithawatha]

Hi friends I m a new comer to this subject.. I have a same pajero and i need to make it fully suspension. I saw what u have done.. Itz really amazing. Can any one help me with it..

[monmendoza]

Hello Hasit,

What exactly do you want to do with your Pajero?

[hasithawatha]

Hy thanks for your earliest reply,

I m having a pajero short wheel base 1990 model.. I like this model very much, so i don't like to sell it.
But i m having a small problem in this. It's not much comfortable. As my technician said it was a common problem for the short wheel base pajero's..
I decided to make the rear suspension Coil springs as i it's currently Leaf springs. I think it may help to increase the comfort. i m using this as my sport vehicle too..
I don't have large amount to spend as i m still studying. So I just want to know your idea about this matter. And if you have more suggestion Please be free to tell me

Bellow are some photos of my jeep.

The Beach off road


The rally




The trophy 2009


Broken suspension after the race but it is now repaired.

[Drujba]

BTW I also bought a low transfer case gears fro the Pajero from
Marks4WD last year but never got to install it because of the still
death wobble problems, now I plan to install it. I have the
instruction sheet but I don't have pictures or videos of the
installation. Is there anywhere in the net that has a more detailed
instruction sheet or video. Any help would be very much
appreciated. Thank you in advance.

Hi,

I also got this kit from Marks4WD, and chose to install it in a professional workshop although I am quite good with mechanics. You have to trim a little bit the aluminum case and there are some fine adjustments which must be done. For the money I paid for it (including transport to Romania, custom duties etc) it did not make any sense to risk anything. I have it for one year already and I am quite happy with it. In 1st gear while in low I have the impression that I could climb the walls with it

[monmendoza]

Hi,
I also got this kit from Marks4WD, and chose to install it in a professional workshop although I am quite good with mechanics. You have to trim a little bit the aluminum case and there are some fine adjustments which must be done. For the money I paid for it (including transport to Romania, custom duties etc) it did not make any sense to risk anything. I have it for one year already and I am quite happy with it. In 1st gear while in low I have the impression that I could climb the walls with it

Hello Drujba, Thanks for the reply.

You might have some pictures of the install? Any would help. I just want to gather all information
before asking a professional mechanic to install it. I will do the installation after the repainting
of my Pajero.

[Drujba]

Sorry, I do not have any pics taken during the installation. Another plus is that now I roll 33" muds with my standard 4,88 diffs.

[monmendoza]

Weather has been good today. No rains. So topcoat have been
applied on the Pajero.






By the end of the week, we expect the Pajero painting to be
completed. I will then proceed to replace, oils in the transmssion
and the engine, Have some minor leaks in the winshield rubber
fixed and install the low transfer case gears from Marks4WD.

[monmendoza]

Finally, I opened the box of the Marks4wd low TC gears for the
Pajero which I bought last year from Marks4WD.
The objective is to increase the crawl ratio.

expected crawl ratio with 2.85 gears and 6.17 (LC40) final
drive ratio is approx. 70.

[fondente]

I'm thinking about it... 3.15 low gears for my 2.8 Tdi...

Mom... your Pajo looks very good !!!!

[monmendoza]

I'm thinking about it... 3.15 low gears for my 2.8 Tdi...

Mom... your Pajo looks very good !!!!

Thank you Fondente.

3.15 low gears for a 2.8Tdi will give it even more grunt and huge amount of torque.

[monmendoza]

After 4 months, I finally have time working on the Pajero and
installed the Low TC gears from Marks4WD. Initially we had
problems installing it , mainly because the installation guide
has no pictures, but eventually with a few emails from the
manufacturer , we were able to install it properly.

Here are the old gear set from the Pajero.



We also started cleaning the carb and changing all the fluids,
install new stereo and central locking and checking if the
front rear ARB lockers works, in preparation for a test run this Thursday.

Finally it is now ready for the trails after 2 years.

[monmendoza]

We trailed the Pajero for the first time last week and I was
happy with its performance. It has a very high torque and
pulled out a Patrol, a ford everest and a feroza effortlessly.

Here are some pictures:






I also noticed that there is a slight leak in the water pump. I have
to replace this water pump before I bring it out for its second major
trail.

[monmendoza]

Today,

I removed the water pump and the vacuum brake booster. They are
both not working properly. I will be sourcing out new parts. Hopefully
this will be the last of the small nitty gritty items I have to replace
before my Pajero is mechanically sound and reliable.


BTW my mechanic said the barke booster is defective.
Does anybody in the forum know how to test if the vacuum
brake booster is good or defective?