Outer Limits 4x4 Board

There are many claims of Pajeros having 5th gear problems, but searching here and the Pajero Club Forum doesn't reveal a huge problem. I'd like to try to gather as much information about this into one thread - here.

From the Tech thread (thanks Frank ) Pajeros have had

KM145
V5MT1
V5M21
V5M31
V5A51

What have Tritons had?

As far as I can tell, early Pajeros were pretty bad - I presume that was the KM145 trans used behind NA-NG 4 cylinder engines (petrol and diesel.) Mitsubishi were reportedly aware of this, and doing something about it. Is it still a problem today?

I've also read first hand reports of 5th gear troubles with the 5 speed autos (V5A51) - but not many of them. I don't think there's many of them on OL...

I found one first hand report (in the Pajero Club Forum) of an NL 5 speed dropping 5th gear - I presume that was the V5M31.

Other than that, claims are a fairly generic "problems with 5th gear" without any details.

Are all these gearboxes really as troublesome as they are reputed to be, or is it all a hangover from the KM145? Are the problems so widespread that nobody bothers to report them anymore?

People, please post up your experiences with these 5th gear problems. I'd prefer to avoid the urban legend "friend of a friend" or "I heard of a bloke" type stories. Ideally, a specific vehicle you know, including its model or year. Triton/L200 and Express/L300 are welcome to join.

What have you got?

Scott

Have had to replace that little bush on the end of the gear stick a few times
Gates are notchy so it keep chewing them out
Be carefull that the bolts retaining the gear stick are not too long as the foul with the box internals locking out 5th and rev
cheers
wayne
89 triton with one foot in the grave Died on Sat night



And there is three different clutch bearings that I have come accross
Replaced the clutch twice and both time had to fit the original bearing as each kit come with a 'shorter' bearing, and both them were different

Check the Exidie(sp?) book myself and they listed two and said that they were interchangable?????

Apparently they changed something with the clutch mid 89

And...
The early shifters are a metal cup/ dog bone arrangement which breaks
Swap it for a later model one (metal cup nylon ball type)



Checked my compliance plates KM145 4625



Edited by NJ SWB 3 April 06

Scott, it was the KM145 that was notorious for dropping 5th gear.
The reason we don't hear about it much these days is that most have been reco'ed with an uprated kit.
Some went as early as 50,000k's but between 80-100,000 was the norm.
The later V6 gearboxes are pretty good but have a reputation of being notchy.

Those gearbox are a really good units, my Montero has 310.000 km on the clock without any problem. I change the gear oil every 35.000 km and I have used 80W90 GL5 Shell since new, also I check the oil every 10.000 km looking for water

mine's done 210,000km and so far the only probem is shifting from 1st to 2nd on those cold mornings down here in tassie. It is ia bit noisy in 5th gear at 100-110kph but i'm not sure if its in the tranfer case or the gearbox.

Only issue I have ever experienced is trouble getting reverse. Got stuck at work once where I could not select reverse at all and had to mount the gutter (yes - the jabber is cabable of gutter crawling) and drive down the shop fronts to get home. In the end found out it is a selctor problem - so not really a gearbox problem.

On the underside of the control housing (where the two shift selectors are attached) there is a small bolt on piece called a transfer case gearshift bracket. Over time and use the tongue on the bracket forms a bur that eventually stops or inhibits the selection of reverse. To fix is a simple case of unbolting and removing the levers and removing the bur off the tongue (or fill with weld and smooth or just replace if parts available)

I've cleaned up the thread a little, for adding to the FAQ. Please keep any experiences coming.

Cheers,

Scott

I worked for Mitsubishi as a detailer back in the early 80's. From memory the problem with the 5th gear was a nut needed to be torqued up tighter. Most where done under warranty during a service.
Toyota loyal press made a bigger story out of it than it really was. In those days I think only top model Hi-luxes had 5speeds. And we always had Pajeros on back order.

hey
I'm from Israel.
I have L200 4x4, 2.5 disel engine (4d56) 1997 model, with31" wheels.

the transmission is V5M21 as far as I know.

I do have 5th grear problems, @ 250K km the transmission was opened and the 5 th gear was replaced due to broken theeth after load noises were heard from the transmission.

after more ~10K km the problem now repeats (load noises when using the 5th gear) and it seems like I need to find and replace a new transmission.

I'll be happy if anyone can advice about this problem and how to avoid it before I replace the transmission.
Does 31" wheels help to create the problem?

thanks for your help and information.

Zohar

Hi Zohar
I have a 95 L200 4D56T and the box died at 250,000, I dont know if it had been done before but going on their reputation I fitted a box from a coil sprung rear Gen1. Drive shaft lengths were the same and the transfer was the same, ie no super select, but the box was the later cast iron 1.
There seemed to be a difference between low range levers, I had to use the 1 that came with the stronger box.

Thanks J top
Can you tell what type of gear box you used? (serial number) is it from a pajero ?
A photo of the new box you used will be excellent.
The boxes I found here have the clutch piston connected perpendicular to the one I currently have (between the flywheel & the bellhousing).
What was the main damage of the last box you had? Is it the 5th?

Thanks

Zohar

My first KM145 was eating up its 3rd gear, but I made it last several years before I finally changed it. It was pretty noisy, but all gears worked fine right up til I pulled it.

The second KM145 (currently in the rig) was taken out of a junker. It sometimes slips out of 1st when going from a standing stop and 3rd gear takes some patience shifting into when up-shifting. It was cheap and is really quiet. I'll probably be changing it out with a newly rebuilt tranny, though.

Despite the issues both had, both worked in all gears and they both had a substantial amount of punishment thrown at them.

Not trying to say the KM145 is actually a good tranny...I know it's not...just sharing my experience.

Dont know if it helps but the miss 99 paj has a superb box in it.
Very smooth no notchiness havent had any problems at all and occationaly it tows around buggys on a car trailer. So its had a work out. Current klms 197000

I have a V5MT1 in my truck with almost 300k km's on it and it's fit as a fiddle. The last 30.000 on 36" and 38" tires.
The KM-145 was supposedly fixed around '89 and most of the 90 and 91's over here never saw that problem.
The thing I've noticed is you must use Hypoid grade gear oil of the right viscosity, I once used regular 80-90 gear oil and it burned up in a couple of months. That goes for the V5MT1 not sure on the old one.

I have an '88 import LWB with the 4D56T engine and 5 speed. One of the smoothest, easiest to use
'boxes I've driven. Odo has 257K on it so it's been around the block once or twice! I think I recall reading
somewhere that the Japanese home market Pajero's had different gearboxes to the official Oz imports?

I'm a truck driver, and this 'box feels like a good 'un.

Bit hard to tell with no Aussie compliance plate, and the existing engine bay plate in in Japanese

Cheers Will.

Hi, I have a triton glx 2.8lt diesel 2002 model 4x4. Had since new. 5th gear had a loud wine for a couple of years & at about 250k klm the whole box shit it. Took it to gearbox specialist & was told it had no oil in it. Seemed odd because it had never dripped oil & was clean underneath. But who was I to argue. A rebuild was required. I had the rebuild done. Box worked ok but 5th gear still had considerable wine. They had a second go with same result. Then they rebuilt another box & swapped it over. Been going good ever since. Now 332k klm. Last week went to shift from 5th to 3rd & couldn't. Could not get 2nd, 3rd or 4th. Went back to 5th, luckily was on a downhill. 5th gear was wining again. Got to town 5 minutes later & all gears were working again. ?? Haven't had it looked at yet.

I wonder if the modern boxes are under engineered? They are all most likely designed by computer, whereas in the earlier days
things were over engineered just to be sure!

Certainly makes one wonder....................

One habit truck driving has taught me is to go up and down the box through all the gears, unless I'm stopping from a very low speed on the flat, then it's angel gear and coast to a stop with the engine idling. Saves fuel and wear on the clutch too

Cheers Will.