Mitsubishi tperkins' 1999 Mitsubishi Pajero

Discussion in 'Members Rides' started by tperkins, Aug 21, 2018.

  1. tperkins

    tperkins Devout AYC Disciple

    Joined:
    Jul 3, 2013
    Messages:
    640
    Location:
    Slave Lake
    Next was addressing 4wd shifter. I could not for the life of me get it into 4 low, couldn't figure out how to do it, and so I got to reading and found a common issue with a bushing in the shifter deteriorating to nothing. Sure enough, mine was missing entirely, and only some chunks of the old one remained.

    I needed to remove the shifter, which shouldn't have been a big deal.. but I guess I didn't read enough because I made quite the mistake.

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    It turns out that those "studs" aren't actually studs. So, when I removed the shifter, I noticed one dropped down a little bit. As quick and gently as I could I put nuts onto two of them, but when I touched the third one it just dropped and I heard a splash. Dropped a bolt right into the top of the transfer case.

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    So, getrag trans as far as I know, I don't know who to blame for this design. But I do blame myself as well.
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    Guess which one fell.

    I eventually got the bolt out, but talk about stress lol. I tried from the top with magnets to no avail. I removed the drain and fill bolts and searched around in there with magnets to no avail. Finally, I removed an inspection cover on the transfer case and it was sitting there right at the bottom. What a roller coaster, I was sure I was going to have to pull the t case.

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    Of course I didn't have that gasket, and i went and tried to make a new gasket from felpro material I got from the store, but on a sunday without a punch I couldn't get the holes right without having burrs. I tried drilling them, then tried sandwiching the gasket between two boards and drilling through everything, still didn't really work. In the end I took the advice of people who have done this exact thing and just cleaned everything really well an used black permatex. A week later it is still bone dry so I would say that was successful.

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    First look at where the bushing used to be, you can see chunks of red in this picture as well as the one showing the studs.
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    New bushing:
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    The 97-99 gen 2.5 (blister fenders) are plagued with this bushing. Years prior were a white poly bushing which didn't break down in this same way. Those shifters are interchangeable, but I got the new bushing for 9$ off amayama. Disassembly of the shifter itself was pretty straight foreward, but I had to bring it to a machine shop and borrow a press to get the pin that holds the bushing out.

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    After all that, shifting in the t case feels good as new, very crisp.. and I still didn't know how to get into 4 low. If you look at the shift lever, seems to be a magical step to get into 4llc (4 low lock)
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    Turns out you have to push the lever down about an inch, and them move it frontwards.

    I also broke the cup holder basically immediately, but was able to find a new OEM one and put it in the other with some gaskets, plastic clips, etc. Things I knew I would need to replace doing the shifter and clips I expected to break doing the stereo.

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    I also was given this cup holder that just slides into the seats, which I use now.
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    And finally I installed a 400w oil pan heater. I am going to get a timer so it turns on an hour and a half before I typically start it.

    Out on the lake after all the assembly!
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    Next to do is install a cell phone booster that I got for Christmas.
     
    IanB and RyanV like this.
  2. Dah_Hunter

    Dah_Hunter Looking over your shoulder, so you dont have to.

    Joined:
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    Wow that would have got me scared, dropped that Stud into the T case.. Glad everything was found. and things back together.
     
  3. tperkins

    tperkins Devout AYC Disciple

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    After dropping it we had Christmas celebrations, so I had to think about it the whole time. And after being unsuccessful with both magnets and all day I was just thinking about how much it is going to suck to drop the t case. Brutal.
     
  4. tperkins

    tperkins Devout AYC Disciple

    Joined:
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    Location:
    Slave Lake
    Installed a cell phone signal booster that I got for Christmas,

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    The antenna that came with it is very low energy and sad, I was recommended to get the upgraded antenna, and I decided to fender mount it so that it wouldn't get wiped off the roof by branches. For those with a 2nd gen Pajero (lol) a 2017 super duty mount works a treat, just needed to massage hole a bit.

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    Ran wire through firewall, had to drill a hole, was sad. But I painted it, rubber grommet, silly cone to keep out the moistures
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    Mounted auxilary 12v on passenger door kick.. might make it work with a switch later that can be used when vehicle is turned off, for now it works just with a the key.
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    Made use of cassette holder under passenger seat
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    Little cutie antenna
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    IanB likes this.
  5. IanB

    IanB New Member

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    Location:
    Winnipeg, MB
    Good job on getting that stud out of the TC, that would have sucked!
     
  6. tperkins

    tperkins Devout AYC Disciple

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    Location:
    Slave Lake
    Yeah, it was a pretty annoying and scary moment.
     
  7. tperkins

    tperkins Devout AYC Disciple

    Joined:
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    Location:
    Slave Lake
    Well, I have put about 14,000km on this unit so far. Trouble free so far.

    Annoying thing happens when snow melts off the side and drains into fuel cap, which freezes closed.
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