Pajero Mk1 Tourer build-up

[Cruisn]

Well, after sitting and thinking for quite sometime I have decided to keep my Pajero and modify it to be a self sufficient long range tourer. I chose to keep the pajero due to its reliability and ease to fix.


A few goals I have so far are:
-1500km Range between fuel stops
-enough battery power for 48 hours rest stop with out starting wagon
-comfy to drive a/c must be maintained

The work not pictured to date is standard maintenance that would be needed. repack the bearing, brakes. overall good clean.

Mod 1 - 2"/50mm lift - allowing to still be reliable yet give me that little extra clearance.

Well I got my lift installed today, 50mm toughdog kit.

50mm medium duty springs - good for 300kgs of weight in the rear.
41mm foam cell shocks on all corners

It started off great installing springs and shocks in the rear....

then it took a turn for the worst, I get underneath to crank up the torsion bars and find that 1 side is already cranked to the max... but no achieving anylift..

Run to the wreckers and get a spare for 110. auz dollars

start installing new bar.... removing the front bolts caused them to all strip..

Walk to bolt shop in blazing heat with no clouds in the sky..

get 2 dollar bolt and return. finish lift.
45mm front lift so far, will turn it up another 10mm max to level it out a bit
the rear is at 70mm lift right now till it settles. I am very happy with it.

The rear:
http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/liftedstart.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/toughdog.jpg

And then I noticed....
http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/wrecked.jpg

Junk bar.. could be used as a beating stick or extra long paper weight
http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/oldtor.jpg

All done, with exception of settling and 10mm front raise to go.

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/pajerolift.jpg

All leveled out:
Fixed the front end lift issue, got it as level as I can safely do with torsion bar fronts. the back should sag about 10mm still.

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/leveledsorta.jpg




For the Inside:

Went online today and found an 80L Waeco fridge for sale for 900.00 so I went for a drive to check it out and ended up taking it home. WOOT WOOT.

http://i898.photobucket.com/albums/ac186/CRUISN06/waeco2.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/waeco.jpg


Roof Top Tent
Got my roof top tent today. got it installed on the new roof rack I built. the rack is not finished as we had to be able to live out of the tent in about 6 hours since we are out of a place to live till wednesday.

looks good all installed. will have opened photos tomorrow. after opening it up already I was to aggrivated to take photos.. LOL. there was a lot of guess work.

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/rooftop.jpg

a little closer:
http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/rooftop2.jpg

[Jnich77]

Nice rig man!!!

[Ozarker]

Very nice! How do you plan to get 1500 km range, would'nt that be about a 50 gal. tank? Or with cans? And what's your electrical plan? Wished my 89 was a LWB, the extra room would be nice.

[Cruisn]

Very nice! How do you plan to get 1500 km range, would'nt that be about a 50 gal. tank? Or with cans? And what's your electrical plan? Wished my 89 was a LWB, the extra room would be nice.

146L long range tank. then add a few jerrys to the roof if needed.
For electrical I will have a deepcell in the engine compartment with a fuse box in the back area. then run all wires form there.

Roof top tent setup:

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/setup.jpg

There is a lot of room inside. very comfy to sleep in.

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/setup4.jpg

[fangars]

What did you use for the roof rack mounts?
http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/rooftop2.jpg

[Cruisn]

I used the gutter, like most people use..

[Storz]

Great looking truck!

[bitoy]

Very nice ! Keep us posted on the build. Good luck in your adventures.

[Cruisn]

Well, we had to test the tent out along with awning, so lets go camping!! went to wedge. caught the brunt of a cyclone whilst out there. that was sure intersting. but a great time. everything performed top notch.

next mod to do will be getting a deep cycle battery mounted with dual battery system.

http://i898.photobucket.com/albums/ac186/CRUISN06/164821_10150174950537995_664842994_8579983_5879237 _n.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/167169_10150174949737995_664842994_8579974_7416818 _n.jpg

From this weather-
notice beach width:
http://i898.photobucket.com/albums/ac186/CRUISN06/180232_185378868160753_100000659222872_492641_3892 328_n.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/166803_184293984934982_100000631442918_480381_5118 409_n.jpg

To this less than half an hour later:
http://i898.photobucket.com/albums/ac186/CRUISN06/164706_185379321494041_100000659222872_492643_7813 617_n.jpg

notice how the storm surge almost wiped the whole beach away
http://i898.photobucket.com/albums/ac186/CRUISN06/166485_10150174952742995_664842994_8580017_2049933 _n.jpg

[Cruisn]

Well, I figure the key to easy wiring is mostly plug and play, and keeping all options added seperate of the stock harness for a power source. so I was given this awesome fuse box setup by a good friend here in perth. lots of options for current output, and is plug and play at each end. keeping it as simple as possible.

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/fuseboix.jpg

Fuses are
4 x 7.5amp
4 x 10amp
4 x 15 amp
4 x 20amp
4 x 25 amp

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/fusebox.jpg

[Cruisn]

Detailed yesterday, still have to finish the interior. its been a long time since it was waxed I figure. made one hell of a difference.

Still needs a few touch ups on the body and underneath. will redo the wheel wells with rock gaurd and redo the mud flaps.

http://i898.photobucket.com/albums/ac186/CRUISN06/wax3.jpg

After:
http://i898.photobucket.com/albums/ac186/CRUISN06/wax1.jpg

Before:
http://i898.photobucket.com/albums/ac186/CRUISN06/wax2.jpg

After:
http://i898.photobucket.com/albums/ac186/CRUISN06/wax4.jpg

Full body shot:
http://i898.photobucket.com/albums/ac186/CRUISN06/detail.jpg

[Cruisn]

Well, it seems the diesel is to fuel of choice for long range touring, let alone dealing with water. I ended up picking up a 2.5L turbo diesel wagon this weekend to swap motors with. 500 bucks needs a head gasket and a new clutch. easy enough.

pulled hte head off yesterday, in great condition.

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/16042011061.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/16042011060.jpg

donor pajero:
http://i898.photobucket.com/albums/ac186/CRUISN06/Powerlines%20feb%2020%202011/edit19.jpg

[Cruisn]

A little more progress in the engine.

Got the parts cleaned at work in the robowash. did a great job.

The underside of the head is still a mess. but when I get it planed that will all be gone.

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/18042011064.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/18042011065.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/18042011067.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/18042011068.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/18042011071.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/18042011072.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/18042011073.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/18042011075.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/18042011076.jpg

[Cruisn]

Got A cb radio, going to redo the headliner and then build a roof console for it today. enthusiastic for progress, but we all know how south thing can turn. LOL

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/183190_10150402205395061_591460060_17386325_419353 5_n.jpg

[Cruisn]

Well, got a bit more done to the Pajero today. mounted the fuse box for power, and redid the roofliner, well a partial anyways, might jsut go the rest of the way now, I like the new colour better. its easy enough to install. I wil touch up the sides, that was my fault for not making sure it was 100% centered upon install... oops

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/stripped2.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/stripped.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/sortadone.jpg

Fuse box isntall:

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/perfectplace.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/fitup.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/mouting.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/fuseinstall.jpg

[Ray Hyland]

awesome build, keep it coming.

Any plans for the first big trip when it's done?

Are you going to build a storage/drawer system?

[Cruisn]

awesome build, keep it coming.

Any plans for the first big trip when it's done?

Are you going to build a storage/drawer system?

I am starting the rear storage tomorrow, Material showed earlier this week, jsut didnt have time to start it today, as the guy with the shop keys showed at 2pm... bahh.. forget that. will be starting at 7am tomorrow for a good start. then if I need anything I can get it while stores are still open.

The first big trip will be to finish our lap around australia, our first bit we went from brisbane to perth via all the central gravel roads aka - middle of nowhere. jsut the way we like it, as the wagon sits now it can head on out on a cruise, but i jsut want a few creature comforts, like a fridge, and a nice sleeping arrangement.

The next leg will either be to ship the wagon back home to Canada and go from the arctic ocean to the tip of south america or we will ship right to brazil, and drive home, which woul dbe pretty cool to.

[Cruisn]

Well, got a little more done today, I started off with cleaning up my wheel wells and cleaning the wheels since they have been neglacted quite badly.

The wheel wells show no rust, but the old coating was chipping away and I figured it was time to get in there with a wire wheel and peel the rest away then recoat.
turned out not to bad, I am happy with the looks.

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/cleanming.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/rubbercoat.jpg


Wheel cleaning: This part I like, they turned out amazing. im scared someone will pinch them now... *shifty eyes*

Before:
http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/before1.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/before.jpg

After:
http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/after1.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/after.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/nice.jpg

Start of fabbing up a drawer system, using 25mm square tube 1.6mm wall. very light, but strong to work with.

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/fabupstage1.jpg

Will be back in the shop tomorrow to get more done on the drawer system. hope to have it carpeted by tomorrow. the drawers will ahve to wait a bit more. still sourcing sliders.

[Ray Hyland]

looking good.

[Cruisn]

Pretty happy with todays progress, got the top of the drawer system finished, which is a miricle in itself as I cannot do carpentry to save my life... but give me some steel and I can make a work of art.. intersting... LOL

Started with a test fit:

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/testfit.jpg

Then I did some carpeting:

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/carpet2.jpg

Installed:
http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/top2.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/top.jpg

little side doors:
http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/sidedoors.jpg

[RU55ELL]

Very nice Pajero! :sombrero:

[off-roader]

Not sure how tall you are but I'm short enough that I can easily sleep in back of my 96SR so I built a folding bed platform to allow me to do just that. It may be worth considering for your build up.

Here's what mine looks like in back....:ylsmoke:
http://i405.photobucket.com/albums/pp137/offroader_ii/DSC_4576.gif

So far I've had it on some pretty rough trails w/out a hiccup.

[Elliot Press]

Stoked to see this thread. Wanna help my mate set up his Paj for touring...and we're in Perth too. This will be a helpful thread.

[Cruisn]

I will be removing the middle row to build more platform for storage and such, since its only me and my girlfriend.

elliot, what are working on? what year? start a build thread too maybe?? would be intersted to see it.

on other news, jsut ordered a deep cycle battery, battery isolator, led strip lights, and gasket kit for the diesel engine.

[Elliot Press]

elliot, what are working on? what year? start a build thread too maybe?? would

Can't quite remember what year it is. It's a 3.0 L V6 I think. We took it away with my Toyota aswell on a big trip down to Bremer Bay and up far North last years. He's a video with some footage of it. It's basically a stock rig. He's been overseas for the last 6 months and now he's home (just arrived) we can hopefully start working on it.

YouTube - Preview video of our epic trip around WA

I need a new rig too. Retiring the Toyota. Don't know if a Pajero is the thing for me. Are the turbo diesels anygood? I refuse to go petrol for expo rigs.

[Cruisn]

Nice video.

more parts arrived
Got my led strip lights for under the awning.

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/ledfarview.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/ledsclose.jpg

[Cruisn]

New goodies for the wagon, A complete front end rebuild less bushings. LOL might order a new set up since I am in there. not sure though. either way tight steering will be nice.

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/rebuildfrontend.jpg

And what is to be my underbody air tank. needs a clean up, but for free you cant complain. with a body lift in place it will sit jsut above the bottom of the frame. so nothing should hit it. its made by cat, so it should be tough regardless.

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/airtank.jpg

[Cruisn]

Today was a good day, still collecting parts right now. but that is still good.

Got a deep cycle battery, 105amp hour heavy duty
http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/deepcycle.jpg

And an isolator to control the dual battery setup:
http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/selenoid.jpg

Relay, this part was free!! thanks to the electricians at work for this one, it is to control the pressure switch that will run my air compressor and tank setup. I have a spare air con pump, not sure if I want a belt driven pump that can really crank out the cfm's or run an arb electric compressor.
http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/relay.jpg

And the engine goodies, top end gasket kit for the diesel engine. cant wait for this part!!!

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/tropendgasket.jpg

[4D55 Performance]

What type of roof top tent is that? Also what type of awning are you using?

BTW the rig looks great.

[Cruisn]

pinnicales camping tent. works great love it so far

[Ozarker]

Nice to see what the new parts look like, mine are difficult to identify, LOL

[Cruisn]

I am going to guess yours is a 90ish too.. with a few oddball parts..

[Cruisn]

Was out and about this weekend and decided to try out the annex, easy to set up. lots of room. looks great

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/annex4.jpg

Straps to hold up the ladder:
http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/annex2.jpg

lots of room:
http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/annex.jpg

Some new goodies!!!

arb air compressor and fill kit:

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/arbgoodies.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/arbpump.jpg

The weekend photos:
http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/foggy3.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/mud2.jpg

[Cruisn]

No photos yet, but rewaxed it today, looking sharp. also ordered a few new goodies

ordered:
1m long fibreglass uhf antenna - should be here this week
safari snorkel - will order tomorrow with return of email request

Diesel status:
Some more bits have been ordered, inlcuding
heavy duty exedy clutch kit
oil pan gasket
and since the engine is out it will get new front and rear seals
rig is getting towed to its new home to be stripped monday night.

Also have lower control arm bushings on the way, then I can finally install all the new parts.

[Cruisn]

Well I got my uhf antenna today, 1025mm long. woohoo, looks a little big form the photos, but its not to bad, about roof rack height so that works fine for me. I like it.
It will be moved to the pass side, but right now there is an old base stuck in it that I have to cut off form the previous owner of the bull bar

gme 6.6db gain

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/antenna2.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/ANTENNA.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/antenna3.jpg

[snakedoctor]

Amazing job and gret looking rig man!

[Cruisn]

Well she got a good wax, camera phone jsut doesnt do justice. to bad it has rained since...

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/13062011160.jpg

And the Donor arrive to be stripped!!! Woohoo

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/13062011162.jpg

[Cruisn]

Well got my oil pan gasket, front and rear seals, ordering a new set of headbolts and bottom gasket set for the timing covers and such. almost have everything to freshen the engine up.
Also recieved my lower control arm bushings!!

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/oilseals.jpg

[Cruisn]

I have begun stripping the donor this weekend. am going back today to pull more apart. should have the engine ready for removal by next weekend. (fingers crossed)

Inspecting wires as I pull them out.. makes it slightly more painful process, but and faults I can pick up on

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/stillstripping.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/wiresout.jpg

Turbo removed:
wastegate and actuator are all there.. but the bypass is welded shut, intersting move by mitsubishi, not sure what year the activated the wastegate though, will have to do some digging, my guess is 89 when they introduced the intercooler. The turbo will receive a rebuild as it leaks a small amount of oil.

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/tuebo.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/wastegateclosed.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/actuator.jpg

[Cruisn]

Well, went insane ordering new parts.

have on order now:
Iron man recovery kit
lower gasket kit
turbo rebuild kit
Safari snorkel
switches
repair manual
head bolts
Nolathane sway bar bushings


and of course what kind of update would this be without something pink!

My exedy heavy duty clutch arrived. woohoo. thanks to bakerboy for hooking me up.

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/pressure.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/disc.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/clutch.jpg

[Cruisn]

More parts!! woohoo

My turbo rebuild kit
http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/turborebuild.jpg

And the head bolts:
http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/headbolts.jpg

[Cruisn]

Engine is out!!

woohoo. wasn' t to bad of an ordeal to get out. found a few faults to go along with out, but that was expected. nothing to major. all maintenance really.

Gotta have the goods right? Jackie packed me a lunch and I have my tunes. away we go!!
http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/jackiecares.jpg

And away we go: I move it in and out of the shop with my pajero! steel bullbars are awesome sometimes. LOL
http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/stripping.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/start.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/progress.jpg

Power steering and oil cooler removed: diesel oil cooler is 2x the size of the patrol version
http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/powersteering.jpg

Radiator removed:
http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/radout.jpg

Driverside stripped:

http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/unhookeddriverside.jpg

Drive shafts removed:
http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/driveshaaftsout.jpg

Gear shifters removed:
http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/gearsticksout.jpg

Engine hoist in place!!!
http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/herewego.jpg

You will notice that the bullbar is removed... couldnt get the hpoist in close enough.
http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/emptybay.jpg

I noticed this stream of oil from behind the headlight after removal... almsot looks like a stream of tears after I tore her heart out... how poetic..
http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/tear.jpg

Block out:
http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/blockout.jpg

Intersting find with the clutch, factory pressure plate, exedy clutch disc, intersting, quite burnt, looks like it was replaced without machining. crack in the disc itself, the pressure plate had seen better days to, the throw out bearing was eating it away at a nice pace.

Worn disc:
http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/disc.jpg

Crack:
http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/crackedclutchplate.jpg

Heat scorching:
http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/burnt.jpg

Throwout bearing wear marks:
http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/heavywearpressure.jpg

[Cruisn]

Bottom end gasket kit arrived:

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/bottomendgasketkit.jpg

[off-roader]

Well, went insane ordering new parts.
...
and of course what kind of update would this be without something pink!
You did go crazy with that LOL... especially the pink!:bike_rider:;)

[Cruisn]

Today was about cleaning the block so there was no oil on it, it will get a full reseal so there will be no more oil leaks... Thanks to Dan for showing up and giving me a hand. turned out not to bad:

http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/lclean3.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/clean.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/clean2.jpg

The tranny/transfer case were not so easy.. here is a start, it is sitting overnight with degreaser on it so tomorrow I have a better shot at cleaning it again...

http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/clean5.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Engine%20Swap/clean4.jpg

[Cruisn]

Was an excellent week for new parts arriving!!

Started with my maps showing up: canning stock route, anne beadell highway and wa's top 50 treks.

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/watop50.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/canning.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/beadell.jpg

Then my led light up switches arrived:
http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/switch.jpg

Iron man recovery kit:
http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/recoverykit2.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/recoverkit.jpg

Repair manual, pdf version. everythign I need for the diesel at least.

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/repairmanual.jpg

The best for last, My safari snorkel, been waiting a few weeks for this to arrive. cant wait to install it.http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/safari3.jpg

Its legit: no fake stuff here
http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/safari2.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/Pajero%20Mods/safari.jpg

[Cruisn]

Well, washing parts then working soaked for a few hours last night maybe was not the best idea. I am sick as today. oh well. lesson learnt. Mainly jsut showed up to clean the tranny/transfer case up. looked okay. I will let it stay this way till it is installed then will hit it with a proper pressure washer at the car wash one day, will have more power.

The oil pan, tranny brace, fan, and fly wheel are in the pajero for cleaning in the robo wash.

All cleaned up:
http://i1196.photobucket.com/albums/aa409/cruisn066/Engine%20Rebuild/tranny8.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Engine%20Rebuild/tranny7.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Engine%20Rebuild/tranny6.jpg

This is the only bit of damage is this torn boot, still looking for a new one.
http://i1196.photobucket.com/albums/aa409/cruisn066/Engine%20Rebuild/tranny5.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Engine%20Rebuild/tranny4.jpg

[Cruisn]

Got a few new parts today, woohoo

Roo lights, 220's with 100 watt bulbs

complete with harness:
http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/harness.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/roo3.jpg

Body lift: 25mm, needed so that I dont loose any clearance with sliders installed.

http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/bodylift2.jpg

[Cruisn]

More new parts, I really have my work cut out for me.

Drawer sliders arrived:
2 sets at 125kg by 810mm for the drawers.
and 225kg slide for the fridge since it has a longer distance to slide out.

http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/sliders3.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/sliders.jpg

opened up:
http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/sliders2.jpg

Sway bar bushings
http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/swaybar.jpg

And for my dual rear tire carrier setup i received spring locks and locks.
for when they are open to stop them from swinging more:
http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/springlock.jpg

And for when they are closed:
http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/locks.jpg

Flywheel was machined to!! can reassemble now:
http://i1196.photobucket.com/albums/aa409/cruisn066/Engine%20Rebuild/flywheel.jpg

[Cruisn]

Well, Second last package arrived today.

My dual spare tire carrier mounts. bearing pivots. I will build the rest. they will hang off the rear bumper. will look good.
http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/dualcarrier2.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/dualcarrier.jpg

Also got my new motor mounts, and a 1/2 torque wrench

http://i1196.photobucket.com/albums/aa409/cruisn066/Engine%20Rebuild/motormounts.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Engine%20Rebuild/torque.jpg

[Cruisn]

Well, this weekend was a bit of a downer.. Got the engine about 60% back together only to finally find the casting numbers.... 4d55... oh noes!! its a 2.3L with a 2.5L top end.. what gives here? I quick phone call and about 4.5 hours of driving later (huge thanks to ron for lending me his Mu with the trailer.) I roll back into the shop with a complete 2.5 along with intercooler, enough parts to build a second motor and a turbo version hood. complete with hood scope.

At least I got my snorkel installed. I like it!!
http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/snorkelon.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/snorkelon2.jpg

What the hood looks like: generic photo
http://i1196.photobucket.com/albums/aa409/cruisn066/1403099039_d871e489e9_z.jpg

[paulleon]

Nice looking truck!!!!
Keep us posted on the build...

[Cruisn]

I am quite tired from this, but making headway, will do a full update tomorrow.

http://i1196.photobucket.com/albums/aa409/cruisn066/Engine%20Rebuild/enginein.jpg

[Cruisn]

Alrighty.. where to start:

I guess with the removal of some more old parts off the donor pajero.

It had 90L of diesel in it. so that was a great excuse to buy myself some steel jerry cans, which I needed anyways... but now there is no guilt behind the purchase.
http://i1196.photobucket.com/albums/aa409/cruisn066/newjerrycans.jpg

And the pedals are out:
http://i1196.photobucket.com/albums/aa409/cruisn066/pedals.jpg


Friday night rolled around and I arrived at about 6pm and started working on the diesel, piecing it together a little more. then Paul arrived at about 9pm, it was a long night of ripping all the electrical out of the 90, along with engine and tranny removal. lots of work. we finished at 4am with an extra set of hands as Ron stayed up to help with removal. A huge thanks to those guys.

Engine assembled enough for install:
http://i1196.photobucket.com/albums/aa409/cruisn066/assembly.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/assembly2.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/cleanedrear.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/rearhousing.jpg

Let the removal begin!!
http://i1196.photobucket.com/albums/aa409/cruisn066/electricalout.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/removal4.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/stripping.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/stripping2.jpg

It was sure nice to remove the computer and all that extra harness. which was great. hook up the hoist and away we go!

http://i1196.photobucket.com/albums/aa409/cruisn066/removal3.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/removal2.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/removal.jpg

It may be 4am.. but at least one of us has a smile!! LOL
http://i1196.photobucket.com/albums/aa409/cruisn066/4am.jpg

Time to clean the engine bay:
http://i1196.photobucket.com/albums/aa409/cruisn066/stripped.jpg

I hate water spraying back at me... solution: wear my welding helmet... LOL
http://i1196.photobucket.com/albums/aa409/cruisn066/cleaning.jpg

Paint the engine bay, And install the clutch mastercylinder and lines

http://i1196.photobucket.com/albums/aa409/cruisn066/cleaned.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/cleaned2.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/cleaned3.jpg

Put that awesome clutch on:
http://i1196.photobucket.com/albums/aa409/cruisn066/clutchon.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/instal3.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/install.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/install2.jpg

And it is in!! Finished saturday at 2am
http://i1196.photobucket.com/albums/aa409/cruisn066/enginein.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/enginein2.jpg

I was out today to do more work, got most of the fuel lines completed, transfer case all bolted up but then started to hit snags...

The drive shafts..
The v6 flanges are a lot bigger then the diesel flanges on the pinion gear shaft. I am going to rotate the shaft 45 degrees and redrill the holes. as for the front shaft, it is about 15-20mm to long, so tomorrow at work I will cut out a bit and reweld.

Then there was a power outage so I was not able to get the shifter sticks installed. so that will be tomorrow.

Both pedals are installed. clutch installed and bled. feels a little odd, soft and the arm that pushes the throwout bearing maybe moved 20mm at full push, and since I never tried the factory diesel clutch I am not sure if that is enough. as the clutch disengages.. or feels that way very clsoe to the bottom of the pedal stroke. normal or no

I feel by wednesday night I will have it running. I need to strip a few parts from the v6 harness for the alternator and starter connectors.

I was going to drop in a diesel tach, but I hate the older model look, so I found a converter to change the signal for the petrol tach. its 65 bucks.

That is all for now... lots of hours were put in.

[Cruisn]

Today was an over all good day.. which is odd...

I started by cutting and shortening the fornt drive shaft, easy to do, took out 15mm should of done 20 but it doesn't foul so it should be okay. you can sorta see my new weld in the photo.

http://i1196.photobucket.com/albums/aa409/cruisn066/frontshaft.jpg

As you can see with the rear drive shaft, if rotated 45 degrees you can redrill the holes and make the 4cyl version work as the centering pin iss the same size.

http://i1196.photobucket.com/albums/aa409/cruisn066/rearshaft.jpg

The fuel tank required some new lines, no leaks, also the electrical for the sending unit is all plug and play.

http://i1196.photobucket.com/albums/aa409/cruisn066/fuellines.jpg

One last issue underneath is that I will need to fabricate my own snubber as the factory does not fit anymore.
http://i1196.photobucket.com/albums/aa409/cruisn066/snubber.jpg

Moving to the interior:
Shifter sticks installed and sealed up.
http://i1196.photobucket.com/albums/aa409/cruisn066/shifter.jpg

And I now have 3 pedals, how cool is that, seeing the clutch pedal reminds me to make a comment that I dont think I bled the clutch properly, I jus noticed the bleeder screw today... oops.

http://i1196.photobucket.com/albums/aa409/cruisn066/pedalsin.jpg

I started playing with the electrical, which meant I had to tear into the v6 harness to get a few goodies I need for plug and play operation. but that is the nice way to go about it, so far the alternator, starter and all lights/sensors are hooked up. I have no wires going to the fuel pump, all I am going to do for that is jsut wire a kill switch to it for a temp solution.

as for the starter, it will not turn over when the key is turned... so I have some digging to do. not sure if it has to send power via the computer then into the harness.. as I have ripped the computer side of the harness out. did the 89/90 diesels have computers?

http://i1196.photobucket.com/albums/aa409/cruisn066/wiring.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/wiring2.jpg

Tearing the harness apart!!
http://i1196.photobucket.com/albums/aa409/cruisn066/wiring3.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/wiring4.jpg

A lot of goodies atached to the engine tonight, alternator/ working on power steering, fan, most belts, rad, oil cooler, oil filter..
I am slowly getting there.
http://i1196.photobucket.com/albums/aa409/cruisn066/motor.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/oilcooler.jpg

And for fun I set my intercooler on to find out how to mount it.

http://i1196.photobucket.com/albums/aa409/cruisn066/intercooler1.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/intercooler.jpg

[MAX1MVS]

Tuned in!!! Awesome build :coffeedrink:

[fatrat]

Yeah sweet build! Keep up the good work! :thumbs:

[Cruisn]

A bit more work the last few days, nothing to much, as I am lacking a lot of sleep lately.
*note to self - 12am bedtimes dont always work when working 10 hour days...*

So basically, I found out that the power steering lines form the 86 pump dont fit a 90 pump, which is not a huge issue as I have driven without power steering before and its a slight struggle but not to bad. I will have to get 1 custom line made.

but all oil and steering cooling lines are run:
http://i1196.photobucket.com/albums/aa409/cruisn066/Engine%20Rebuild/lines.jpg

I have finished bolting all the intake pieces on, less the intercooler. as you can see the wiring is a bit of a mess, some are to short between petrol and diesel since the alternator is lower on the diesel. but I have jsut bought a wire kit, with crimps and heat shrink so I will get all that sorted after it is running. as that will be a nice final touch to clean it all up.

http://i1196.photobucket.com/albums/aa409/cruisn066/Engine%20Rebuild/intake.jpg

Moving onto the fuel filter, I have mounted it to where the charcoal canister sits on the petrol model, not needed anymore so why not? and also the petrol doesnt have the tabs in the proper spot regardless, I am not sure if that is a year difference or jsut a dropped item since its petrol. anyone have a photo of a 89/90 turbo diesel?

http://i1196.photobucket.com/albums/aa409/cruisn066/Engine%20Rebuild/fuelfilter.jpg

grill is back in:
http://i1196.photobucket.com/albums/aa409/cruisn066/Engine%20Rebuild/grill.jpg

better shot of the drive shaft:
http://i1196.photobucket.com/albums/aa409/cruisn066/Engine%20Rebuild/reweld.jpg

Best part, i figure was jsut test fitting the hood, I like the look with the scoop.
http://i1196.photobucket.com/albums/aa409/cruisn066/Engine%20Rebuild/hood.jpg

[Cruisn]

Sorry for the lack of updates, I needed a week off jsut to catch up on sleep. LOL.

Well here is a photo of her all back together.. well almost.
I still have a list of items to sort out

Rear driveshaft - is at the shop getting a new flange put on along with balancing and new universals. dropped it off today actually. so hopefully done for the weekend. I thought I moved past the whole FWD stage... LOL
Wiring: I have all required tools to cut wires and solder them into the factory location.
*I am on the hunt for a 89/90 Pajero wiring harness diagram , let me know if you have one.*
Tuning - it is still not running correct, I have included a start up video so you can hear what is going on. idles like ****, rough. missing. have double checked the timing. could it still be off?
I have also bled the lines and #3 is always putting out a misty foam and the engine rpm doesnt change, bad injector? 1,2 and 4 when the lines are cracked the engine damn near dies.

any help would be greatly appreciated as I am in a bit of a rut. diesels are new to me and I am on one hell of a learning curve.

Moving under its own power: and looking rather badass I may add...
http://i1196.photobucket.com/albums/aa409/cruisn066/06082011235.jpg

Start up video:
http://www.youtube.com/watch?v=vdcnxyhFl3w

And a few more goodies arrived:
my gps receiver. getting a netbook, with 10" screen and ozi explorer for mapping software. and will make a bracket for it to sit off the dash.
http://i1196.photobucket.com/albums/aa409/cruisn066/gps.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/receiver.jpg


Thermostat finally arrived:
http://i1196.photobucket.com/albums/aa409/cruisn066/thermo.jpg

And the big ticket item, long range fuel tank #1
132L vs factory 92L with no lost clearance.

A few flaws though, some welds have porosity and pinholes, along with some cold lap. its hold pressure according to the manufacturer, but honestly, I am not impressed. as it may hold pressure sitting still but after 1000km's of corrugations I am sure that those fail points will fail, leaving me stranded with no fuel. I have tried to contact the company who keeps telling me they will call back but never do... I am not impressed, tank is covered in weld spatter too. I am going to get them to give me a ro for getting it repaired and will reweld the main seals myself. then I can at least trust the welds. Not impressed at all with the customer service after dropping 950 bucks..and yet most companies here wonder why people order from china and the states.. "but what about customer service?" well... I am not getting it here, so what does it matter where I order my parts from..

http://i1196.photobucket.com/albums/aa409/cruisn066/tank.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/tank2.jpg

[off-roader]

...will make a bracket for it to sit off the dash.

A couple of the simplest bracket solutions I've found is this...
http://i10.photobucket.com/albums/a122/srv200/Junk/002.jpg

or a variation of this but for the Gen I's guage pod cluster (add a 1/4" plate as a spacer/riser so it's the same height as the dash)...
http://inlinethumb35.webshots.com/12194/2309803150104986527S600x600Q85.jpg

(without the netbook)
http://inlinethumb55.webshots.com/3318/2449143270104986527S600x600Q85.jpg

[rxinhed]

Nice to see OffRoader's Montero on two continents, huh? :ylsmoke:

[Cruisn]

Well.. the woman is gone back to Canada for 1 month, so that means I have a bit more time on my hands...

So, metal fab projects all this week.

about 3 hours +paint to go then the roof rack will be good to go:
http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/roofrack.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/roofrack2.jpg

[Cruisn]

Custom driveshaft arrived today, thanks to cam for picking that up. appreciate it. although the note was rude.. LOL.
http://i1196.photobucket.com/albums/aa409/cruisn066/Swap/wtf.jpg

ends changed for proper bolt pattern, along with balancing and straightening. new u-joints to match.

http://i1196.photobucket.com/albums/aa409/cruisn066/Swap/driveshaft.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Swap/driveshaft2.jpg

And since I am having clutch issues with it leaking. I bought a new master cylinder, jsut waiting to order a slave cylinder to match.

http://i1196.photobucket.com/albums/aa409/cruisn066/Swap/master.jpg

[Cruisn]

Finished the roof rack. I like it, will definitely do the job.

http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/paint.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/paint2.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/paint3.jpg

[Cruisn]

Got my roof rack home, I like it, Looks good. thanks to dan for transporting it home while the pajero is out of action.

http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/rack2.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/rack.jpg

It a tight fit... Can only back in, If I put on 33's and 1" body lift I highly doubt I will even be able to fit..

http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/rackinstalled.jpg

[Cruisn]

well, its sunday here in Oz and I have been getting a bit of work done to the pajero. I have a full week off coming up so I am only doing a few hours per weekend. and a bit of custom fab on the weekend. works well for me.

I have installed my new slave cylinder, whihc now holds pressure. so that is another item off the check list. no photo of that, maybe one later.

I also installed the new drive shaft I got, perfect fit, looks great. I am pleased with the quality of the work.

http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/installeddrivesahft.jpg

Moving to the outside I ended up test fitting my new headlight covers, to find that it has a set prior and now there are to big of holes to use now.
http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/lightsurrounds.jpg

But they look good:
http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/cover.jpg

Moving on I also installed the uhf antenna.
A shot of the front end: looking the part now. I am super happy so far. included is a test fit of my new roo light

http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/wagonsmall.jpg

Here is a side shot of the lights, there a little big and protrude a bit. but not to bad:
http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/lightfitment.jpg

Now onto the big purchase!!
58L aux fuel tank, with electric transfer, this one is a huge increase in quality over the main tank replacement. no spatter, great welds, good paint. I am pleased.

transfer switch and gauge:
http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/fueltransfer.jpg

All fittings included:
http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/auxtank.jpg

The tank itself:
http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/auxtank2.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/auxtank3.jpg

With this tank I am now able to carry 190L under the pajero with 40L in jerry cans on the roof rack for emergency.

[bizflats]

that was an amazing ride...

[Cruisn]

Thanks, I guess I need to do a large update since I have a lot more added, but since I was heading out bush, I slacked on the updates.

here is a photo of it all prepped for my trip.

http://i85.photobucket.com/albums/k48/cruisn/Steep%20point/pajerobeachsmall.jpg

[Cruisn]

Has been a while since I updated this thread.

I have almost finished the engine bay, I need a few sensors hooked up still, and to finish mounting the intercooler. but it is coming along nicely and looking quite nice

http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/engine.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/engine3.jpg

Dual battery all wired up:
http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/batteryssetup.jpg

Had to have a custom power steering line made up:
http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/powersteeringline.jpg

I bought a fridge slid, nice to be able to open my fridge up all the way.

http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/slide3.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/slide2.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/slide.jpg

Uhf mounted:
http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/uhfsetup.jpg

Compressor tucked away here for now to see how I like it:
http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/compressor.jpg

And had a weekend out. lots of fun.. except all the cleaning that followed:
http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/pajwatersmall.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/pajhillclimb.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/snatch2.jpg

[fatrat]

http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/snatch2.jpg

That is crazy! :ylsmoke:

[Cruisn]

Well, the weekend is coming.. well not really, but its a great excuse to work on the pajero. tonight goal was a rough mock up of how the led strip lights will sit under the awning and to test light output, I am rather impressed with them. I will soder the wires and heat shrink it all so it never shorts out over corrugations.

In place:
http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/lightsoff2.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/lightsoff.jpg

Powered up:
http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/lights3.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/lights2.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/lights.jpg

A magazine on the ground, taken with no flash, buthand held so deal with the fuzziness.
http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/mag.jpg

And of course a few goodies from milner:
new primer pump as mine was leaking:
http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/pump.jpg

The mystery bag. pedal covers, output seals, pressure sensor, washers, the works.
http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/newgoodies.jpg

And the biushes I need, this will complete my kit of all bushes except the upper a arms.
http://i1196.photobucket.com/albums/aa409/cruisn066/Modifications/bushes.jpg

[fatrat]

Those LED strips are awesome!

[Cruisn]

THe output is great on them.

Bit more work done, I installed soem new 4" speakers in the front, since the old ones sucked ***. these are a lot better, no photos though.

Then I installed some new pedal covers, much better then the chrome racing covers I had,

http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/oldpedals.jpg

new:
http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/newpedals.jpg

Some new parts came in, my 5 way manifold for my breathers, no more water in this guys transmission.. LOL
http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/manifold.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/diffbreathers.jpg

Camp setup, got a new stove, along with a lantern. our campsite is almsot complete.
http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/campsetup.jpg

Running the lights while cooking:
http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/lighting.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/lighting2.jpg

[SOFpirate]

Now that is one well done (but not complete ... what is?) rig. Very impressed sir.

[Cruisn]

Thank you, lots to do still. I have a shop stall lined up so I can put the wagon up on jack stands and get all the running gear freshened up, along with getting the wagon prepped for inspection for the engine swap.

[fatrat]

Bit more work done, I installed soem new 4" speakers in the front, since the old ones sucked ***. these are a lot better, no photos though.

The speakers in my Monty suck & need replacing bad but every time I think about buying new ones something more important pops up.

[fatrat]

Camp setup, got a new stove, along with a lantern. our campsite is almsot complete.
http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/campsetup.jpg

Running the lights while cooking:
http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/lighting.jpg

http://i1196.photobucket.com/albums/aa409/cruisn066/Touring%20Parts/lighting2.jpg

Looking good! Nice kitchen setup.

[Cruisn]

The speakers in my Monty suck & need replacing bad but every time I think about buying new ones something more important pops up.

Tell me about it, the other speakers were flopping around behind the dash for the last 10000km's LOL.

then I seen a set on sale for 30 bucks and couldnt say no.

[fatrat]

I have to turn the bass all the way to -5 on my radio so my speakers don't pop & rattle. LOL!

[off-roader]

Looking nice although IMHO you would have been better served with 5.25" speakers in the door panels versus the tiny OE front speakers. Been there. Done that. Got the tshirt. :ylsmoke:

[Cruisn]

or... I can keep the doors 100% wire free. LOL this is a travelling wagon, not to concerned about loud music.

[off-roader]

Who said anything about loud music? I just want it above the drone of the mud terrains on washboard trails.:ylsmoke:

[Cruisn]

washboard? australia has no washboard... LOL.

these speakers can drown it out though. there not to bad. and after sinking it, I figure keeping all the wires above the bottom of the dash is a good start.

[Elliot Press]

love the mundaring PL pics :)

[Cruisn]

Thanks,

a little update:

hood and lower silver panels are now black. black pin stripe and have ordered a black set of wagon stickers.

most issues have been sorted. all new ball joints and bushes and bearing installed on the front end

I have tyres that should arrive thursday, 33x10.5 bfg all terrains
rolling on n 15x8 black sunnies in a -22 offset. pictures friday with all the new gear installed...

[fatrat]

Looking forward to seeing some updated pics.

[Cruisn]

hey, updated photos:

Alrighty, I figure I am far enough in to this build for a before and after photo:

Before:
http://i85.photobucket.com/albums/k48/cruisn/Australia/trucksmall.jpg
http://http://okayface.com/okay-face.jpghttp://i85.photobucket.com/albums/k48/cruisn/okay-face.jpg

After:
http://i85.photobucket.com/albums/k48/cruisn/Australia/pajeroposesmall.jpg
http://i85.photobucket.com/albums/k48/cruisn/5353awwwyeah.jpg

[fatrat]

That is one bad arse Pajero!

[roaming knome]

I have been watching this thread some time now and seeing all of the modifications and travels that you have been doing. I must say that I am impressed with both you and your Pajero! Your Pajero is indeed one of my favorite Pajero/Montero. Great work too!
The gen 1 Pajero/Montero is still my favorite of them all. I have a gen 1 Montero w/ V6-auto that I want to convert to Diesel as well, and your vehicle is a great example of what I want to do.
Keep up the great work and travels! I will be following this thread.

[Cruisn]

I have been watching this thread some time now and seeing all of the modifications and travels that you have been doing. I must say that I am impressed with both you and your Pajero! Your Pajero is indeed one of my favorite Pajero/Montero. Great work too!
The gen 1 Pajero/Montero is still my favorite of them all. I have a gen 1 Montero w/ V6-auto that I want to convert to Diesel as well, and your vehicle is a great example of what I want to do.
Keep up the great work and travels! I will be following this thread.


Thanks, the diesel swap was quite straight forward. since the engine wiring harness with the v6 is completly seperate form the lights and starter circut. keeps wiring to a minimum. and all the bolts line up to. except the tranny support, you need the 5 speed support.

I finally got photobucket to work up here at camp as uplaod speeds are... well... horrible.

making the msot of the 33's
all hail the Pajero salute:
http://i85.photobucket.com/albums/k48/cruisn/pajeroclimbsmall.jpg

[SOFpirate]

It's a masterpiece!

I absolutely love the rugged go anywhere look of the Gen I's. Coupled with your practical and sensible build, I would say you have close to THE truck to own.


... the only thing that would make it perfect would be cruise control.

[Cruisn]

It's a masterpiece!

I absolutely love the rugged go anywhere look of the Gen I's. Coupled with your practical and sensible build, I would say you have close to THE truck to own.


... the only thing that would make it perfect would be cruise control.

it has crusie control! well... hand operated throttle that you can lock... loll australia is pretty flat so it works a treat

[SOFpirate]

it has crusie control! well... hand operated throttle that you can lock... loll australia is pretty flat so it works a treat

Then you do have the perfect truck. Congrats. You've made it! :wings:

[Cruisn]

excellent.. i shall celebrate by eating a whole bag of cookies and not feeling quilty after... muahahahaha

[Cruisn]

Little more work this weekend:

got the u- joint fixed, fixed the steering and installed the fender flares, which the missus doesnt like, she states I need to order the 5" flares of ebay.. oookay... if you say so..

http://i85.photobucket.com/albums/k48/cruisn/pajposesmall-1.jpg

http://i85.photobucket.com/albums/k48/cruisn/pajpose2small.jpg

[fatrat]

The fender flares look sweet! Do you have the rear jump seats? The US 1st gen LWB didn't have the vented rear windows or 3rd row jump seat options.

[Cruisn]

The fender flares look sweet! Do you have the rear jump seats? The US 1st gen LWB didn't have the vented rear windows or 3rd row jump seat options.

it "had" the rear jump seats in the back, they were ditched long time ago.

[scrubber3]

Thank you for not getting the larger fender flares. They look perfect as it sits now. Not too small, not to large....just right. It's looking very nice and everything you have done is purpose built. Good job! Love the blacked out hood BTW and I ditched my jump seats last year as well. I found them useless and took up too much space. I need some bumpers similar to yours.

[off-roader]

looking nice!!


... I need to order the 5" flares of ebay...
What 5" flares on eBay?

[bitoy]

Are those ROH wheels? What off set do you have?

Arent those things heavy to roll?

Nice looking rig mate.

[Cruisn]

Are those ROH wheels? What off set do you have?

Arent those things heavy to roll?

Nice looking rig mate.



yes they are roh wheels on a -22 offset. yes they are heavy. i notice them, but not to bad.

fender flares:
http://www.ebay.com.au/itm/220868008987?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649#ht_953wt_1037

[bitoy]

what size tires are you running?

They look tall and thin. Just the way an expe rig should look. :smiley_drive:

[Cruisn]

33x10.5r15

thats what I was going for, good for highway, but if it gets rough I have the clearance to get out of it.

[off-roader]

fender flares:
http://www.ebay.com.au/itm/220868008987?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649#ht_953wt_1037

AU$650?!? Wow, that's a bit pricey IMHO but I guess they're really the only source currently for aftermarket units.

[Cruisn]

I got more work done today!
on the way to work I rolled over 300000kms
http://i85.photobucket.com/albums/k48/cruisn/10032012542.jpg

And started on a dual spare tyre carrier.
http://i85.photobucket.com/albums/k48/cruisn/10032012543.jpg

http://i85.photobucket.com/albums/k48/cruisn/10032012544.jpg

http://i85.photobucket.com/albums/k48/cruisn/10032012546.jpg

[scrubber3]

NICE!

[Cruisn]

painted:
http://i85.photobucket.com/albums/k48/cruisn/11032012550.jpg

http://i85.photobucket.com/albums/k48/cruisn/11032012549.jpg

[fatrat]

Awesome dual spare setup! :ylsmoke:

[Cruisn]

Almost finished, jsut need led tail lights and to remount the plate.

http://i85.photobucket.com/albums/k48/cruisn/12032012551.jpg

http://i85.photobucket.com/albums/k48/cruisn/12032012552.jpg

http://i85.photobucket.com/albums/k48/cruisn/12032012553.jpg

I need to drill some stopper holes so they stay open on funny angles.

http://i85.photobucket.com/albums/k48/cruisn/12032012554.jpg

[Cruisn]

A little closer to finishing my rear bar, led lights installed. nothing to fancy, simple setup, they are very high quality lights though.

http://i85.photobucket.com/albums/k48/cruisn/lights.jpg

http://i85.photobucket.com/albums/k48/cruisn/lights2.jpg

And of course on board air is nice, but having a 9L tank to help out is even nicer. welded this up for me and a mate.

http://i85.photobucket.com/albums/k48/cruisn/airtank3-1.jpg

http://i85.photobucket.com/albums/k48/cruisn/airtank2-1.jpg

http://i85.photobucket.com/albums/k48/cruisn/airtank-1.jpg

[scrubber3]

Top notch job. I may use your idea for my rear bumper, only mine will have one spare as I don't have the need for 2.

[Cruisn]

Top notch job. I may use your idea for my rear bumper, only mine will have one spare as I don't have the need for 2.


ya, my plans require 2 spares. I like to head out into the bush. remote is key. I failed to have the wagon ready last year for the anne beadelle highway, but this year i will be good to go. september I figure. spend my birthday in the desert

[Cruisn]

More work completed tonight, finished welding up 1 of the drawers.

THey are 900 long by 400 wide and 300 deep. lots of room. and very strong but not to heavy overall.

http://i85.photobucket.com/albums/k48/cruisn/drawer.jpg

http://i85.photobucket.com/albums/k48/cruisn/drawer4.jpg

http://i85.photobucket.com/albums/k48/cruisn/drawer3.jpg

http://i85.photobucket.com/albums/k48/cruisn/drawer2.jpg

[Cruisn]

http://i85.photobucket.com/albums/k48/cruisn/spacecase.jpg

Spacecases thanks to Matatak for hooking me up.

780x380x380
Will be used for me and the womans clothes and stuff.
adds 10 poser points. not sure on what that converts to for hp gains though..

[Cruisn]

I am getting a little more done this weekend.

I have installed my aux tank so far, whihc bolts to the body. using 4 m12 bolts and large backing bars as to not rip through the thin sheet metal.

its a tight fit. very tight.

http://i85.photobucket.com/albums/k48/cruisn/tank2.jpg

http://i85.photobucket.com/albums/k48/cruisn/tank.jpg

http://i85.photobucket.com/albums/k48/cruisn/clearance.jpg

New gas cap:
http://i85.photobucket.com/albums/k48/cruisn/gascap.jpg

For those that are intersted its a long range automotive tank, 58L capacity. come with everything you need for the install. including electric pump to transfer fuel to main tank. its a little pricey but to get the weight off the roof and underneath in a proper tank it was worth it.

[Cruisn]

well, both tanks are in, I can now carry 190L in tanks.
132L main
58L aux

win win. install was not straight forward. bolts didnt line up. pipes didnt clear.. it was not the best thing to do on a sunday. when you need the rig monday. lol

Main tank in:
http://i85.photobucket.com/albums/k48/cruisn/maintank.jpg

Had to cut for clearance:
http://i85.photobucket.com/albums/k48/cruisn/messup.jpg

Issues with filler neck, had to weld on a pipe at 90 degrees to the tank.

http://i85.photobucket.com/albums/k48/cruisn/edit-2.jpg

The filler setup, I still have to edit the cover so its all hidden and the road spray doesnt destroy the hoses.

http://i85.photobucket.com/albums/k48/cruisn/filler.jpg

[Cruisn]

Drawer are in and finished... finally. my god that was a drawn out process.. in between finishing them I had time to do an engine swap!!! haha

I am happy with them. could be a little smoother around the edges.

enjoy:
http://i85.photobucket.com/albums/k48/cruisn/drawer7.jpg

http://i85.photobucket.com/albums/k48/cruisn/drawer6.jpg

http://i85.photobucket.com/albums/k48/cruisn/drawer5.jpg

tested them out, haha. no sag, worked great!!!
http://i85.photobucket.com/albums/k48/cruisn/jackie-1.jpg

[Cruisn]

New parts day!!! yay!!!

I recieved a Redac 1220 dc charger to keep my deep cycle battery running at top performance.
http://i85.photobucket.com/albums/k48/cruisn/1220.jpg

6m of wire to go along:
http://i85.photobucket.com/albums/k48/cruisn/wire.jpg

And because for once I would like to know what is in the tank I bought a new fuel sending unit and gauge.

http://i85.photobucket.com/albums/k48/cruisn/gauge-1.jpg

http://i85.photobucket.com/albums/k48/cruisn/sendingunit.jpg

[SOFpirate]

Holy cow, you store her in that drawer?!?

With the extra tank and all that extra fuel weight, how bad have you noticed as far as handling and "trailability" goes?

[Cruisn]

Holy cow, you store her in that drawer?!?

With the extra tank and all that extra fuel weight, how bad have you noticed as far as handling and "trailability" goes?

yuo bet, its all good. I open the door and ask if she is in a good mood, if not, dont open the drawer. its win win.

as for all the extra weight, its fine until I am at full load for camping. then she shows in the back and the front feels a little different, I am going to look into airbags to level it when its loaded. as when touring after 500km I will lose enough weight to even out a bit better. it doesnt handle it power wise okay. its not fast, but will jsut chug all day.

[Cruisn]

Got a bit more work done, Middle storage section. Part way there. still need to finish cutting plywood.

I have ordered a set of pull rings and locks for the doors to finish the storage up next weekend.

In for paint:
http://i85.photobucket.com/albums/k48/cruisn/flasefloor3.jpg

Looking back from the front:
Its tight, the seats can still bounch. without rubbing.
http://i85.photobucket.com/albums/k48/cruisn/falsefloor2.jpg

The front section still needs to be bolted down to sit level.

http://i85.photobucket.com/albums/k48/cruisn/falsefloor.jpg

[Monterorider]

Looks solidly overbuilt.

[fatrat]

Very impressive Cruisn!

[Cruisn]

Looks solidly overbuilt.

You bet, has to deal with a lot of abuse.


Very impressive Cruisn!

thanks mate

[Cruisn]

Well... I guess its time for a big update since I have been off the radar for 2 weeks haha.

In list form:
finished rear of wagon floor idea
rear barrier installed
extra led lighting added
40" led light bar added
arb seat covers
water tank set in place
wiring almost sorted
red arc 1220 installed
immobilizer installed
can now start off key - no switch required
new viynl floor installed
recovery point on rear added
turbo installed

For starts, I got a new turbo installed, overall it works great. a lot more power and actually gets decent fuel economy again:
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/turbo.jpg

This is tough to sort out. so let smove onto led lighting

OUtside:
Installed a new 40" led light bar, test shots to follow.
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/ledlightbar.jpg

Inside:
new leds inside my RTT. great lighting, even has a switch. haha
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/ledbar.jpg

http://i85.photobucket.com/albums/k48/cruisn/Major%20update/tentlight2.jpg

no flash:
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/tentlight.jpg

http://i85.photobucket.com/albums/k48/cruisn/Major%20update/lightswitch.jpg

Rear of wagon:
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/lightswitch2.jpg

Just rear door light:
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/doorlight.jpg

http://i85.photobucket.com/albums/k48/cruisn/Major%20update/ledbarreardoor.jpg

extras:
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/interiorlight.jpg

A little more outside work, finally finished gettig the badges removed...
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/badgegone.jpg

and a clean side to follow:
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/wax.jpg

Finially got a new floor in. tough install. hard work but worth it.
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/newfloor5.jpg

http://i85.photobucket.com/albums/k48/cruisn/Major%20update/newfloor4.jpg

http://i85.photobucket.com/albums/k48/cruisn/Major%20update/newfloor3.jpg

http://i85.photobucket.com/albums/k48/cruisn/Major%20update/newfloor2.jpg

http://i85.photobucket.com/albums/k48/cruisn/Major%20update/newfloor.jpg

Moving onto the storage unit now... this took a while to build but houses all my electrical keeping them off the floor, up high and away from under the dash.
keeping most of the factory wiring untouched.

http://i85.photobucket.com/albums/k48/cruisn/Major%20update/workinpro4.jpg

http://i85.photobucket.com/albums/k48/cruisn/Major%20update/workinpro3.jpg

http://i85.photobucket.com/albums/k48/cruisn/Major%20update/workinpro5.jpg

http://i85.photobucket.com/albums/k48/cruisn/Major%20update/workinpro2.jpg

Along the way I had to fabricate a rear barrier for safety reasons:
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/barriertest3.jpg

http://i85.photobucket.com/albums/k48/cruisn/Major%20update/barriertest2.jpg

http://i85.photobucket.com/albums/k48/cruisn/Major%20update/barriertest.jpg

http://i85.photobucket.com/albums/k48/cruisn/Major%20update/rearbarrier.jpg

[Cruisn]

Some carpet added:

http://i85.photobucket.com/albums/k48/cruisn/Major%20update/rearsetup.jpg

http://i85.photobucket.com/albums/k48/cruisn/Major%20update/rearstorage.jpg

Shot from the back:
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/rearview.jpg

Water pump installed:
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/waterpump.jpg

Air pump on the other side of the water tank:
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/pump.jpg

Almost there... I figure jsut wiring is left now:

I have set everything into a simple box.
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/electrical.jpg

A bit of a mess right now. but once the wires are bundled it will look great,
contains:
fuse black
redarc 1220
dakota digital tach box
immobilizer
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/electricabox.jpg

dakota digital tach box on left, egt on right
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/dakota.jpg

under dash before:
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/messy.jpg

after:
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/underdashwiring.jpg

switch combo:
contains 4 switches, fuel transfer pump, gauge for main tank, arb compressor switch
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/complete3.jpg

seat covers:
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/complete2.jpg

finished shot:
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/complete.jpg
A little safety added:
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/immo.jpg

A shot of her all cleaned up for the photo shoot with 4wd action.
http://i85.photobucket.com/albums/k48/cruisn/Major%20update/cleanwagon.jpg

[LaOutbackTrail]

Be sure to share the article with 4WA... they stopped carrying it at my local book store... looks great!

[SOFpirate]

Wow. Just wow.

That rig is a beauty! Well done.

[Cruisn]

Thanks guys, I am very happy with how she looks. and drives.

[Cruisn]

Camping??? mud comp??? yes please
http://i85.photobucket.com/albums/k48/cruisn/179988_10151770862240061_591460060_24366086_727501 41_n.jpg

A few hours mudding on the weekend, this basically lead to my engine having a valve touch a piston on the way home. luckily it was at idle so no damage, but getting a new head due to cam wear I am worried about. then she will be all new. haha

http://i85.photobucket.com/albums/k48/cruisn/398785_10150823693516644_720776643_9963038_9837954 58_n.jpg

Lookin sharp:
http://i85.photobucket.com/albums/k48/cruisn/398785_10150823693536644_224204356_n.jpg

The Offroadwa crew
http://i85.photobucket.com/albums/k48/cruisn/552825_10151774386580061_1588790952_n.jpg

[corsaoceano]

Awesome truck! When you did the diesel swap, do you remember the model of the 5spd that you used? I have a 1990 3.0V6 with a 5spd and I've always wondered if it would bolt right up to a 4d56? Thanks!

[Cruisn]

Awesome truck! When you did the diesel swap, do you remember the model of the 5spd that you used? I have a 1990 3.0V6 with a 5spd and I've always wondered if it would bolt right up to a 4d56? Thanks!

I used a 5 speed from a 2.6/2.3 or 2.5L any of the 4cyl models basically.

the 5 speed from the v6 does not fit. differnt bolt pattern

[corsaoceano]

I used a 5 speed from a 2.6/2.3 or 2.5L any of the 4cyl models basically.

the 5 speed from the v6 does not fit. differnt bolt pattern
Good to know, thanks for the info. Would you say it was worth the upgrade? Here in the US it seems to be much easier to find the 4d55 compared to the 4d56 since they were used on various small trucks like the Ranger and D50.
Did the hp/torque difference seem noticeable?

[Cruisn]

I went from a petrol v6, haha. bit of a power difference. the 4d55 isnt to low on power. I thoght it was worth it.

Well I was after a daily driver that could sit more than 2 people. both my vehicles only seat 2.. haha
I found this little gem online,
92 Pajero
rear diff lock
electronic adjustable shocks
sunroof
power windows
automatic :(
super select
4.875 gearing

good little ride overall. slight hail damage on the hood, but I can always get anew one.
the heads are off since it blew the ehad gasket. but all I need to do is put it together.

picked it up for 950 bucks.
all ready thinking of putting my 31's on the factory chromies on... hmmm...
few photos:

http://i898.photobucket.com/albums/ac186/CRUISN06/92%20Pajero/WP_000236.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/92%20Pajero/WP_000234.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/92%20Pajero/WP_000233.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/92%20Pajero/WP_000237.jpg

http://i898.photobucket.com/albums/ac186/CRUISN06/92%20Pajero/WP_000239.jpg

[roaming knome]

Wow! That is nice for $950! But good luck on keeping it a daily driver. 1 mod here and another there, next you know you have 2 expo rigs! HAHAHA
There is nothing wrong with that at all. And it all starts with tires and rims :sombrero:
I wouldn't be able to leave it as a DD. I sure hope you have more will power that me. Congratulations on the new rig! I love it

[Cruisn]

Wow! That is nice for $950! But good luck on keeping it a daily driver. 1 mod here and another there, next you know you have 2 expo rigs! HAHAHA
There is nothing wrong with that at all. And it all starts with tires and rims :sombrero:
I wouldn't be able to leave it as a DD. I sure hope you have more will power that me. Congratulations on the new rig! I love it


haha, I am sure going to try though. if I dont lift it it should remain stock haha. just want something to cruise in.

[Cruisn]

Oh damn... I have seen a lot of this lately... :(
http://i85.photobucket.com/albums/k48/cruisn/92%20Pajero/WP_000243.jpg

the parking stall
http://i85.photobucket.com/albums/k48/cruisn/92%20Pajero/WP_000244.jpg

[LaOutbackTrail]

Uh oh....

[Cruisn]

Uh oh....


Dammit... everyone says this haha. I can do it.. I can own a stock vehicle... come on matty you can do it!!!

[Cruisn]

Well.. I finally got my baby running. woohoo!!! and a new list of updates to.

I got a new head installed. its running, and running well. very happy so far. I will point out this is a cheap style head I am testing. if it fails it fails. if not I will do a reliability report.

http://i85.photobucket.com/albums/k48/cruisn/WP_000348.jpg



I have a new set of led lights to install. 10 watt in size for the corners of my roof rack. saves me having to set up the awning for led strip lighting and will illuminate a larger area.

http://i85.photobucket.com/albums/k48/cruisn/WP_000351.jpg

http://i85.photobucket.com/albums/k48/cruisn/WP_000353.jpg

http://i85.photobucket.com/albums/k48/cruisn/WP_000354.jpg

And on the mod list I am swapping my rear diff for a gen II with 4.875 gear with factory air locker. and disc brakes. which means no more drums. win win I hate drums anyways.

Thanks to a source from the states I have a set of gear to match for my front diff on the way too.
I will ahve to get a front lokka jsut to even it all out.
I will also be swapping to second gen brake calipers on the front. safety first.

She lives again!!!

http://i85.photobucket.com/albums/k48/cruisn/WP_000355.jpg

[geocrasher]

Very nicely done, I'm almost jealous! But I love my truck too much to be jealous of yours! lol

Gotta ask though, what is the reason for the barrier behind the front seats? You mentioned safety- are you using it as a prison transport vehicle on off hours? :p

[Cruisn]

Its for the missus. Haha. Nah. To kelp everything in the back should there be an accident or on a steep decline

Sent from my Lumia 800 using Board Express

[LaOutbackTrail]

To kelp everything in the back should there be an accident or on a steep decline


Yeah, for a country that reports some of the highest numbers in vehicular accidents, few put much thought into these barriers. In fact, there's really only two or three companies that even offer anything rugged enough for our uses... the rest only have flemsy metal or plastic barriers to keep dogs in the back. I'll be doing a very similar setup behind the rear seats, soon.

[Tim.plante]

Yeah, for a country that reports some of the highest numbers in vehicular accidents, few put much thought into these barriers. In fact, there's really only two or three companies that even offer anything rugged enough for our uses... the rest only have flemsy metal or plastic barriers to keep dogs in the back. I'll be doing a very similar setup behind the rear seats, soon.

for mine i just used a cargo net i found at a pawn shop and then carabiners clip it in place when i need it..other wise i have it in a amo box in my storage area

[Cruisn]

thsi wagon is gettign moved to the strictly touring section of my driveway. once I have a bit saved up I will pick up a daily driver. so the steel one made sense. tough as. small mesh size. and since I have a flat floor from the back door to the front seats an item could pick up a lot of speed.

[Cruisn]

Well, I got a call to be featured in a 4wd action magazine here in OZ, I am in issue 187 for the video portion which comes out before the write up, so I can post the video today, but you will have to wait till Oct 2nd for issue 188 for the feature writeup.

enjoy the videom, and have a laugh at my expense. haha. I had to say pajero so much for the director... for realz!!!! haha


4WD Action - Matt's Pajero - YouTube (http://www.youtube.com/watch?v=nXELX2SjFww&list=UU0mrNxzQSlRcz_9eU1CQpIQ&index=1&feature=plpp_video)

[Jrally]

Pajero was mentioned a few times! Great video exposure for such a great rig. I just noticed that magazine at a local book store here in Arizona yesterday, I'll have to keep an eye out for issue 188.
-Jon

[Cruisn]

Well the mag is out. got a 5 page spread. good write up, here is a terrible camera phone photo, once I am back in perth I will get better photos up so you can read the write up.

http://i85.photobucket.com/albums/k48/cruisn/001-35.jpg

and a shot from my camping trip along the holland track, I will psot a write up on it later.

http://i85.photobucket.com/albums/k48/cruisn/399702_10151445743542818_1138592237_n.jpg

[Cruisn]

Well, I guess a small update is needed, the rig is running, but overheating. constant issues with it on the highway, basically at wits end. haha, but I am going to hgave anotehr crack at it once I am back home from work. i hope she lives. otherwise the missus says its time to buy a landcrusier. haha, which would be fine but I am now attached to this wagon. due to time and effort and trips done

but there is a 3 week trip planned for it over chirstmas up to exmouth and through the outback. should be epic. its a mans trip. this missus is gone to canada so me and my little bro are going to wreak havic. haha.

a few photos as she currently sits:
http://i85.photobucket.com/albums/k48/cruisn/dual%20pajero/pajerosmall.jpg

http://i85.photobucket.com/albums/k48/cruisn/dual%20pajero/pajero2small.jpg

A few along the holland track: see she gets used:

http://i85.photobucket.com/albums/k48/cruisn/Holland%20track/IMGP0020.jpg

http://i85.photobucket.com/albums/k48/cruisn/Holland%20track/IMGP0072.jpg

And a size comparison:
http://i85.photobucket.com/albums/k48/cruisn/Holland%20track/IMGP0121.jpg

[Cruisn]

It seems my overheating issue may be completely related to my waterpump. so I have discovered that there are 2 water pumps for the 4d56t one for intercooled, one for jsut turbo, and I have the jsut turbo one. I have ordered a intercooled version pump will be here in about 5 hours i hope. really hoping this is the cure all to my over heating issue.

[bitoy]

slight off topic question sir, given the many different places your rig has been to, its safe to assume that your source of diesel is diverse as well, doesnt the sedimentary light on the dash light up every so often, and if so, how do you address this?

Thanks and safe expedition always.

[Cruisn]

Never has... oh wait.. its not hooked up. seriously I am not to worried about it, I have plans to actually mount a aftermarket water seperator before the filter. but since shes an oldschool engine there is a bit of wiggle room for poor fuel. but when I change my pump which is about every 5-6oookms it has always look decent. and there is a factory water seperator at the bottom.

the constant changes are basically because of the use it sees, about 4-5 trips, sometimes less then I change it for those reasons.

[Cruisn]

I lost my travel buddy... my koala off the front fell of on a test run... sad Matt is sad... :(

[off-roader]

...my koala off the front fell of on a test run...
Maybe he wanted to join his brothers in the wild?

[Cruisn]

Maybe he wanted to join his brothers in the wild?


no koalas in Wa though... haha. my bet is that she was sicks of the constant bashings, splashes with water, trees whipping her and bugs in the face... i dont blame her at all. LOL. but I do have a replacement

[Cruisn]

5 more days of work than a 21 day 4wd trek up the coast of western australia. venturing into new territory. wish me luck. excellent photos shall follow. and possibly a movie if we get some go pros lined up

[off-roader]

21 days? heck I'd be lucky to get 2 weeks off much less 21 days!

[Cruisn]

Wow, they cut a week off my trip. Buy in sure I will take another month off in a few month anyways

[gusmorfin]

Very Nice!! never seen anything like this, Awesome!!

[Cruisn]

we leave tomorrow on our trip, almost fully packed, fueled up and ready to go, with a fresh service.

http://sphotos-a.ak.fbcdn.net/hphotos-ak-ash4/200081_10151296356584581_1090558626_n.jpg

[Cruisn]

Small update.

going to be doing a quick 1 week trip to broome, never been, so I have a few things to touch up before this 4400km round trip.

Things to fix:
Swap the 4 speed for the 5 speed, long highway travel would be ncier with the 5 speed

new fuel transfer pump for the second tank - easy job

wire in boost gauge to see what the engine is up too. since we upped the fuel.

Otherwise the wagon is holding together just fine. Shes slow though haha. jsut have to live with that fact

http://i85.photobucket.com/albums/k48/cruisn/Exmouth%202012/pajeropose_zpsf83447e9.jpg

[Clem]

Lookin' good...Heard on the radio most of Australia is having a crazy heat wave up to 120 degrees F. Stay safe and cool in your travels.

Clem

[Cruisn]

It is hot here, on the trip we had 50 degree days, and now that I am back at work its floating around the mid 40;s with humidity.. ooohhh the humanity!!!

[off-roader]

Well if its any consolation it's <0c here at night and I'm in warm wonderful California...

[Cruisn]

it helps, lol.

here is a shot from my last trip. love it, the colours were so vivid in the sand.

http://farm9.staticflickr.com/8211/8337013699_b10456711a_z.jpg

[kingg5]

sweet lookin rig matt, but you already know i like it ;)

[Cruisn]

Not a lot going on as of yet with the rig, prepping for some big plans, she will be up on jack stands for a few moths I figure. the roads are hard on her and she needs a slight bit of work.

I will post a video of our last offroad trip when mate gets it done, but for now all I can tell you is that I had some issues,
front auto hub failed - wear and tear, didnt explode or anything, jsut nicked the little engagment tab off
bent front link bar... again.. going to remake this out of 4140 i think
alternator packed with mud and no longer works
blew a brake line - replacements ordered for the whole wagon.

poser shots:
http://i85.photobucket.com/albums/k48/cruisn/harvey%202728april%202013/camp17_zps6773f4ac.jpg (http://s85.photobucket.com/user/cruisn/media/harvey%202728april%202013/camp17_zps6773f4ac.jpg.html)

http://i85.photobucket.com/albums/k48/cruisn/harvey%202728april%202013/camp18_zps5da33afb.jpg (http://s85.photobucket.com/user/cruisn/media/harvey%202728april%202013/camp18_zps5da33afb.jpg.html)



New gauge cluster:
I now have a diesel tach and have replaced the temp and fuel gauge with auber gauges, EGT and boost.

We tweaked the engine a bit, upped the fuel and now run 19psi of boost. it moves better but still only does 90 on the highway.
http://sphotos-g.ak.fbcdn.net/hphotos-ak-frc1/250722_10152491454480061_193592721_n.jpg

teaser of the video to come:
http://www.youtube.com/watch?v=7dMvHFQG2hs

[GFO]

Nice looking truck. Those rain-gutter mounts look homemade, did you fabricate them yourself?

[Cruisn]

Yes the mounts were done by me. they have been on there for over 2 years without issues.

[Cruisn]

Well where to start, I have decided to put the wagon on jack stands for a bit to redo a few things. well a lot of things. since its not a daily driver any more I have more time to perfect my setup and wiring. haha.

I got the garage cleaned out today and ready for the rework to begin:

http://i85.photobucket.com/albums/k48/cruisn/Pajero%20Round%202%20rebuild/WP_000757_zps8c09aebe.jpg (http://s85.photobucket.com/user/cruisn/media/Pajero%20Round%202%20rebuild/WP_000757_zps8c09aebe.jpg.html)

http://i85.photobucket.com/albums/k48/cruisn/Pajero%20Round%202%20rebuild/WP_000758_zps7284399f.jpg (http://s85.photobucket.com/user/cruisn/media/Pajero%20Round%202%20rebuild/WP_000758_zps7284399f.jpg.html)

I just need to pick up a 5" grinder and a welder and I shall be good to go for all future projects.

so far on the list of rework:
All wiring - complete strip and redo
front sway bar couplings need fixing
replace all bent steering parts
redo fuel tank lines
replace all rubber brake lines


that is the small list so far. its much bigger. lol

started by removing my bumpers:
rear came off easy enough, half the bolts snapped as they had rusted. so that will require a rethink.
http://i85.photobucket.com/albums/k48/cruisn/Pajero%20Round%202%20rebuild/WP_000761_zps2f3ff8da.jpg (http://s85.photobucket.com/user/cruisn/media/Pajero%20Round%202%20rebuild/WP_000761_zps2f3ff8da.jpg.html)

Front bumper, not so luck, the nuts have busted there tack welds on the inside of the frame rail so I cant actually get it off without a grinder. but that will be sorted soon enough.

http://i85.photobucket.com/albums/k48/cruisn/Pajero%20Round%202%20rebuild/WP_000759_zps90ffffae.jpg (http://s85.photobucket.com/user/cruisn/media/Pajero%20Round%202%20rebuild/WP_000759_zps90ffffae.jpg.html)

But I did get the headlights and grill surround stripped and both batteries removed.

http://i85.photobucket.com/albums/k48/cruisn/Pajero%20Round%202%20rebuild/WP_000760_zpse62989d7.jpg (http://s85.photobucket.com/user/cruisn/media/Pajero%20Round%202%20rebuild/WP_000760_zpse62989d7.jpg.html)


I know a lot are wondering why so much lvoe for this wagon, or why keep working on it. I guess I get attached to wagons. lol. this girl has got me across the country an some very cool places. and since nothing is interchangable with any other model I would lose heaps of coin starting on a new rig. and if I were to sell it, I would be lucky to get 1500 for it, due to dents (character) and small flaws ( more character) and it qwerks when trying to start it ( more character then even I can handle)

so tune in for the reworking of the wagon, should be good. few mods will be added, stuff that was pointless will be lost.

[SoCalMonty]

Not a lot going on as of yet with the rig, prepping for some big plans, she will be up on jack stands for a few moths I figure. the roads are hard on her and she needs a slight bit of work.

I will post a video of our last offroad trip when mate gets it done, but for now all I can tell you is that I had some issues,
front auto hub failed - wear and tear, didnt explode or anything, jsut nicked the little engagment tab off
bent front link bar... again.. going to remake this out of 4140 i think
alternator packed with mud and no longer works
blew a brake line - replacements ordered for the whole wagon.


Man, I love your Mk1! :) Makes me miss mine (fargo brown '89)! ;)

What's causing the link bar to keep bending...is it because of a BJ flip or something?

And is there a source that you know of for SS braided lines, or did you just get new OE lines? I'm thinking of getting some made, with a little extra length...

Keep the pics and stories coming! :)

[Cruisn]

Man, I love your Mk1! :) Makes me miss mine (fargo brown '89)! ;)

What's causing the link bar to keep bending...is it because of a BJ flip or something?

And is there a source that you know of for SS braided lines, or did you just get new OE lines? I'm thinking of getting some made, with a little extra length...

Keep the pics and stories coming! :)

I have opted jsut for stock rubber lines, if the old ones lasted this long, new ones should be fine.

as for the link bar... well I may have dropped into a slippery mud hole ad with 33's there is a lot of pressure that has to go soewhere. and that bar is the weak point on mine.

Thanks for the comments on the wagon. more to come!!

[we18fi]

what offset do you have on those wheels? i asume they are 31´ rubbers !?

[off-roader]

what offset do you have on those wheels? i asume they are 31´ rubbers !?

I think in the post just above he mentions 33" tires.

[Cruisn]

Yes, they are a 33x10.5 tyre. Riding on a -22 offset wheel to really get them pushed out. Zero clearance issues as moat run a 12.5" tyre with the same offset.

[we18fi]

I think in the post just above he mentions 33" tires.
LOL i see that now i was focused on the offset and did not read all of the post´s and here 31 is largest you can fit on gen 1 so i just asumed that but asimed wrong.

[off-roader]

...and here 31 is largest you can fit on gen 1... Really? You can fit 32's w/out any modifications to a gen I other than the possible need to ever so slightly (~2-3mm) trim the front rubber bumper ends.

[we18fi]

this god dam european union bull**** has been the worst time in all of finlands history ...............
there are pre E U time pajeros with 32-35´s.


Really? You can fit 32's w/out any modifications to a gen I other than the possible need to ever so slightly (~2-3mm) trim the front rubber bumper ends.

[GFO]

Yes the mounts were done by me. they have been on there for over 2 years without issues.

I wish I had your fab skills.

I noticed that you mentioned your alternator dying due to mud intrusion. I used to own a 1995 Cadillac Deville and it had a water-cooled alternator. While I don't think it's outright waterproof, as it still had a few small openings in the back of the casing, it was for the most part an enclosed unit. With your mechanical knowledge/skills, wondering if this could be made to fit to your rig as it would likely take care of future mud issue.

Now the issue of how reliable are GM parts and the cost of the unit and extra modifications, that's up to you :)

[Cruisn]

Bit more work done today,

Pulled about 60% of the electrical out, it was rough. haha. well msot was good but a few buts were last minute additions rushed to get on the road. so now it can all be done properly with no rush to complete it. I also pulled the center gauge cluster to install some more auber gauges for oil pressure and coolant temp. go for a clean install look.

http://i85.photobucket.com/albums/k48/cruisn/Pajero%20Round%202%20rebuild/WP_000775_zps4cd274c1.jpg (http://s85.photobucket.com/user/cruisn/media/Pajero%20Round%202%20rebuild/WP_000775_zps4cd274c1.jpg.html)

Brought home a grinder, cut the last of the bolts holding the bull bar on, also cut the roo lights off, as the bolts had siezed. bit of work to sort out with that, not sure if I will ditch them for a smaller light of better quality as these really shake on the road.

http://i85.photobucket.com/albums/k48/cruisn/Pajero%20Round%202%20rebuild/WP_000773_zpsd01383c4.jpg (http://s85.photobucket.com/user/cruisn/media/Pajero%20Round%202%20rebuild/WP_000773_zpsd01383c4.jpg.html)

Love the look, with the front end stripped.

http://i85.photobucket.com/albums/k48/cruisn/Pajero%20Round%202%20rebuild/WP_000774_zpsd8a81009.jpg (http://s85.photobucket.com/user/cruisn/media/Pajero%20Round%202%20rebuild/WP_000774_zpsd8a81009.jpg.html)

Will be on the hunt for some bigger jack stands so I can pull the front and rear diff for rebuilding. lots of work to get it back to spec. but its worth it.

[Cruisn]

Sundays work:

Were to start, today was a clean and tear down day, I was going to tackle the trany but instead ended up jsut draining all the oil and then begain tearing into to cooling system.
I am finding a few issues that for sure as I tear deeper and deeper into her. poor girl was getting tired. mind you all the parts i orginally used were used. so I guess I cant overly complain.

I noticed my oil cooler has started to split around the bolt, so that will need to be replaced with an aftermarket setup. I will see what I can find in the future, is anyone running an aftermarket cooler?

http://i85.photobucket.com/albums/k48/cruisn/Pajero%20Round%202%20rebuild/WP_000777_zps5a08248d.jpg (http://s85.photobucket.com/user/cruisn/media/Pajero%20Round%202%20rebuild/WP_000777_zps5a08248d.jpg.html)

Next after removing the fan I noticed the bolt holes on my pulley were elongated, I know what caused this though. so I will jsut find a new replacement part for that.

http://i85.photobucket.com/albums/k48/cruisn/Pajero%20Round%202%20rebuild/WP_000778_zps5aace972.jpg (http://s85.photobucket.com/user/cruisn/media/Pajero%20Round%202%20rebuild/WP_000778_zps5aace972.jpg.html)

I swear these roads are rough as hell on this poor wagon. I found cracks in the body around where my second battery sits, now this is a tricky one, as the replacement battery tray that is aftermarket actaully holds a smaller battery and I have opted to deal with the close tolerances and fit another n70zz battery. so what i will be doing is welding a fish plate to the inner fender well to take the weight better, nothing to serious. jsut another repair I didnt want to deal with. I should start a list soon....

http://i85.photobucket.com/albums/k48/cruisn/Pajero%20Round%202%20rebuild/WP_000782_zps4711f5c2.jpg (http://s85.photobucket.com/user/cruisn/media/Pajero%20Round%202%20rebuild/WP_000782_zps4711f5c2.jpg.html)

Why do pajeros have front bash plates? to stop you from doing this to the front sway bar, a good hit allowed it to work loose. i knew of the issue before hand but jsut threw some good bushes on and figured it would hold till I could tear it apart and reweld it. wrong, corrugations on the last trip sorted that issue out for me right quick.

http://i85.photobucket.com/albums/k48/cruisn/Pajero%20Round%202%20rebuild/WP_000783_zpse5efa09b.jpg (http://s85.photobucket.com/user/cruisn/media/Pajero%20Round%202%20rebuild/WP_000783_zpse5efa09b.jpg.html)

Most everything that can be removed from the front end has been pulled off. and there was a ton of mud in those areas. so i suggest people do a good job of spraying those corners.

http://i85.photobucket.com/albums/k48/cruisn/Pajero%20Round%202%20rebuild/WP_000780_zps54d7d1b2.jpg (http://s85.photobucket.com/user/cruisn/media/Pajero%20Round%202%20rebuild/WP_000780_zps54d7d1b2.jpg.html)

Since there is quite a bit of welding and repainting I would like to sort out, I am atthe point now where its going to be way easier to do all this work with the engine out of the rig. Saves me trying to struggle, and that means I will half-*** it again. whihc is what I want to avoid.

http://i85.photobucket.com/albums/k48/cruisn/Pajero%20Round%202%20rebuild/WP_000779_zps9472d541.jpg (http://s85.photobucket.com/user/cruisn/media/Pajero%20Round%202%20rebuild/WP_000779_zps9472d541.jpg.html)

http://i85.photobucket.com/albums/k48/cruisn/Pajero%20Round%202%20rebuild/WP_000784_zps282d9076.jpg (http://s85.photobucket.com/user/cruisn/media/Pajero%20Round%202%20rebuild/WP_000784_zps282d9076.jpg.html)

Overall, I am happy with the progress and the damage I am finding does not suprise me at all as I some of it I was aware of and other bits are jsut needing a freshen up from the flogging. after its sorted though I doubt it will see much hardcore 4wding, jsut trips and long range touring. I need to get a little toy for the tough stuff as that is where most of my damage originated from.

[SoCalMonty]

Nice work so far! I'm sure she'll appreciate the reconditioning. :) Do you guys have wrecking yards out there? I'd probably just try to source another OEM oil cooler, only because it can sometimes be pretty expensive to get the adapter fittings to run an aftermarket cooler. I can't remember the banjo bolt size, but I want to say it's M14x1.5 or M16x1.5. Though, if you're going aftermarket, you'll probably go all the way back and delete the steel lines all together (another reason I haven't done it yet, I have too much going on as it is!). Good luck!

[off-roader]

Yeah the last time I checked they have 'Breakers' where they can get used parts from. As for a harder core rig... what kind of hard core trail riding are you thinking of?

[Cruisn]

I will most likely dig up another used unit and give a good clean/refurb.

not sure on a prject yet. would love a shorty pajero.

Progress for today:

Was a good day, mitre 10 had a sale, so I got a makita 5" grinder for 85 bucks and a work light for 25 bucks. win win in my books, now I jsut need that welder.
but I have sourced a welder,

The welder I am sourcing is a tig, good for aluminum welding which was my main concern. if it can do ally, it can do almsot every other metal. and it has high freq. start so no touch start.
http://www.weldsmart.com.au/welding-australia/tig-welders/weldsmart-200-amp-acdc-pulse-tig-stick-welder-arc

Toys I bought today:
http://i85.photobucket.com/albums/k48/cruisn/Pajero%20Round%202%20rebuild/WP_000787_zps023802fd.jpg (http://s85.photobucket.com/user/cruisn/media/Pajero%20Round%202%20rebuild/WP_000787_zps023802fd.jpg.html)

http://i85.photobucket.com/albums/k48/cruisn/Pajero%20Round%202%20rebuild/WP_000788_zpscb8680d7.jpg (http://s85.photobucket.com/user/cruisn/media/Pajero%20Round%202%20rebuild/WP_000788_zpscb8680d7.jpg.html)

Now onto the pajero work, I was able to drop the transmission today, it was still in good shape, this will make it a lot easier to pull the engine now. which is win win in my books.
it was dirty as hell though. although the oil cameout half *** clean which is good. no internal damage then. but since its a 4 speed it will be put on the back burner as a spare if ever needed again. I now have 3 transmissions sitting in my garage.. ugghhhh they multiply somehow..

http://i85.photobucket.com/albums/k48/cruisn/Pajero%20Round%202%20rebuild/WP_000790_zps9d4b5ce3.jpg (http://s85.photobucket.com/user/cruisn/media/Pajero%20Round%202%20rebuild/WP_000790_zps9d4b5ce3.jpg.html)

And of course that means that all the drive shafts had to be dropped, the front drive shaft needs 1 uni joint replaced. but its not tobad, but hey, its out and easy to fix so why not. I am noticing that I will be doing a lot of clean up underneath the rig. mainly with a wire wheel so I can repaint

http://i85.photobucket.com/albums/k48/cruisn/Pajero%20Round%202%20rebuild/WP_000791_zps05a7aba0.jpg (http://s85.photobucket.com/user/cruisn/media/Pajero%20Round%202%20rebuild/WP_000791_zps05a7aba0.jpg.html)

Starter is out: this needs a clean for the contacts. otherwise its all good to go still woohoo!!! something thats not ****ed!!
http://i85.photobucket.com/albums/k48/cruisn/Pajero%20Round%202%20rebuild/WP_000793_zps186753cf.jpg (http://s85.photobucket.com/user/cruisn/media/Pajero%20Round%202%20rebuild/WP_000793_zps186753cf.jpg.html)

How am I staying organized? a big box and everything pulled off is placed in zip lock baggies and lables. this will make re assembly much much easier. Thanks to James for the idea.

http://i85.photobucket.com/albums/k48/cruisn/Pajero%20Round%202%20rebuild/WP_000794_zps30b3c7b8.jpg (http://s85.photobucket.com/user/cruisn/media/Pajero%20Round%202%20rebuild/WP_000794_zps30b3c7b8.jpg.html)

What are peoples thought on what to use for undercoating a 4wd? anyone using bedliner? or jsut thick paint? I see a lot of gravel roads and sand. its takes paint off in no time flat

[off-roader]

In addition to the baggies, a project as big as this, I'd take little videos of the disassembly process as well, then download them to your PC each night naming each video with the appropriate step as you save them for future reference. Plus you can also share them with others who may need to undertake the same process.

[Cruisn]

In addition to the baggies, a project as big as this, I'd take little videos of the disassembly process as well, then download them to your PC each night naming each video with the appropriate step as you save them for future reference. Plus you can also share them with others who may need to undertake the same process.

But but so much work... LOL. I could though. would be intersting to do a time lapse setup of the complete build.

[Mudrunner]

I don't see why it would be a problem using something like a bed liner product on the underside. It doesn't look much different than the sound proofing stuff we used to put on the Chrysler's in the early 2000's.

[GFO]

If you do spray the underside with bed-liner, you might want to avoid the textured stuff, as it will make mud/dirt cling to it more.

[SoCalMonty]

I heard that zipock baggies zip the other direction down there...is this true? :)

[HARABAS]

I heard that zipock baggies zip the other direction down there...is this true? :)

Not true. From what I understand, it zips the same direction as here in the US, but where ours opens from the top, theirs opens from the bottom :)

[off-roader]

Wait, wait wait... you're in Australia! Australians don't use zip lock bags! You have Kangaroo's for that! :ylsmoke:

[Cruisn]

Not true. From what I understand, it zips the same direction as here in the US, but where ours opens from the top, theirs opens from the bottom :)


Bang on the money, its a little odd, but you get used to it over time.

I do get sick of rotating all my images for everyone though..