Piotr's toy
Hi I,m Peter and i bought myself a little Pajero 1.8 MPI (2 years ago :D)
Until now it,s stock but last winter i got stuck few times while hunting so i have some plans to make a real offroad vechicle out of it.
I plan to buy 205/80 R16 tires, lift it a bit by using spacers on front and a rear, and new type KYB shocks, and new rear springs.
I also want to change the gearbox for the one with low range gears as mine is peramnent 4x4 with no low range gears. I wish i get some answers here if its possible to do it becouse as far i only know that gearbox with low range gears fits the mounting holes on my Pinin,s engine.
I thought about making a side steps, but lift and gearbox is more important for me now.
perfect!!
perfect - a standard transfer case will bolt straight in - loads in germany and across europe. just unbolt between gearbox and transfer box, no need to replace entire gearbox.
you would probably need to get the 4wd controler box that is under the carpet, under front seat on RH side - this makes the lights work and activates the front axle vaccume system, and also check to ensure the front axle has the vaccume clutch to disengage the front wheels.
I've never seen a permanent 4x4 model io - I know they exist from 2003 onwards but they were never imported here, only the 2wd / 4wd / 4wd+loc / 4wd+loc+low
The 4WD controller isn't an absolute necessity
I don't think the 4WD controller is absolutely necessary - all it does is control the display and provide alerts if something fails to engage.
The front freewheel vacuum system is controlled be a switch on the transfer case, wired directly to the vacuum switching valves, the 4WD controller only monitors it's engagement.
Ok, perfect. That makes me
Ok, perfect. That makes me happy, I checked prices and it looks that i can get a gearbox for 200 up to 300 euros. The strange thing is that boxes for permanent 4x4 starts at 700. One more thing, if i change transfer box,can i use 2wd then?
I know of no one else
who has swapped out a full time 4WD for a part time 4WD, so you are probably the "guinea pig" on this swap and may need to figure out many details for yourself - those of us who have the part time 4WD can probably provide some details on how it works - some of the guys are very familiar with the transfer case internals, I can probably assist with details on the electronics & switching side of it.
Yes - I see no reason why, if you swap in a part time 4WD case, you would not be able to drive in 2H.
Front axle
Just wondering if your vehicle has the front axle freewheel mechanism at all... It would only be used to switch between 2wd and 4wd so yours probably won't have it.
To be honest, this is probably one of the most problematic parts of the Mitsubishi super select system.
The drawbacks to having the front axle permanently engaged are more fuel consumption, more diff wear, more tyre wear? Though in theory there should be nothing wrong with doing this as your vehicle would have been using the front axle it's whole life anyway.
I almost feel like I would want a front axle without the freewheel mechanism, for more reliability and less moving parts (controlled by little rubber hoses!), if that is what you have on your vehicle.
I heard from someone that it
I heard from someone that it has a freewheel mechanism, but it,s all the time engaged, and if I change gearbox I will not be able to use 2WD becouse I don,t have a vacum pump to disengage it. I don,t really care about it, I do not use this car on freeways or any long distance, mostly driving on gravel, mud, deep snow so I just don,t need a 2WD. The only reason I wont super select gearbox is that I badly need a 4LLc, so if it requires some extra modifications to have 2WD, then I won,t do it. I will make some photos of front axle this week and then we will compare.
low range
if all you want is the low range then throw the box in - will work no worries!
the price is because the constant 4wd box is heavier and has a viscus center diff - the non-constant boxes have an open center diff with a locking collet.
check your crossmember mounts for compatiability - (have a look at the DIY low range gears thread for pics)
if you don't want 2wd i cannot see a single issue!
if you DO want 2wd again it is an easy install - a second-hand front axle would bolt in and the vaccume comes from a single tiny tube off the manifold and a vaccume can under the floor - easy to install.
2wd
As far as I know, the transfer case will disengage power to the front drive shaft when put into 2H, but both front wheels will still be turning the diff (and drive shaft) as you drive.
The freewheel mechanism disengages the left front wheel meaning that only the right front wheel is turning the diff and hence the diff centre / drive shaft doesn't turn, which reduces wear to the diff and reduces fuel consumption by not 'pushing' the front wheels as they spin more metal under the car.
One of the biggest fears for using the super select off road is that if the freewheel mechanism doesn't engage then you are stuck with 2wd, as the transfer case will be spinning the front driveshaft, but the diff will send all power to the left side axle which is not engaging the left wheel, and no power will be transferred to the right front wheel unless you have a front diff locker. Hence for some of us, the non free-wheeling front axle may be preferred? Having said that, I've not had too many problems with the front not engaging, though it seems that if I don't drive in 4H at least once every few weeks, the freewheel mechanism gets a bit 'sticky' and won't engage immediately when I want it to.
Fordem might be able to confirm all this mechanical stuff..?
I checked front diff and it
I checked front diff and it looks like it doesn't have freewheel mechanism.
My concern now is how my diffs will work with other gearbox, they are 4.636 or something like that. When it do 100 km/h it has a exacly 3000 rpm, is there a posibility that it could change after replacing gearbox. My other concern is that i can move a drive shaft using hand for about 10 - 15 degrees and then I can hear a smashing inside a gearbox, is it normal or I schould worry?
4wd
Hi,
The rear diff backlash should be about 10-15mm when measured between tailsaft and diff housing (scribe a mark then twist and measure) rear axle manual describes this better.
if you have more then mabe your rear diff needs adjustment - or maybe the transfer box is worn - either way unlikely that the gearbox is damaged.
Keep your gearbox and just bolt in the new transfer box - will not affect ratios - will be fine.
IF you select 2wd then all that will happen is that the front tailshaft will not be driven by the transfer box and the front tailshaft will continue to turn from the front diff - In our io's, if the front diff freewheel mechanism fails the io will happily drive with transfer in 2wd and front diff connected to tailshaft.
sounds easy!
Jimny similarity
I almost feel like I would want a front axle without the freewheel mechanism, for more reliability and less moving parts (controlled by little rubber hoses!), if that is what you have on your vehicle.
I know it's an older post but I am just catching up on all things iO.
I have a Jimny that had vac operated front hubs which I changed to manual using SJ man. hubs. I leave the fronts engaged at all times for a number of reasons so the diff is always turning.
Regarding the Pinin with permanent 4x4, is it a 60/40 split or such and which way round; front/rear or rear/front? My Rav 4 is permanent and for me it has been fine. However, I have never taken it off road at all so far as it is a street machine for me.
I only have to cross fields which I currently do in my 2.5TD Pajero and have never had to go into 4LL even when I got it stuck it came out (eventually) in 4H. It has super select and I am wondering if the iO I am getting has the same. I guess centre diff lock will see me through most all muddy fields I will ever negotiate.
Hi Piotr, where do you get
Hi Piotr,
where do you get transfer cases for 200-300 Euros?
I've checked a few sites and ebay Germany, and prices seem to start at 400 to 450 plus shipping. They wouldn't even sell diffs for 200-300. And many of the cases I've seen are completely rusted up on the outside, which is probably only be a cosmetic point, but does not increase confidence 
Syndicate
4wd
Hi,
I am guessing you have a 2.0L GDI motor?
manual or automatic?
not sure on the transfer box conversion, is likely a direct swap onto the back of your existing gearbox - I don't beieve the transfer box controller is anything more than a check-switch setup.
a 1.8L transfer will also likely swap in as they appear identical here in Australia. - while the transfer is out, maybe to the lower low range conversion too!!
.