[GideonKrynauw]

Hi there,

Recently my parents made a great rip across Southern Africa that included game reserves in South Africa, Zimbabwe, Zambia (10km from Malawian border) and Namibia towing a 4x4 trailer in a LWB 2005 Pajero (Gen3) 3.2 Diesel. Even though the tour was good they had some bad luck from a fridge that packed up due to Zimbabwe irregular power, shock failure and finally the rear diff packed up.

The following happened:
At approximately Mana Pools in Zimbabwe the rear shocks totally gave in. This was due mainly to driving with incorrect tyre pressures on really terrible dirt roads. At that stage, the tyre pressure was 2.7 BAR on the Pajero as opposed to a more appropriate 1.5 to 2 BAR....

The shocks were replaced in Lusaka and the trip continued adhering to better tyre pressure practise. However, in Namibia, the rear diff started leaking oil without them picking it up. It was the left rear side shaft / companion that pulled out of Diff and totally destroyed the left back seal. This caused them to drive for 200 km (in Etosha) with no oil in the diff before it could be fixed with a new seal and some much needed oil. The car took them back home safely with a humming sound the last 1200km to Cape Town.

Mitsubishi told them (without looking at the car) that diff is stuffed and needs to be replaced (or fixed), but most likely after driving 200km without oil, it will require an overhaul. The cost of doing this at best would be +-R12’000 and a new diff will be closer to R30’000.

To assist with the situation I purchased a second hand 2006 Pajero (3.2 SWB) diff from the breakers for R4’500 (E34D 3.917 ratio), and this is currently on route to Cape Town for installation. My questions are threefold:
1. Looking at the diff it has a pneumatic pipe at the back, what is this for, given that it is a limited slip diff coming from a GLS and thus no rear diff lock, but rather traction control? I suspect that this is a breather pipe?
2. When did Mitsubishi fix the rear diff problem with a bigger side shaft clip? Would the 2006 diff require a fix?
3. If the 2006 diff require a 'fix', I suggested that when they get the new diff changed in Cape Town they give the new diff the ‘fix’ of a bigger / stronger clip and bigger grove to lock in the clip. Where is the best place to get this done in Cape Town?

Thanks for the assistance. My opinion is that the over inflated tyre pressure caused the shocks to fail and this in turn made the car bottom out many times on bad roads and this in turn caused the diff to leak oil….

As a matter of interest, the diesel consumption varied between 10.5 l/ 100 km and 12.5 l /100 km over the trip, excellent taking into consideration that they were towing a 4x4 trailer and dowing some light off roading.

Regards
Gideon

[Greg_SA]

I'm not sure on what model the larger circlip was fitted, but mine had to be fixed (2005 Pajero).

I think the problem is only fixed on Gen 4 Pajeros. So if I were you, I would fit the new circlip anyway.

[GideonKrynauw]

Thanks Greg,

Do you know who in Cape Town who fit the larger circlip?

Gideon

[Greg_SA]

I had mine done under warranty at the dealer - it was a very quick job.

[craigdre]

Not too sure on a bigger cir clip, but I had to replace the companion shaft with a new "improved" one, was roughly R1500 from the dealers. Few threads saying you can have the old shaft machined to fit a bigger cir clip. My 2 cents, have them both replaced.

Cheers

[GideonKrynauw]

Thanks for all the feedback.

After speaking to a number of people there is still some confusion on the size of the circlip and if you need to machine a larger grove in the shaft host the larger circlip.

We have decided to make the modifications to the sump before we install it replacing the damaged unit, thus ensuring the problem will not recur. However, speaking to Mitsubishi, they informed us that you only need to buy the larger circlip (2 week waiting period ): ) without any shaft modification. Elsewhere people suggest that you need to modify the shafts if you want to fit the larger circlips or buy two new companion shafts.

What is the best way to go about this?

Regards
Gideon

[Greg_SA]

I read about the problem when it happened to mine (on local and Australian forums), and the only info that I came across was that the circlip was to be replaced with a bigger / improved one. My companion shaft was not machined or replaced.