Dad's gen1 pajero clutch job

4ePikanini · Sat Jan 18, 2014 12:06 pm

The clutch gave up mid December 2013 for no known reason. It has no drive, just a slight shudder when releasing the clutch.

Having checked all options it's clear the clutch gave up the ghost.

Dad's V10 touareg towed it (with a nervous me at the wheel of the gen1 pajero) to the infamous workshop here on the farm.

It has a 3.2 Di-D engine in from a gen3 and a gearbox from 2.8 gen2.

The clutch is a standard 2.8 clutch and flywheel assembly.

Early January I will start to drop the gearbox and document it here.

Should be interesting.

The car in question

The heavy box that needs to come out.

4ePikanini · Sat Jan 18, 2014 12:14 pm

started work today.

Hard going. Everything hasn't been touched in a while so all the bolts are pretty tight and with lots of my tools being stolen recently it was a bit of a struggle.

Managed to get the center console out to get to the selector arms.

Got the bashplates off. Propshafts off. here and there some ground cables and speedo drive etc.

Also got the clutch slave off and the pressure plate bolts through the inspection hole.

Still to do by the looks of it, is to get a jack under the gearbox support crossmember, undo the bell housing bolts and carefully drop the box while looking for anything that is still connected.

Calling it quits for today. The heat and humidity in that shed with no ventilation while surrounded by the smell of gearbox oil can only be handled up to a point.

Notes
- one of the clutch slave cylinder eyes have been broken for some time. I think a new one should be in order
- new propshaft bolts is also a good idea.

llec999 · Sat Jan 18, 2014 10:31 pm

Good luck... I had to do brakes outside in the Mozambican sun.... So I have sympathy for ypu with the humidity! Following this closely... Would live to do 3.2 in my Delica.... With autobox though...

4ePikanini · Wed Jan 22, 2014 10:39 am

eish. a mission to get the box out. That thing is very heavy.

Unfortunately it's bad news.

The input shaft sheared off. Very weird as they are truck gearboxes. Clutch disc looks fine.

4ePajero · Wed Jan 22, 2014 10:52 am

Bummer!

Please post clear close-ups of the break as well as the spigot shaft end of the main shaft.

Main shaft carrier bearing failure can cause this type of failure, but is usually accompanied by warning signs (oil leak, vibration or noise).