Pajero Owners Club of South Africa

YES I know I am crazy: but I have been inspired by the forum to try this.
And even if I don't get the box working again we have some pictures...
(Note to self: The trasnfercase/gearbox combination weighs about a half ton... it took 3 men to lift it to the work bench!)

Adaptor between Transfer and gearbox: Transfer case to be removed first to access bolt inside adapter to remove adapter from gearbox View from other side Torque converter remove - just "wiggle" it out... This is what you find behind Torque converter:
T/c Adapter: Another pic of the adapter:
Notice the gearbox mount is on this: Just saw a SWB Pajero which was in left front accident where this adapter broke under inpact:

Transfer case without adapter: This is the back of the gearbox after transfer case adapter was removed: To be continued en next post...

Continued from previous post...
Stripping more or less in sequence from torque converter side (ie front of box)
For most stripping you need flat screw driver/circlip pliers to remove a whole lot of circlips (according to manual "snap rings")
To remove the oil pump (after you removed the torque converter and bellhousing you need to make a "Special" puller to pull out the pump... you also need a similar type (but different size) puller to remove the unit at the back of the box. In the oil pump and the back unit you will find 2 threaded holes to insert puller (clearly marked on my pump by an "A")

Here goes the picture story...
After bellhousing removed this is what you find.. remove the bolts and use puller to remove oilpump: "Back unit" with puller attached: Don't worry it's not blood... it nice clean DiaQueen... looking empty... but notice snap rings and parts in following pic's to be continued...

more... another view: completed disassembly in next post - as well as photos of valve body and sump removal:

Last part removed: sump and valve body removal:
(sump and filter removal detailed by 4ePikanini) but here are some pictured ..
I was privileged to use a lift for this job (sorry about quality of photo's...)

Here is where you have to look for the oil cooler pipe removal (I searched in vain closer to the gearbox at first... ) 4ePikanini said you aim the pipe in a bucket... this is what happens if you don;t get the aim right... the oil comes with force... Cross member that needs to be removed: (6 bolts and 2 nuts).. easy job... Sump removed... inside from different angles... inside my sump.. my worst fear.. brake/clutch linings... new oil and filter won;t solve this problem... this is what gearbox oil filter looks like (very dirty...) kept in place on valve body by 2 bolts: filter cut open... the inside valve body removed: several "golden colored" bolts... NOT THE black once will let you remove the valve body.. be careful not to damage the gasket.. and not to drop the springs.. there are also 2 locating dowel that can drop and one pin.
A HUGE amount of oil was drained when removed.. I would strongly suggest removing the valve body if you are doing a major oil drain... it is not difficult and apart from the pin, dowels and maybe damage to gasket not a difficult job.

Its even bulkier than i thought


Sent from my iPad using Tapatalk because forumrunner keeps crashing on ios 6

Geez, 4e... are you bored

Not a job I will ever contemplate myself.

Stripped my beetle gearbox once. Lets leave it at once....

Not me doing the strip.

But maybe you wil help with the assembly .....

Hi

Just wondering what issues you box gave before you decided to open it up??

I have a look at the service manual for the autobox, there are 704 pages just relating to the INVECS II box....

142 pages just on the autobox overhaul itself, I am very interested to see how one goes about overhauling one!!

Good luck + Subscribed!

llec999 wrote:But maybe you wil help with the assembly .....

I wish. I understand the concept behind them but gearboxes are a dark art that I haven't delved into.

This will be a thread that I will follow closely and hope to learn something new.