Pajero Owners Club of South Africa

Hello Guys,

On Saturday for the first time I took the IO out for a off-road day and to say the least PAJERO IO NEVER DISAPPOINTS. After leaving our clubs legends red faced with massive built up jeeps with lexus V8's and lockers front & rear I made all the heads turn.

After leaving to watch the bulls win I saw my speedo was not working. Thinking the cable might have pulled out I wasnt that worried. But leaving for work on Monday I saw a small puddle of oil underneath her. So first thought that came to mind was that I damaged my oil sump. At work I crawled underneath my car as saw the oil came out of this part (picture underneath) What I could see is that is was next to my transfer case and a cable was mounted on the housing (wondering if it might be my speedo cable)

Please I need some help to stop the leak and fix the problem quickly as I drive with her every day and dont know where to look for oil levels to see if it has dropped, and I dont want to damage anything.

that looks like the clutch fork.

If oil is coming out the bellhousing ( part between engine and gearbox ) you have blown a gearbox seal or crank seal and need to remove the gearbox to fix it.

clutch fork


clutch fork inside bellhousing


clutch fork and throw out bearing close up


rear engine crank seal - the maroonis coloured seal between the bolts and the aluminium carrier

O my greatness, you have no Idea after reading your mail how things was thrown around my office. @&%E@*&%^!@
ok if I stripped the gearbox, how will I know which one has gone? (Gearbox seal / crank seal) Is there any clear identification what to look for?

Marius, not being such a Pajero boffen will I need to pull the motor out before I can remove the gear box? #*^@&()#& Is there anyone who can help me in JHB / PTA / North West or Mapumalange that you know that will be able to help me?

more than likely the parts are cheap. Won't be more than about R500 for a couple seals.

The way to do it is to drop the gearbox. Support gearbox, gear levers off, propshaft off, mountings off, bellhousing bolts off and it should com out. If you can borrow an engine hoist you can remove the engine mountings and support the engine with the hoist to help alignment and angle to pull the gearbox input shaft out of the clutch.

I would get a friend to help out. It's not that big a job but it's not something I would do alone as the gearbox is pretty heavy.. Someone who has done it before should help you sort it on a saturday morning.

I wouldn't leave it though as the oil can contaminate the clutch and then you need to replace a clutch at a couple thousand.

If it's the gearbox seal it's pretty easy, but if it's the crank seal it's more involved as the flywheel clutch needs to come off and then there is the high torque bolts on the flywheel etc.

IMHO I would actually spend the money on the crank seal, gearbox seal, clutch kit and thrust bearing while I am at it. As well as changing out the gearbox oil.

If you can have a friend help you out with some beers ( afterwards ) it can work out fairly cheap but a workshop will probably charge about 8 hours for the job plus parts.

K my IO is back on the road. The parts replaced is:

1. Timing belt,
2. Tensioner,
3. Fan felts,
4. Seal in gearbox.

Bought at a dealer +- R1100.

Took it to a RMI dealer who pulled the gearbox and fitted all the parts I bought. He charged me R1900 for the labour. Was that alot?

it was a fair deal IMO

I would have spent the extra bit of money on getting the clutch, thrust bearing and main seal replaced while you had access.

Let's hold thumbs they don't give in soon. Nothing as bad as having to pay twice for the same job.

touch wood!

Hello Marius, went to a spare shop this afternoon looking for a clutch for the IO. They recommended a LUK clutch for a 4G18 motor. I know the lanser 1.6 has the same motor as my IO and the guy quoted me on the 4G18 motor. Is it the same clutch and will it make a difference with the IO having a transfer case and the lancer not? Is there any other parts you have to replace with the clutch plate? Something like a bellhousing, pressure plate ect?
 

LUK clutches are excellent. AFAIK they supply mitsu for OEM anyway. I have a LUK clutch in my gen2 pajero 3.0 V6 and it takes smooth and easy without any judder.

When you do the clutch the recommended items to service while you are in there are

- thrust bearing / throw out bearing / clutch release bearing( should actually come with the kit )
- gearbox seals
- rear crank seal
- spigot shaft seal
- freeze plugs / welsch plugs
- service the clutch cylinder
- clean and regrease the clutch fork