Offroad-Express

I currently own a LWB 2.5TD GLS NH Pajero with a Manual transmission and the Super-Select transfer case. I am looking to swap in a 4D56T from a newer Triton and upgrading the drivetrain to cope with the torque. I am looking at a 3.5 V6 Manual as I have heard these are the strongest of the Gen 2s, and I have a few questions.
1 - What components will need swapping? (Obviously the Diffs, but is the entire axle required? etc. )
2 - Will a 3.5V6 SWB drivetrain be fine provided a LWB driveshaft is used?
3 - What are the differences between the GDI and Non-GDI transmissions?
4 - Will the majority of IFS components remain the same bar diffs and axles?
5 - I know the 2.8TD has a factory body lift to clear the transmission, is this the same with the 3.5?
6 - Any recommendations on how to make the swap as simple as possible?

Cheers, Karl

Anyone?

I'll help...

karllovesmercedes wrote:I currently own a LWB 2.5TD GLS NH Pajero with a Manual transmission and the Super-Select transfer case. I am looking to swap in a 4D56T from a newer Triton and upgrading the drivetrain to cope with the torque. I am looking at a 3.5 V6 Manual as I have heard these are the strongest of the Gen 2s, and I have a few questions.

I wouldn't bother, I'd just put the engine in and be done with it. What are you planning on using it for? Hard off road? If you are going to still do it I'll answer below but you'll find the standard gear will be fine. Maybe a front diff if you want to later down the track using it hard.

karllovesmercedes wrote:1 - What components will need swapping? (Obviously the Diffs, but is the entire axle required? etc. )

Rear 3.5 has bigger diff's and axles. Front diff should be bigger as well. CV's should be the same.

karllovesmercedes wrote:2 - Will a 3.5V6 SWB drivetrain be fine provided a LWB driveshaft is used?

Yes, but the driveshaft's need altering, the long one will not fit the bigger transfer case

karllovesmercedes wrote:3 - What are the differences between the GDI and Non-GDI transmissions?

No idea but doubt there are any differences. Never seen a gdi manual anyway.

karllovesmercedes wrote:4 - Will the majority of IFS components remain the same bar diffs and axles?

Yes, all the other threads about how shit IFS on other jap 4WD's is not relevant to Mitsi IFS, they are well designed and strong.

karllovesmercedes wrote:5 - I know the 2.8TD has a factory body lift to clear the transmission, is this the same with the 3.5?

Yep

karllovesmercedes wrote:6 - Any recommendations on how to make the swap as simple as possible?

Yep, put the bigger engine in and drive it!!!

Do you have the donor vehicle? If so it makes more sense but I wouldn't go spending loads of money getting it, You will need to do a body lift on yours to fit the 3.5 gear.

Thanks NJV6, I was hoping you would post in here!

I thought the stock NH drive train was just fine, but everyone on the Pajero Club of Victoria reckons it's quite weak

[quote="Yes, but the driveshaft's need altering, the long one will not fit the bigger transfer case[/quote]

By this, do you mean that a LWB 3.5 rear driveshaft will not fit up to the SWB 3.5 transfer and diff?

I have found a SWB 3.5V6 manual with a blown engine and good drivetrain for $800 which I am close to buying. The engine however is sourced from an engine reconditioner who will fit it with all the ancillaries etc. a 2 inch body-lift will be done before hand from 4crawler.com, then possibly 35s

Now you have my interest! It is on the bucket list to drive across Africa as well having been there twice for a look.

I think the Paj would go very well there. If you are doing it would you not consider the 3.2 DiD engine? If I was doing it in a Paj (yep I've put some thought into it... ! ), I'd get a late model 2nd gen (like your shape) which came with the factory 2.8 TD, decide on what state the engine is in and possibly bolt a 3.2 into its place. NZ new 2.8's all ran the manual fuel pump too rather than electronic. That way you have all the heavier running gear from scratch. I'd probably run a manual, but thats because I like a manual, can't see there being any problem with the auto's, they are a pretty common transmission.

The NH drivetrain, well if you push them they can break axles but apart from that i believe them to be pretty good. Transfer case chains can stretch but this was largely solved with the later larger transfer case.

Yes the driveshaft will bolt up, I miss read what you had written, if you are using the 3.5 rear diff and a 3.5 transfer then it'll be sweet.

Don't spend to much on a body lift kit, they are very simple... If you stick to 30mm then the gearlevers and everything should be ok for fit. And 35'sfor Africa... a bit keen maybe, remember to put on the most common used size for them over there so its easy to get spares.

I certainly did consider the 3.2 but the work needed to slot it into my NH was far to much and complex, though they should fit up to the 2.8 body as the mounts are the same I believe? I also considered buying a later model Pajero, however in all honesty I couldn't bear to get rid of my truck! It spent most of it's life owned by a mechanic and had excellent servicing down in Nelson, then it got bought by a family in Auckland where I bought it at 180,000kms in utterly pristine condition - never been off road once. Everything is in tip top shape, immaculate chassis, no rust big knocks etc. hence why I want to stick with it haha!

The truck is manual at the moment and for reliability and personal preference will stay that way with the conversion. the 4D56 block is the same even till now, so the block should fit the mounts alright. I am going wit a D-iD Triton engine due to their abundance in the market, the fact the 4D56 is highly reliable, and also the limited electronics - I am looking at a simple direct injection though if common-rail is all they have I will deal with it and fit a water trap and a pair of decent fuel filters. The biggest issue would be mating the 2.5 engine to the 3.5V6 gearbox (any idea if much would need work?)

No worries haha, I have seen and heard a few stories of the NHs actually snapping the rear diff and axle housing in half (looks like those cambered hellaflush cars afterward haha ) I thought 50mm was fine without any major mods? Might be wrong, though the lower radiator hose is said to pinch on some models

karllovesmercedes wrote: taking 3 trucks, my Pajero

Maybe you should get something like a Patrol instead