Pajero Mini 1995 - My first 4x4

[chall3ng3r]

Assalamu Alaikum,

I am truly impressed by the work you have done so far and the years of dedication you have put into it. Your efforts are truly commendable.

W. Salam,

Thank you for the appreciation.

Recently, I purchased a well-maintained 1997 Mini Pajero 660 (non-turbo, automatic), and I’m really enjoying driving it. I have plans to upgrade the tires and a few other components in the future. However, I’ve been facing an issue: when in Drive (D) mode, the RPM stays above 2000 under normal driving conditions, and the gear shifts don’t feel as smooth as they should be.

My guess is ISC valve is not working and stuck at high RPM. Check the Idle Speed Control valve, make sure it works. To test if its working correctly, you can view the following video I made https://www.youtube.com/watch?v=MiXK3Om0gT8

For automatic transmission, the idle RPM without AC should be 1100, and with AC it should be about 1400.

If ISC valve is damaged and not working, you will need to replace it and get the main ECU checked as well, the ICs to drive ISC valve burn.

Hope if helps.

[pwuser159289930213]

Let me check the video and I will update you, The gear shifting is not normal sometimes it stuck in 3rd gear and didn't change it most of the times it's on cold start. The reverse gear is aslso not responding in the morning, my guess is it's TCM/Gear ECU issue. I can come over or we can meet if you are in Karachi for coffee and Mini's discussion. Let me know if you time.

[chall3ng3r]

Let me check the video and I will update you, The gear shifting is not normal sometimes it stuck in 3rd gear and didn't change it most of the times it's on cold start. The reverse gear is aslso not responding in the morning, my guess is it's TCM/Gear ECU issue. I can come over or we can meet if you are in Karachi for coffee and Mini's discussion. Let me know if you time.

Ahan, the gear shifting issue is also been reported here in in PW forums. One of PW members, @Ijaz_Ahmed sb also had this issue, where the gear computer would require the metal case of gear ECU to warm up before it would start shifting correctly.

What you can try is go to used car parts market ( Magazine line https://maps.app.goo.gl/1JDdUiQB1KQDWZhG7 ) and find replacement gear ecu. Ask the seller that you'd like to try it for few days and you'd return if it doesn't resolve the issue (have it written on invoice). Hopefully it will solve the shifting issue. Components in gear ecu could change their values due to age factor and weather conditions. Sometimes a hack, warming up the casing, works but it's best to have it repaired or replaced.

About meeting, I moved to ISB side few years ago. So meeting unfortunately is not possible now, but sure in future if you're visiting ISB/Rawalpindi side, we can connect and chat about Pajero Mini.

Best regards,

[Ijaz_Ahmed]

Reverse and "L" positions have nothing to do with TCU. Both are mechanical in nature. Other issues you mentioned might be related to TCU. You need a rebuild TCU

[bilalmehmood.kc]

I have talked with some old spare parts shops in rawalpindi they quote me around 8k for repaired ECU. In Karachi the prize is around 15. The mechanic ishaq suggested to get it replaced with alto ECU he also recommended a person but I don't want to play with wiring. I am thinking to order one from RWP as @chall3ng3r suggestedon few days checking and I don't have much knowledge in electronics so It would be verydifficult for me to rebuild it. Any suggestions or guidelines are appreciated if I am in a right direction

[chall3ng3r]

The mechanic ishaq suggested to get it replaced with alto ECU

Mixing parts with other manufacturers, doing experiments on your time any money. Never do this. That's wrong advice.

Source a replacement gear ECU from Karachi, Rawalpindi or Peshawar. Try to get a month's warranty, a week's minimum, to replace if it fails.

[pwuser159289930213]

Exactly, I have managed to source TCU it replace after EID, For reverse gear I think the issue is with the gear oil I recently changed it and i think the mechanic poured wrong oil (I don't know what oild he used). I was reading your comments on other thread and found out the correct gear oil is Sp111.

Questions:

1. Should I change the gear oil to original Mitsubishi Sp111 or Please suggest other
2. Will it resolve the reverse gear issue, The issue is on cold start reverse gear is engaged but mini doesn't move but after some time it work as expected. The issue occurred after changing the oil. I changed all the fluids after purchasing Mini last month.