Recent Posts

Pages: 1 ... 6 7 [8] 9 10
Gen 2 Montero / Intake Manfold Vacuum Leak
« Last post by radar56 on September 30, 2019, 06:12:06 PM »
Anyone every rebuilt the intake manifold on a 3.5?  Mine appears to have a pretty bad vacuum leak on the front where the butterfly valve leakage is.  I can hear the leak it is so bad...

Build Threads / Re: Rambo Penguin's Gen 3 Montero Build
« Last post by Rambo Penguin on September 23, 2019, 11:35:26 PM »
I finally did it! I built a front bumper! Iíve wanted to do this since i moved to Montana to give me a fighting chance against the massive population of deer out here. My goal was complicated. I wanted to build something that matched the lines of the Montero, was as light as possible, was removable for ease of maintenance, could protect against light animal strikes, wouldnít hinder the epic approach angle that i already had, and would be cheap. Obviously if I was really worried about animal strikes and performance i would just get an ARB, but they are out of my budget and I think they look ridiculous on the gen 3. There isnít a straight line almost anywhere on the car, and the ARB is just an angular block. Doesnít fit the style and it adds about a foot to the front of the car. The big challenge here is that the Gen 3 doesnít have anywhere to mount a bumper too, since itís a unibody. Iíll go into a good amount of detail about the build here, if you just want to see the end result skip it and check out the pics at the end, my feelings wonít be hurt.

Step 1) prep the front end for a bumper. There are 2 things that need to move when building a bumper: the windshield washer reservoir and the factory crash bars. The crash bars are easy, grab a sawzall and go. I cut through the thinner metal and left the rest intact. I cleaned it up with a dremel and painted the whole thing black. The washer reservoir is also easy to remove and some people just leave them off, but I like being able to wash off my windshield so I decided to come up with an alternative reservoir. A quick Ebay search lead me to a $10 washer fluid bag with a pump included. Splice it into the factory wires, run the plumbing to the factory spots and itís done. I hung it right behind my passenger headlight.

Step 2) build a bumper mounting point.

I saw a lot of different designs for this. All are by DIY intensive and require a lot of tools and skill. Mine, unfortunately, is not any different. I opted to basically continue to build out the Box and ladder frame design that the montero already had (even though itís a unibody.. So weird how they built these). So I used a hole saw to cut a 2Ē hole in the rails, put a piece of ⅛Ē wall tubing through it and welded it to the frame as best I could. This is about as solid of a mount as it gets. It would be nearly impossible to get that bar to move in the frame rails. After that I welded some mounting plates to it. I used ⅛Ē metal for everything. This would serve as the permanent side of the bumper mount and allow for me to have a clear spot to attach the bumper and also allow me to easily remove it later.

Step 3) The actual bumper

Similar to the mounting point, I designed a plate that would bolt on and hold the bumper. I decided to go with a tube bumper to save weight and to follow the montero styling. This proved to be a lot more work than i thought. Iíd never worked with tubing before and it proved to be much harder than expected. After hours of bending, measuring, cutting, redoing, welding and a lot of head scratching and staring, I finally settled on something I liked. Simple, clean and attainable. This was far from my best work, my welds were strong but ugly, my angles are off, things are uneven, but in the grand scheme of it all, you wonít notice unless you were looking for it. Overall, iím happy. Iíll probably keep cleaning it up and making it look a little better. I plan to add some amber fog lights as well to help with snow glare this winter. Iím proud that i built it myself, i feel like it will be sufficient to protect my rig in most applications and i like the way it looks well enough.

And now, pictures. Unfortunately I didnít take a lot of shots during the creation process.. Basically there was a lot of grinding, bending and welding.. But now itís done and looks like this!

Side note: Chances are very high that this is hurting my MPG because you can see almost all of my 33Ē tire haha. I might try to make it more aerodynamic (something like filling in the sides or making an integrated front skid plate.. But those are problems for the future)
Build Threads / Re: Rambo Penguin's Gen 3 Montero Build
« Last post by Rambo Penguin on September 23, 2019, 11:26:39 PM »
Some shots of the painted wells

Build Threads / Re: Rambo Penguin's Gen 3 Montero Build
« Last post by Rambo Penguin on September 23, 2019, 11:23:38 PM »
Remember how those wide wheels were running into my fenders? Yeah thatís still a thing. My bump stops helped a lot in the rear, but the front was still smashing into my guards, linders and bending stuff. This was very apparent when i went to the sand dunes and treated my montero like a dune buggy. I had the suspension at full compression multiple times at high speeds, and everything got crunched. Here are some pics that better explain what time talking about

This was before the stiffer/taller lift in the front, so that will help slow things down for sure, but i still needed to remove stuff. Iíve ripped out 3 sets of fender liners already, so those were already removed. Next was to cut the fender and flares back. Iíll be honestly, there wasnít exactly a science to this. I cut the metal fender back so that it was nearly even with the height of the frame so that i wouldnít smash it. Next I drilled out the rivets on the plastic flares and cut them back as well. This gave me nearly an inch of extra width and should be enough to clear the wheels at full tuck. Itís hard to explain exactly what this looks like so just check out the pics. I finished it off by covering the exposed fender sheet metal with paint and then some door trim rubber for a cleaner look and also so that I didnít have sharp edges in my wells. Then i painted everything to prevent rust and called it a day. I suspect with will be enough to solve my rubbing issues, but i wonít completely know until i push it to the limit again.. Iíll report back when i do

Build Threads / Re: Rambo Penguin's Gen 3 Montero Build
« Last post by Rambo Penguin on September 23, 2019, 11:19:53 PM »
I want to take just a minute to comment on the weight thing I mentioned earlier. Yes, according to my local scale, my montero fully loaded is about 6,000lbs. This is with all the armor, camping gear for 4-5 days, probably 27 gallons of gas (including the jerry can) and 10 gallons of water total. Itís really heavy. Part of that is that the Gen 3 weighs 4,800 stock, so it can get up there fast. Up until this point weight savings wasnít a huge deal, but now that itís really climbing up there it has become a major factor (this is the story of every overland build haha). I took some time to really evaluated what iím carrying as well as whatís on the rig. Aftering some thought and planning I came to a few conclusions. The first is that less liquids will really help keep the weight down. I donít do any trails were I need more than a few gallons of fuel so jerry isnít needed, I also donít need as much drinking water as I usually pack. Instead, i will fill the can only to what i think i need and bring a water filter if for some reason i run out on the trail. The other is that added a winch and heavy front and rear bumper would only make things worse. I can easily justify the need for both, however at this point the cost is too high. With that, let's talk about 2 things that the weight really effected, lift and that front bumper idea..

First is lift. Man this has been a pain. I think iíve taken the front end of my truck apart 10 times by now. But iím at a point that iím really happy with. My OME and Bilstein setup was working really well, however, it just wasnít that tall. After everything had settled and was aligned i realized i was only ĹĒ over stock! Thatís almost nothing. So once again, i was on the hunt for more lift to get the ground clearance i needed for simple trails. Fortunately, the bilstein front struts have some adjustment. There is a circlip located under the bottom spring seat. It moves the seat up 10mm (functionally producing 20mm of lift because of the preload) So that got my about 1Ē extra lift. Relatively simple to do, and free! I have HD springs in the rear already. They are rated for about 400lbs over stock which is right about where iím sitting with everything loaded up. They ride fantastic even when weighed down, i just needed a little more boost. A fellow montero owner tipped me off that XJ jeep spring spacers work with our rear springs, so I picked up a set of those that are 1Ē thick and they did the trick! I think i still sag just a touch in the rear but it doesnít matter as much anymore because everything is up higher. At this point i have almost 13Ē of ground clearance under the front skid and rear diff. Bring on the rocks!

The ride is notably stiffer, however after just a few days of driving I've gotten used to it and couldnít tell you the difference. Off Road itís amazing. Iím still getting flex out of both front and rear and it feels planted and stable. Hereís to hoping thatís the last change!

Build Threads / Re: Rambo Penguin's Gen 3 Montero Build
« Last post by Rambo Penguin on September 23, 2019, 11:17:02 PM »
Itís time for a regear! Let me first off say that when I first got into this build I NEVER thought that I would be in as deep as doing a regear. Then I found out how simple, cheap and beneficial it is and it became a very attainable modification. There is lots of info about 4.9 diff swaps out there, but I will cover some of the basics here so everyone can get caught up to speed if you are unfamiliar. I might post later on about how to actually get the diffs out of the car, but itís pretty simple and there are some good youtube videos out there (like this one I drove 7 hours round trip to pull these diffs, took me 2 hours to pull them in the yard, cost $160 out the door for both. Considering this is usually a $2k- $3k job in a normal vehicle iíd say thatís pretty good!

1st! What monteros have what gears? Gen 3ís (2001-2006 in the USA) have two different gear ratios: 4.3 and 4.9. Almost all of them have 4.3. Only the 01-02 XLS models have 4.9. The 01-02 XLS with a sunroof (not the limited) have 4.9 and an LSD.. which is pretty sweet but i didnít get one of those :(. They directly bolt on and are already set up from the factory so you just swap the diff assembly (sometimes called the carrier or 3rd member) and donít have to open the diff at all!

So why did I go with a regear? Three reasons stand out. 1) As I mentioned before, it was cheap and simple to do. 2) The 33Ē tires did take away some of the punchiness and power to the ground that I had when I was on stock tires and 3) My rig weighs 3 Tons.. Not a joke.. Itís 6,000 lbs fully loaded without passengers. So the 3.8 V6 and nicer tranny that they put in the 03-06 models was good, but I really needed all the advantage I could get.

Let me explain #2 for a sec. As long as lift and tires are a thing, people will ask the question: What fits? How does it affect the torque? MPG? Yada yada yada. After a year on 33Ēs I have some feedback on how they ran on my rig. I immediately noticed the negative effects of bigger tires on the performance of the montero. The most noticeable was actually on dirt roads. When I hit the dirt I would get into 4H (AWD) and the montero would get really slow. It was constantly downshifting to keep accelerating and felt sluggish. I would often find myself shiting all the way into 4LLC just to get the low range gear advantage to save the stress on my transmission. In 4LLC they ran great. I also felt this sluggishness on the street, especially if I was moving more than 2 people or loaded up for a trip. I know the Montero is not a race car so I wasnít expecting much, but for the sake of longevity I wanted to help the transmission and motor out as much as I could. The reason the montero felt so sluggish is because these motors make almost no power below 2,500 rpm.. At least it doesnít feel like it. With stock 4.3 gears and 33Ēs my effective gear ratio was 4.01. This meant that it spent a lot more time at lower RPM than it did when stock. Combine that with weight and it was a slow, fat pig.

Now that iíve done the swap here are some highlights!

The best way to describe the power coming back to the Montero is that it went from feeling lethargic and lazy to fit and healthy. It is still not a race car. But it has some of the punch back, it spends more time in the ďpowerbandĒ and it doesnít feel overworked anymore! 4H has become a usable drive option and 4LLC feels amazing! Tons of torque and slower crawling speeds. If feels like itís aggressively geared for trail work and climbs with ease. Itís also nice to have the extra low gearing for hill descent.

As far as MPG goes, I didn't see anything crazy. I would say i went from around 11-13 mpg combined to 13-15mpg. On the Hwy doing 80 iím still down in the 11-12mpg range just because this thing has the aerodynamics of a cinder block. But on slower 65mph roads with mild grades iím all the way up at 18-19! So it definitely helped, but wasnít crazy.

So in summary, regearing is awesome and iím excited that I did it. It very well might be the best performance mod and preventative maintenance mod iíve done to date. Here are a few pictures of the swap.

Gen 3 Montero / Re: 2003-2006 3.8 Timing belt and heavy maintenance list
« Last post by magoh on September 19, 2019, 07:37:40 AM »
Well crap, just saw the post about the forum closing.
Gen 3 Montero / Re: 2003-2006 3.8 Timing belt and heavy maintenance list
« Last post by magoh on September 18, 2019, 01:39:40 PM »
This is awesome. Is there a similar list for the 2001-2002 3.5?
Mitsubishi Related / Re: Gen1 shock advice?
« Last post by GrantCee on September 03, 2019, 07:42:32 PM »
Would you happen to have that part number for the fronts? Thanks!

I've been scratching my head why they would only list part numbers for the rears.

Sorry to be so very late getting back to this thread...I hope this is still helpful!

Bilstein part # is B6 4600 24-013369

Bilstein lists them for '88 to '90 Monteros, but not for the earlier models - even though they use the same part from Mitsubishi! Just one of those little things Monty owners need to know that the companies themselves don't.
General Discussion / This Forum Is Open
« Last post by Shovel on August 30, 2019, 09:13:00 AM »
Registration is slow, forum is for technical data.
Pages: 1 ... 6 7 [8] 9 10