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Thread: Not So Modest 2000 (Gen 2.5) Montero Build

  1. #1

    Talking Not So Modest 2000 (Gen 2.5) Montero Build

    Well - I took my wife's advice and drove off the deep end and bought a second Montero. This time it's a two tone red/gray 2000 Montero Endeavor. Some of you may recognize my other build thread for a tan Gen 3: Modest 2002 Montero Build.

    This project will be in stages over the next year or two and I am keen on doing much of the work myself. As I'm not super proficient with 4wd systems and all the gearing/sizing options- will be reliant on help from users here for guidance. The overall purpose of this vehicle is currently a spare winter vehicle and will become the primary camping/over-landing/general trail shenanigans. The Gen 3 has been claimed by the wife for her work.

    Stages as I see them:
    1. Clean & Inspect
    2. Interior Overhaul
    3. Mechanical Inspections & Maintenance
    4. Gearing/Tires/Differentials
    5. Bar Work (Bumpers/Skid Plates/Rocker Bars)



    I'll need some guidance with the following:

    • Rear Diff Lock. Heard a Montero Sport locking diff can work?
    • Gearing options suitable for larger tires. Thinking of 33" tires at this point?
    • Larger tires. Haven't decided on anything yet, but likely going to select either the K02's or something more aggressive. Need a suitable tire size that works well with a new gear set. Pictures of other setups are always appreciated - so feel free to post up pictures if you'd like!
    • Will be considering a front locker as well. Thoughts on the Aussie Locker?
    • Suspension setup. Will be looking to ADD for gear. Will need guidance if I need a lift for the tire sizes I'm looking into.



    As it currently stands, this vehicle was purchased on a bit of a whim as I liked the color and body style. It was in fair mechanical shape upon first inspection with basic maintenance done as needed and ran fairly well. Far better mechanically than the Gen 3 when we first bought it. The interior however was a disaster. The owner had smoked in the car and transported dogs around for the better part of 10 years. Likely hadn't been cleaned since purchase... Let that sink in.... Years....... Upon purchase, drive 3 blocks to a car wash for a quick exterior rinse and spent 30 minutes with the vacuums getting piles of dog fur out of the car. Took a few pictures despite it being 20 degrees F outside.
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    Drove it home and the next day took it to a better car wash for a second mini detail so I could stand sitting in the car for more than 30 minutes without my eyes watering up.

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  2. #2
    Upon returning home, started assessing the interior and formulating something resembling a plan...

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    The wife and I quickly concluded that drastic action was needed... Seats up front are pretty much shot, and the middle row isn't in great shape either. We are working out some sort of a plan for that, but need to sell the other spare car before we consider our seat options. Seat covers up front are pretty much required at this point as the upholstery is falling apart. Decided to engage the first stage of the project - Deep Clean the Interior.

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    With the carpet disposed of (with great malicious intent), we began scrubbing the interior plastics with the best interior cleaner we could find.... Scrubbing Bubbles. Yes, you read that right. The bathroom cleaner in a metal spray can. Apply generously and after a moment- scrub with a clean microfiber cloth. After a whole can of the spray, and all of my microfiber cloths- we called the preliminary scrub complete as the temps were still below freezing and we were out of suitable microfiber cloths. The brightly colored neon cloths were all various colors of brown and black after contact with the foam covered.

    All of the interior trim is coming out and I've scrubbed all of the small interior plastic bits. This is including the seat frame covers, which all were glued to the carpet with what I assume is a custom composite solution of dog hair, coffee, soda and caramel coffee candies. No pictures of this as I dared not touch my phone during this process...

    As it stands- the cleaning is on hold as we are addressing other items on the car.
    First up- emissions testing. Wife took care of that today and the car passed without a hitch. Certainly raised an eye brow as there was only a driver's seat bolted in the car. Next up is the windshield. Scheduled to get replaced tomorrow afternoon. Will have ask the wife to snap some pictures of the process!

    More pictures to come over the coming weeks as we make progress.
    New carpet has been ordered from stockinteriors.com, new headliner fabric ordered from yourautotrim.com and odds and ends are in the mail. Will have my work cut out for me, but we are intent on getting this vehicle's interior sorted out in a quick order.

  3. #3
    Join Date
    Oct 2010
    Location
    WNC
    Posts
    313
    Love that color.

    Not sure where you are at, but I have a near mint set of second row seats in NC that are available.

    They are gray.
    K9ADV
    98 Montero
    05 KTM 400 EXC, with torn seat
    @k9adv

  4. #4
    Join Date
    Jul 2013
    Location
    Los Angeles
    Posts
    912
    if you're going through the effort of adding a locker.... I would suggest pulling one from a gen 2 with the 4.63 gears... pull the front as well... then you'll be set for 33" wheels.

    Because the 2000 didn't have a locker, you can't just swap one in... something about one of the axles is slightly longer with the locker, so the axle shaft you have in the rear isn't long enough. There is also a difference in the mounting flange for the anti-lock brakes.... which I think causes some other issues.



    Everything is wired electrically for the locker though.... pull the center console and you'll find a place for the locker switch to plug into (it's in front of the low range selector).... and everything is in place for the air pump, but you'll need an air pump, and the hoses that connect back to the rear diff.

    not sure where you are located, but LKQ pick your part seems to have a somewhat steady flow of gen 2.5s coming through... at least here in SoCal. You might actually be better off pulling the entire rear axle (with the diff) as well as the front diff and housing....

  5. #5
    Join Date
    Jun 2015
    Location
    Houston
    Posts
    245
    Same color and peeling clear coat as mine lol, my carpet was dirty, but the seats are good. Good luck on your build!

  6. #6
    Join Date
    Jan 2017
    Location
    North Alabama
    Posts
    38
    Looks kinda like mine…

    I had gone ahead and had my front seats recovered by a local upholsterer. It was cheaper to do vinyl instead of leather..
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  7. #7
    Join Date
    May 2011
    Location
    Utah
    Posts
    6,459
    I happen to have the driver rear axle shaft, locker switch, and air pump you need to do the swap. When you get closer to upgrading send me a message.
    1998 Montero with winter/locker package with Old Man Emu springs/torsion bars/shocks, ARB winch bumper, 33x10.50 km2's, aluminum roof rack with ARB awning

  8. #8
    Join Date
    May 2016
    Location
    Denver - CO
    Posts
    240
    As far as the smoke smell, if you want to try an experiment (for me) I've heard great things about using an ozone generator such as this one. I've got a buddy that swears by it for deodorizing hunting gear and it's supposed to work really well on smoke. But I haven't had a reason to buy/use on yet, so I can't personally vouch for it's efficacy. Basically you stick the unit in with all the stuff that smells, and close all the doors/windows and let it chug away for a bit and the ozone oxidizes away all the residual crap. Potentially it could save you some time.

  9. #9
    Quote Originally Posted by jeep-N-montero View Post
    I happen to have the driver rear axle shaft, locker switch, and air pump you need to do the swap. When you get closer to upgrading send me a message.
    Thanks! I'll take you up on that offer!
    Quote Originally Posted by coffeegoat View Post
    As far as the smoke smell, if you want to try an experiment (for me) I've heard great things about using an ozone generator such as this one. I've got a buddy that swears by it for deodorizing hunting gear and it's supposed to work really well on smoke. But I haven't had a reason to buy/use on yet, so I can't personally vouch for it's efficacy. Basically you stick the unit in with all the stuff that smells, and close all the doors/windows and let it chug away for a bit and the ozone oxidizes away all the residual crap. Potentially it could save you some time.
    Good to know - going to see what new carpet and headliner do for the smell first. The seats will need attention too, but I'm not sure of the plan there just yet.

    Sent from my LGLS992 using Tapatalk

  10. #10
    Join Date
    Dec 2017
    Location
    Bay Area, CA
    Posts
    13
    zerodrift: Looks awesome so far, great job! Keep the pics coming

    Thanks for the Scrubbing Bubbles and Ozone generator tips, I need to try those. One of my Montero's previous owners smoked heavily (center console is filled with ash, haven't gotten around to taking it out to clean underneath yet) and my Sport has been used to transport dogs for 7 years (w/ dog barrier, canvas liner and yearly thorough cleanings, but the cargo area carpet still got ruined).

    Also, thanks for the carpet and headliner links. I might take a stab at re-upholstering my front seats if the leather glue method doesn't help.

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