While the Gen2 pathfinder may have a better motor option the gen1 is a better platform as it is body on frame, with a stronger rear axle. I am not too fond of the Montero Sport, but do like the older 2dr Montero.
How easy would it cost to put lockers on a rav4? Would the newer Camary 4cylinder fit? Any links to making the rav4 a better off-roader like you are describing? Thanks.
off-road.com did a whole series on the 4.1 Rav4. Just google it to find each part of the series. They did a good job with it and show its full potential as well as limits.
www.rav4world.com has a forum with a lot of information and if you use google to search it you can actually find things.
I have never heard of any one putting a true locker in a RAV4. The first gens came either with a viscous coupling center diff or an electronic locker straight from the factory. As for the rear differential a torsen torque sensing limited slip could be had as a factory option or pulled from an all trac. The differential is a common part with the all trac celica. The front differential is open and I know of no LSD or locking option.
If you want a Camary 4 cylinder just get a 4.2 generation RAV4. The 4.2 has the option of a 2.4 Liter 2AZ-Fe which is used in camrys, rav4s and scions. The best toyota engines and the ones that have a trd super charger option since they are built tougher. The 2az has that option. Some of the scion TC tuners run turbo(s) and a ton of boost on the 2AZ-FE and report great reliability up to 250hp, so its a tough engine. With a second generation (4.2) a 2004 or 2005 is the one to get as these have no transmission / ecu problems and offer a ton of standard equipment like disc brakes and a lot of air bags and safety stuff. The 4.2 second generation only comes with a viscous center diff and the torsen unit for the rear is a hard to find option. The second generation is a true full time all wheel drive with a 50/50 torque split making it a lot of fun to drive.
I would not worry about lockers or traction in a RAV4 its practically never the limiting factor. I have climbed some crazy steep pitches and generally the torque converter on my auto transmission stalls out before there is any wheel spin. Its also great in deep snow and loose sand. Gearing and ground clearance are limiting and only some what.
If swapping an engine into a 4.1 the only confirmed swaps are the 3SGT and 3SGTE and the 3VZ-Fe. The 3SGTE should be relatively straight forward. Woodsport does V6 conversions for the 4.1.
The first thing to do for off roading a RAV4 is an auxiliary transmission cooler if is an automatic. Then go for the arb old man emu kit and bigger tires. I have heard of tires all the way up to 235 75 16 fitting with minor rub.
I have the ARB old man emu springs on the back of my RAV and they have made a huge difference I will eventually spend the money on the front springs and struts/shocks.
In the world markets the same D-CAT diesel that goes in the hilux is available in a RAV4 which has got to be insane. More horse power, way more torque and better mileage and a 6speed standard transmission. I do have some diesel envy.
