New kid on the block. :)

[PAJEROLYFE_19]

New to the EP community just popping in to say hello and I love all of the content here. I just purchased a 2002 Montero XLS w/ 4.90s and the hybrid LSD, she is down as of right now with a blown head gasket but I will soon be embarking on the overhaul neccesary to get her reliably back into service. Has 149k on the odometer, and has had the transmission replaced roughly 2 years ago at Mitsubishi. What are some of the biggest shortcomings of the Gen 3 Montero/Pajero platforms in your experiences?

Some of the first things planned for the build include:

Stripping factory roof rails to upgrade to rhino 6 tower mount full length flat rack (may fabricate), to accomodate a RTT setup as well as some minor light duty storage.

Skid plates from Adventure Driven Design front to rear.

Winch bumper/winch

Aisin Manual Locking hubs up front

Anyone have any suggestions apart from this?

Also interested in Jerry Can mounting options below the universal "spare tire carrier" kits (so as to lower the center of gravity as much as possible and improve handling).

 

[ChrisCosta416]

Welcome!

Biggest shortcomings would be lack of power, especially once you start adding stuff. I am not aware of any Aisin lockings hubs as there are no locking hubs for the Gen3 platform. Depending on your mileage, be sure to give the brake system a check as failures often occur and be sure to use OE parts as much as you can.

I would avoid putting too much weight on the hatch besides the spare tire. Do not forget proper suspension will make a world of difference. Be sure to do plenty of research on what will work and what does not. Be aware of "overland" products that just look cool and have no function.

Feel free to refer to the guides I made for suspension and roof rack advice
- https://www.expeditionportal.com/fo...ll-a-roof-rack-on-a-third-gen-montero.210445/
- https://www.expeditionportal.com/forum/threads/gen3-montero-aftermarket-suspension-sheet.202220/

 

[PAJEROLYFE_19]

I may be thinking of the manual hubs being installed on the gen 1s and 2/2+'s. Apart from the obvious, installing all-terrain tires, doing a full brake system overhaul, full driveline fluid flush and fixing any faulty seals/leaks underneath, I think this could be a very reliable platform. I think my biggest fear is recurring cooling system issues once the HG repair is done. I'll just have to be sure not to cut any corners and be thorough in my repair work.

 

[PAJEROLYFE_19]

And thanks for the links/info, much appreciated! Glad to be on board!

 

[ChrisCosta416]

They are very reliable if maintained.

be sure to use the correct fluid, specifically for the Transmission. Use genuine Mitsubishi SP3 or Aisin SPIII ONLY.
Ensure to do the brake bleed per the FSM.

 

[PAJEROLYFE_19]

They are very reliable if maintained.

be sure to use the correct fluid, specifically for the Transmission. Use genuine Mitsubishi SP3 or Aisin SPIII ONLY.
Ensure to do the brake bleed per the FSM.

Yes I have heard Mitsu is picky and only likes to work with Mitsu stuff, avoid aftermarket where possible in other words.

 

[plh]

Aisin Manual Locking hubs up front

Unfortunately impossible to do this mod.

 

[PAJEROLYFE_19]

Hi PLH, as I mentioned before, I had a few last night and realized the build I was reading about was a gen2.5, curious about the XLS center diff, is it Torsen? Or locking? Or is that only with the Limited's that feature SuperSelect? I would like to know more about my gearboxes/t-case, at the moment all I know is this XLS I bought has the hybrid 4.90 lsd in the back but I am not sure if for the 2002 XLS they offered center locking diff. What kind of fluid do you guys run in your gearboxes/T-case?

 

[plh]

Hi PLH, as I mentioned before, I had a few last night and realized the build I was reading about was a gen2.5, curious about the XLS center diff, is it Torsen? Or locking? Or is that only with the Limited's that feature SuperSelect? I would like to know more about my gearboxes/t-case, at the moment all I know is this XLS I bought has the hybrid 4.90 lsd in the back but I am not sure if for the 2002 XLS they offered center locking diff. What kind of fluid do you guys run in your gearboxes/T-case?

GL4 only in the T-Case. Not GL5 -->GL4 compatible.

 

[ChrisCosta416]

Also refer to your manual and you should have all the types and capacities listed there. The Super Select 4wd system has a center locking diff.

 

[ChrisCosta416]

I forgot to add, I would ensure you have proper suspension and braking before adding any weight, it really helps!

 

[PAJEROLYFE_19]

Unfortunately the space cadet kid I bought this from lost his owners manual, so I supposed I'll be sourcing one from the bay of E. Well, even if the XLS doesn't have the center locker, as long as its got a tough LSD in the back I should be worry free for most of my endeavors, the only major driveline mod I've heard can make a real difference is adding an air locker on the front. I know ARB has a variant that runs around $1k, but that is low on the list as of this very moment until she is 100% mechanically sound. I am looking at picking up a donor motor for this thing soon so that I can rebuild my secondary, and just drop in the donor with new gaskets/timing belt/water pump/necessary PM parts replaced to at least keep her rolling a little longer while I work to overhaul the original motor. Trans was overhauled 100% as of about 2 years ago with very little in-town mileage put on it since then, roughly 10,000 miles since trans replacement, but no issues or "hiccups" so to speak of. I can start the car with no issues and it will run with a little throttle support (valve pockets must be warped enough to affect compression to the degree that it will allow the engine to die if you don't feather the throttle to keep her breathing), and I have driven it around my townhome block once or twice just to check steering and other mechanical components function (the trans shifts buttery smooth, steering is tight and responsive, power steering seems fine, 4x4 engages and disengages fine, etc.), so functionally she checks out pretty well. But I really just did the "test drive" to check things out with little regard to further engine damage (as I'm overhauling it anyways, before anyone blows an o-ring thinking I'm that dumb lol). I plan on doing a full fluid flush once she's all back together and rolling strong. From what I've gathered, and the most critical piece of advice thusfar was to use ONLY MITSUBISHI TRANS FLUID for the trans. As any other brand can damage the internals. I appreciate all the hints and suggestions guys. Gotta finish out this work day and pick a productive task to take on when I get home, y'all have a good one!

 

[ChrisCosta416]

Unfortunately the space cadet kid I bought this from lost his owners manual, so I supposed I'll be sourcing one from the bay of E. Well, even if the XLS doesn't have the center locker, as long as its got a tough LSD in the back I should be worry free for most of my endeavors, the only major driveline mod I've heard can make a real difference is adding an air locker on the front. I know ARB has a variant that runs around $1k, but that is low on the list as of this very moment until she is 100% mechanically sound. I am looking at picking up a donor motor for this thing soon so that I can rebuild my secondary, and just drop in the donor with new gaskets/timing belt/water pump/necessary PM parts replaced to at least keep her rolling a little longer while I work to overhaul the original motor. Trans was overhauled 100% as of about 2 years ago with very little in-town mileage put on it since then, roughly 10,000 miles since trans replacement, but no issues or "hiccups" so to speak of. I can start the car with no issues and it will run with a little throttle support (valve pockets must be warped enough to affect compression to the degree that it will allow the engine to die if you don't feather the throttle to keep her breathing), and I have driven it around my townhome block once or twice just to check steering and other mechanical components function (the trans shifts buttery smooth, steering is tight and responsive, power steering seems fine, 4x4 engages and disengages fine, etc.), so functionally she checks out pretty well. But I really just did the "test drive" to check things out with little regard to further engine damage (as I'm overhauling it anyways, before anyone blows an o-ring thinking I'm that dumb lol). I plan on doing a full fluid flush once she's all back together and rolling strong. From what I've gathered, and the most critical piece of advice thusfar was to use ONLY MITSUBISHI TRANS FLUID for the trans. As any other brand can damage the internals. I appreciate all the hints and suggestions guys. Gotta finish out this work day and pick a productive task to take on when I get home, y'all have a good one!

Your truck DOES have a center locking differential.

 

[PAJEROLYFE_19]

Well now, isn't that a pleasant surprise! I guess maybe the bulb is burnt out in the cluster ? (No surprise there). I saw a technical write-up on how to pull the cluster out to change all the bulbs but heard some require the resistance of an incandescent type bulb in order not to bleed over into other indicators windows. So no cluster LED upgrade for me. But I definitely would like to see my fun lights.

 

[Toasty]

He means yours is always locked in 4hi and 4low, there is no AWD or viscous coupler like the Super Select has. Yours is regular ol' 4WD, it's actually a really good T-Case and the Strongest most reliable of the Montero T-cases.