vectorsc
Adventurer
Well, I we drove our manual 1999 gen 2.5 montero today. It's much more fun now than it was. I won't lie it wasn't easy. Some things that should have been hard, like the clutch slave, were dirt easy and some things like the engine position and shifter body cutouts sucked. Anything anyone wants to know?
Now with write up:
Things you need (i used a 1994 manual 3.0):
Manual transmission and transfer case
Metal adapter plate from back of engine
Pedal box
Driveshafts
Transmission mount cross member
New clutch master
Clutch master hardline
Manual center console
Shifters for the tranny and tcase
Starter from the MT
Flywheel and clutch
New coolant hose
Essentially, its exactly like installing a replacement auto tranny with the following exceptions:
1. You have to remove a brake line retainer from the back of the engine bay behind the engine. It runs next to some coolant pipes and has to be taken out.
2. There is a mount that is made out of sheet metal on the drivers side, part of the firewall. it needs to get hammered flat or cut out. Its at the extreme right edge of the intake plenum.
3. You have to make new engine mounts that move the engine back 1.75-2" Its in the right spot when you have 1/4" of firewall clearance where that bracket is. I can measure it later based on the fan shroud.
4. You have to cut a hole in the central hump for the shifters. Man these trucks are tough metal.
5. You have to hole saw a hole for the clutch master. There is a stamped hole for it already.
6. On the transmission neutral switch wiring, you have to join the input and output wires for the park position. This allows the truck to start.
7. Fit a new coolant hose that is longer.
8. Install the rest and GO!
I'm still figuring out if I will need electric cooling fans as the engine fan is way out of the shroud now. Might be helped by no transmission fluid interchange in the radiator LOL.
Now with write up:
Things you need (i used a 1994 manual 3.0):
Manual transmission and transfer case
Metal adapter plate from back of engine
Pedal box
Driveshafts
Transmission mount cross member
New clutch master
Clutch master hardline
Manual center console
Shifters for the tranny and tcase
Starter from the MT
Flywheel and clutch
New coolant hose
Essentially, its exactly like installing a replacement auto tranny with the following exceptions:
1. You have to remove a brake line retainer from the back of the engine bay behind the engine. It runs next to some coolant pipes and has to be taken out.
2. There is a mount that is made out of sheet metal on the drivers side, part of the firewall. it needs to get hammered flat or cut out. Its at the extreme right edge of the intake plenum.
3. You have to make new engine mounts that move the engine back 1.75-2" Its in the right spot when you have 1/4" of firewall clearance where that bracket is. I can measure it later based on the fan shroud.
4. You have to cut a hole in the central hump for the shifters. Man these trucks are tough metal.
5. You have to hole saw a hole for the clutch master. There is a stamped hole for it already.
6. On the transmission neutral switch wiring, you have to join the input and output wires for the park position. This allows the truck to start.
7. Fit a new coolant hose that is longer.
8. Install the rest and GO!
I'm still figuring out if I will need electric cooling fans as the engine fan is way out of the shroud now. Might be helped by no transmission fluid interchange in the radiator LOL.
Last edited:
