Eurosonic's Montero 2.5Gen Build Thread

[Mudrunner]

Ahh it's not that hard if you have the specs and tools. I mean as long as you have specs for both rigs if different, and have all the shims you might need it will be fine. just trust your gut. nothing on a car is that hard if you take your time.

 

[SoCalMonty]

Ahh it's not that hard if you have the specs and tools. I mean as long as you have specs for both rigs if different, and have all the shims you might need it will be fine. just trust your gut. nothing on a car is that hard if you take your time.

Pretty much true. Nothing complex about installing a set of gears in a rear end. Rebuilding an automatic trans? *THAT* is complex. Gears aren't any more complex than, say, installing a camshaft. Actually...gears are more simple than that. A lot less parts involved.

I can do it for pizza and beer if you're near Orange County, CA.

 

[Justice R]

The issue with setting up a used ring and pinion is that the gears wear in the old rig a certain way, and when you install those gears in a new housing and carrier of the new rig, it can make it impossible to read the mesh pattern accurately. This is why a lot of shops wont install used sets, since they cant accurately read the mesh pattern, the quality of the set up may be unkown. Like anything, its a risk. Personally when I swap the 4.90's into my 99 I'll probably go with new for the rear and a used set for the front. Since the rear gets the most use and load it is of the most concern. One thing of note also, the later Sports that we are looking at as donors are all wheel drive so the front R&P may show significant wear as well.

 

[LaOutbackTrail]

Good point with the new R&P in the rear.

 

[Monterorider]

Gen 3 01-02 XLS had 4.9 as well and part-time t-case so front will be pretty much intact. I'd still suggest getting whole front axle/diff carrier. That might require swapping diff companion flange and monkeying with brackets but still lot less hassle than setting up gears. Front end uses shims to adjust backlash rather than side nuts like on rear diff. If original shims won't work you would need to get whole new set for like $60-100 or have them machined or something. And of course that would be perfect timing to get front ARB locker in.

 

[Justice R]

I've seen the front diff assemblies from Gen 3's relatively cheap from time to time. I was just unsure of the fitment into a gen 2. Anyone tried it yet? I've noticed the front cover is different but holes for mounts/brackets appear to be about the same but that's just looking at it without taking any measurments. That would make the swap to 4'90's way easier.

 

[eurosonic]

Couple of pics from the last trip with guys on EXPO.

Full trip report>>> http://www.expeditionportal.com/for...-Stanislaus-National-Forest-November-4-6-2012

 

[KarmannMarco]

Great pics! Your 2.5 looks great.

 

[eurosonic]

another pic from last weekend

 

[Monterorider]

very nice

 

[RU55ELL]

Looking good!

 

[eurosonic]

Quick update on what Ive been up to.

Picked up a homebrewed safari rack that was originally on a XJ jeep. Rack was not in the best shape, so I decided to freshen it up with new paint and hardware. Rack came with a new set of KC Daylighters and some cheapo' lights in the back. Maybe will use them later.

The rack was about 60 miles away from me, so I took the family wagon to pick it up. Figure I could just strap it on and go.

Sprayed some paint remover. Never tried using that stuff before. Paint comes off almost instantly.

Cleaned up the mounts. Old, polished, painted.

After some metal brushing was ready to paint.

Couple of cans of Rostolium later..

Rack is a good size for the monteros roof.

Also as a temporary solution before I fab up the bumper, mounted the HiLift on the rear frame rails.

Not much to it, welded L brackets and couple of bolts. Fit there perfect. Gate closes w/o problem.

 

[LaOutbackTrail]

Now how are you going to get to the roof rack without the bumper there??

 

[eurosonic]

Now how are you going to get to the roof rack without the bumper there??

I get up and stand on the rear frame mounts, sliders, tire. Works for now. :sombrero:

 

[shmabs]

Rack looks like a good fit! I really like how it attaches to your rails, that whole clamp setup seems pretty slick. And of course, your B6 a4a is gorgeous.....