Montero transfer case swap info

[Toasty]

I figured i should post a little info because it's been getting brought up a lot lately. Anyone who knows feel free to add info and links to stuff.

First off anyone looking to regear a Gen 2 Montero with the larger drivetrain (1994-2000) Tom Woods has the driveshaft and flange info on hand so that anyone looking to do this swap can just place an order and get what you need to connect your axles to your NV241 transfer case. These cases come in two ratios 2.72: and 4:1, the first one is the common one and typically cost around $100 while the second one is the Rubicon Rocktrac and will run you around $1000.

You will need:
98+ Jeep Cherokee AW4 tailhousing and pulse gear (Ian Sharpe says you can clearance the AW4 housing for the Montero gear alternatively but i haven't done that yet)
NV241 23 spline short shaft
speedo interface (Dakota Digital makes some nice ones)
New Driveshafts (Tom Woods or a local source or if you're feeling precise DiY)
*if going the route of using the Jeep pulse gear you will need to counter bore the back side of the gear to match the height of the Montero pulse gear (i'll post up a pic a little later)
Modify your transmission cross member, the new tailhousing accepts the Jeep style mount so there are a lot of options and simple solutions. The Montero cross member is flippable in case you need to offset it's location depending on what you do


Here's some usefull threads

ES 97 Sport's swap

NathanC's swap

 

[Toasty]

On early Gen 2 Monteros (12v 3.0 small drivetrain) you have a different but more compatible transmission the AW2. The bolt circle is nearly the same as the standard 6 bolt circle except the dowel pin is in the wrong location and one hole is wrong. It's ok because you can remove the dowel pin and drill the 6th hole in the right location, at that point you just bolt up your choice of 6 bolt 23 spline short shaft T cases, from there it's the same old swap and you pick your support pieces; driveshafts, speedo etc (most are cable so just get the non VSS NP231). No need to change your transmission mounting setup.
Unfortunately dual cases are tricky on these because of the torsion bar cross member, with a NP231/231 setup the front output sits right on top of the X-member so you would need a massive body lift or body chop to make it work. A Np231/D20 might fit a little easier.

 

[Toasty]

Gen 1 Monteros practically swap themselves, the 6 bolt 23 spline cases just bolt up and there are cable speedos available for them in your favorite junk yards so it's just a matter of drive shafts.

Same problem here with dual cases though, get crafty if you want to go this route. I do.

 

[eurosonic]

this is a great thread already.

I was able to install the Jeeps pulse gear onto monteros shaft without any modifications.

Here is a pic of it being on the Jeep.



and here it is installed on the Montero transmission. They look identical.

 

[Toasty]

Good to know, the transmissions in the late model Monteros are a little different. It'll be cool if it all just goes together on these trucks.

 

[eurosonic]

hey Toasty,

Im having no luck in finding a D300. I think ill be going with NP241.
Which one should I go with? Id rather not install a SYE. I know the later models 241s already came with them from factory.

Also do I need to have a VSS in a 241 or no?

 

[Toasty]

TJ Rubicon NV241 because you want a VSS, if not you'll need a GPS Speedo from Dakota digital. I think if you want a cheap NV241 with the normal ratio you can get one out of a Dodge but i'm not sure.

If you decide to do a single Rubicon T-case we have the driveshafts all worked out for you.

 

[eurosonic]

TJ Rubicon NV241 because you want a VSS, if not you'll need a GPS Speedo from Dakota digital. I think if you want a cheap NV241 with the normal ratio you can get one out of a Dodge but i'm not sure.

If you decide to do a single Rubicon T-case we have the driveshafts all worked out for you.

Ill be doing a doubler. Already have DD machine kit with a chopped 231. Now i need something for the back. Rubicon case is too much money and honestly I dont need that low of a gearing since I will have a NP231 up front.

Besides Rubi case, can use any NP241 with a VSS? I hear somewhere there are certain once to stay away from.

 

[Toasty]

Ill be doing a doubler. Already have DD machine kit with a chopped 231. Now i need something for the back. Rubicon case is too much money and honestly I dont need that low of a gearing since I will have a NP231 up front.

Besides Rubi case, can use any NP241 with a VSS? I rear somewhere there are certain once to stay away from.

look into the dodge NV241 t-cases, you'll probably be looking at a Ram 1500 with the solid front axle, https://www.novak-adapt.com/knowledge/np_nvg_input_gears.htm has some good info.

Also you can use the brake master cylinder out of certain mid 90's Dodge ram pickups, you'll want the bigger bore to push the large pistons on the D44. The Dodge one bolts on, unfortunately i don't have a part number. Az Crew has a tendency to just wing it on swaps and not document anything. I always think i'll just remember or that i'll just refigure it out next time but that's usually the case.

 

[jeep-N-montero]

Great info, I will be going this route pretty soon.

 

[Ezzo]

Hi guys... I'm running a v5mt1 gearbox on my diesel 2.5 pajero... what transfer box options have I got from above that'll fit ?

 

[plh]

Hi guys... I'm running a v5mt1 gearbox on my diesel 2.5 pajero... what transfer box options have I got from above that'll fit ?

Pretty sure none fit the v5mt1 except the stock Mitsu.