New to me 91 Montero

[livetoride]

So after everyone telling me to go for the gen 2.5 I bought the 1st gen. I just think they look bad ***. I choose the 91 mainly due to the work that has been done on it and the low miles. Plus I have always loved the white color on these. Currently, the rig has 116K with a rebuilt engine that was done 50 miles ago. New radiator, alternator, and water pump. I think the interior is in ok shape, but I will be redoing the seats and side panels and probably carpet too. So now comes the fun part, mods! I have owned Toyotas my whole life so I know everything there is to in terms of modifications and fabricators, but the Monty is a whole new thing for me which is exciting too. I know the aftermarket isn't like toyota or jeep, but any help would be huge from you guys. In the next couple of weeks I am planning on the following:

- OME suspension
- Safari snorkel
- Roof rack - Help on this one? I am looking at ARB or diamond rax, but I am wanting to find a good quality rack for the least amount of money. I am not too handing at building my own or else I would do that.
- Front bumper - It currently has a brush guard, but I am looking at the ARB bumper or any people out there fabbing their own?
- Fixing up the interior
- Front and rear lights for the rack
- Powder coating the wheels and new tires
- Diamond plate rocker panels

When I can get more funds I will be adding some ARB lockers and.......

Any suggestions for mods is hugely recommended as I am in the dark on most of this. Here are some pics on how the rig currently sits.

 

[eurosonic]

man, that thing looks nice. Welcome to the Mistu crowd!:smiley_drive:

 

[off-roader]

So after everyone telling me to go for the gen 2.5 I bought the 1st gen. I just think they look bad ***. I choose the 91 mainly due to the work that has been done on it and the low miles. Plus I have always loved the white color on these. Currently, the rig has 116K with a rebuilt engine that was done 50 miles ago. New radiator, alternator, and water pump. I think the interior is in ok shape, but I will be redoing the seats and side panels and probably carpet too. So now comes the fun part, mods! I have owned Toyotas my whole life so I know everything there is to in terms of modifications and fabricators, but the Monty is a whole new thing for me which is exciting too. I know the aftermarket isn't like toyota or jeep, but any help would be huge from you guys. In the next couple of weeks I am planning on the following:

- OME suspension
- Safari snorkel
- Roof rack - Help on this one? I am looking at ARB or diamond rax, but I am wanting to find a good quality rack for the least amount of money. I am not too handing at building my own or else I would do that.
- Front bumper - It currently has a brush guard, but I am looking at the ARB bumper or any people out there fabbing their own?
- Fixing up the interior
- Front and rear lights for the rack
- Powder coating the wheels and new tires
- Diamond plate rocker panels

When I can get more funds I will be adding some ARB lockers and.......

Any suggestions for mods is hugely recommended as I am in the dark on most of this.

Before doing anything else, I would recommend either re-enforcing the trailing arms by welding a piece of 1x8x1/4" steel plate to the thinnest section.

Then I would recommend figuring out what kind of wheeling you wish to do first then going out and doing that kind of wheeling on a mild trail. While on the trail, determine what kind of mods would be of greatest benefit. You may find that the stock vehicle with AT tires is sufficient and all you'll want to focus on are creature comfort mods like a bed/drawer system in back, etc.

The drivetrain is already pretty beefy. In fact a pretty much stock rig, won the 84 Paris Dakar rally (IIRC, it was the 1st one Mitsu entered with this vehicle) so fortunately, there isn't a lot that needs to be done.

It that's an LS model it may already have a Limited Slip differential. In good condition, it will work almost as good as a Locker. I did the entire Rubicon Trail in a 90 4 door with just the limited slip and only needed the strap on a couple of obstacles (one I remember is the very steep incline near the end)

Instead of the ARB locker, you can also do a Gen II SR rear axle swap and get the OE locker and bigger differential. You'll need to either use the OE compressor (low pressure compressor) or an aftermarket compressor w/ the proper regulator as needed.

Other mods could include any of the following..

TIRES:
31" fit w/out any mods
32" fit w/ a very slight trim to the front bumpers (or let the tires trim the rubber from the bumper ends)
33" w/ a mild lift (~1-2")

WHEELS:
Just be careful about the offset. Too little or too much will let the tires rub on either the inner or outer fenders.

ARMOR:
Bumpers (Used ARB, or custom)
Rocker panel protection (Trail Gear has inexpensive but decent protection. You'll want the 67" tacoma sliders)
Skid Plates: custom made. No aftermarket options available.

TRACTION AIDS:
Front Locker (ARB RD110)
Rear Locker (ARB or Gen II SR rear axle w/ Mitsu Air Locker)

BODY LIFT
Body Lift: 4crawler.com

SUSPENSION:
Rear coil springs: Gen II stock coil springs, or various other aftermarket offerings (ARB, Coil Spring Spacers for a Toyota Sequoia, etc.)
The rest would all be generic options (rack, fog lights, etc.)
Front Suspension Lift: torsion bar crank, or stronger aftermarket torsion bars from Australia.

Again, each of these should be done based on what kind of wheeling you intend to do.

 

[livetoride]

Before doing anything else, I would recommend either re-enforcing the trailing arms by welding a piece of 1x8x1/4" steel plate to the thinnest section.

Then I would recommend figuring out what kind of wheeling you wish to do first then going out and doing that kind of wheeling on a mild trail. While on the trail, determine what kind of mods would be of greatest benefit. You may find that the stock vehicle with AT tires is sufficient and all you'll want to focus on are creature comfort mods like a bed/drawer system in back, etc.

The drivetrain is already pretty beefy. In fact a pretty much stock rig, won the 84 Paris Dakar rally (IIRC, it was the 1st one Mitsu entered with this vehicle) so fortunately, there isn't a lot that needs to be done.

It that's an LS model it may already have a Limited Slip differential. In good condition, it will work almost as good as a Locker. I did the entire Rubicon Trail in a 90 4 door with just the limited slip and only needed the strap on a couple of obstacles (one I remember is the very steep incline near the end)

Instead of the ARB locker, you can also do a Gen II SR rear axle swap and get the OE locker and bigger differential. You'll need to either use the OE compressor (low pressure compressor) or an aftermarket compressor w/ the proper regulator as needed.

Other mods could include any of the following..

TIRES:
31" fit w/out any mods
32" fit w/ a very slight trim to the front bumpers (or let the tires trim the rubber from the bumper ends)
33" w/ a mild lift (~1-2")

WHEELS:
Just be careful about the offset. Too little or too much will let the tires rub on either the inner or outer fenders.

ARMOR:
Bumpers (Used ARB, or custom)
Rocker panel protection (Trail Gear has inexpensive but decent protection. You'll want the 67" tacoma sliders)
Skid Plates: custom made. No aftermarket options available.

TRACTION AIDS:
Front Locker (ARB RD110)
Rear Locker (ARB or Gen II SR rear axle w/ Mitsu Air Locker)

BODY LIFT
Body Lift: 4crawler.com

SUSPENSION:
Rear coil springs: Gen II stock coil springs, or various other aftermarket offerings (ARB, Coil Spring Spacers for a Toyota Sequoia, etc.)
The rest would all be generic options (rack, fog lights, etc.)
Front Suspension Lift: torsion bar crank, or stronger aftermarket torsion bars from Australia.

Again, each of these should be done based on what kind of wheeling you intend to do.

Thanks this is very helpful. I won't be rock crawling this thing so it will be primarily destination type of camping and expedition type of wheeling.

 

[off-roader]

Thanks this is very helpful. I won't be rock crawling this thing so it will be primarily destination type of camping and expedition type of wheeling.

Probably good enough in stock or near stock form then. Does it have the rear Limited Slip? Should have a sticker either in the driver area or on the rear pumpkin indicating it's a limited slip and requires LSD additive when replacing the rear diff fluid. If you want to be certain, lift the rear end onto jack stands (parking brake off) and turn the rear wheels. If they turn in opposite directions, then it's almost 100% certain to be an open diff (unless the LSD clutch plates are completely worn out). If they spin in the same direction, then it's almost definitely a limited slip.

If no LSD, then either the used SR locker or used Gen I diff w/ an LSD is the cheapest route for a traction aid. An ARB locker won't be a cheap alternative.

Don't forget to also do the trailing arms. Even on easy trails, they fatigue and break. You don't want to have that happen. I'm speaking from personal experience on this one.

 

[skids]

Clean looking motor, good luck with the upgrades


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[4D55 Performance]

If your interested I do have a brand new set of 5.29 gears available for your Monty. They are extremely rare and but worth every penny if plan to go offroad. I am just located in Farmington, so you could pick them up to save on shipping.

 

[off-roader]

If your interested I do have a brand new set of 5.29 gears available for your Monty. They are extremely rare and but worth every penny if plan to go offroad. I am just located in Farmington, so you could pick them up to save on shipping.

Good suggestion. I'd do it if I had a Gen I v6 dif.

 

[livetoride]

If your interested I do have a brand new set of 5.29 gears available for your Monty. They are extremely rare and but worth every penny if plan to go offroad. I am just located in Farmington, so you could pick them up to save on shipping.

pm sent

 

[livetoride]

Since I don't have the rig in my possession yet I need someone's help that has access to a gen1. I am going to have someone help me make a rack and I need dimensions of the roof. Can someone measure the length and width of their roof? Much appreciated!

 

[GrassCat]

I won't be rock crawling this thing so it will be primarily destination type of camping and expedition type of wheeling.

You don't need to waste your money on 5.29 gears for the type of off roading you plan to do. As far as Ray's suggestion on welding the trailing arms, get a set of GenII's. They bolt right up and are much stronger, use the Gen I rubber grommets, but there are thousands out there running off road without a problem in stock dress.

Pull the running boards off and go wheeling to see how it does before you start spending money.

 

[livetoride]

Yeah the first thing I'll do is rip the running boards off and see how she handles in the hills. Preventive maintenance and cosmetic fixes will be first on the list.

 

[geocrasher]

+1 on what Grasscat said. I've wheeled the wee out of my Gen1 2 door Raider, with 30" tires. Taken me everywhere I've pointed it so far! They're great trucks. Save the mods for what you discover the need for. The list is fairly short.

 

[fangars]

Take the running boards, safari thing on the front and anything else you can peel and sell. I would do that before you wheel and damage any of that junk.

I am currently developing rock sliders that will double as steps for better access to the roof rack, and I am developing the roof rack.
Front and rear bumpers are in the future.

If it rides anything like mine you will want to deal with the suspension first.

 

[livetoride]

Take the running boards, safari thing on the front and anything else you can peel and sell. I would do that before you wheel and damage any of that junk.

I am currently developing rock sliders that will double as steps for better access to the roof rack, and I am developing the roof rack.
Front and rear bumpers are in the future.

If it rides anything like mine you will want to deal with the suspension first.

I have been looking for step sliders like this so let me know. I would like to attach the steps to a front bumper like some of the arb ones. So the front bumper would have flares down to the sliders.