Se7en62's '99 Montero Gen 2.5 Overland Build & Adventures

[reversecaoboy]

Removing the rear sway bar is going to require unbolting one of the shocks.

How are you liking the kit? I was thinking of going this route as well, but I hardly carry anything so an extra 440lbs of carrying capacity may be a bit too stiff for me.

 

[Se7en62]

Progress like good! I'm likely going I'm a very similar direction with regards to suspension once I get my interior and gearing swap sorted out.

Once you have some miles on the suspension, I'd like to get your thoughts on the kit and ride quality.

I've had OME's before and have always liked their characteristics. The Bilstein 5100's are very, very nice, but I only have OME and KYB to compare them too. These specific 5100's are custom-spe'd by Adventure Driven Designs in Mesa, AZ for the Gen 2.

Removing the rear sway bar is going to require unbolting one of the shocks.

How are you liking the kit? I was thinking of going this route as well, but I hardly carry anything so an extra 440lbs of carrying capacity may be a bit too stiff for me.

Interestingly enough, when I removed the springs that were in it, I discovered that they were the OME 910's (standard load). The ExPo load versions I installed are the 910X's. I'm planning to bolt down some additional weight so the characteristics will get smoother as I load them down. - Similar to my OME system in my XJ, these are designed to carry a constant load.

PM me if you want the standard OME springs I replaced. They are in excellent shape, just dusty from Southern CA.

 

[Se7en62]

Another 4x4 enthusiast in a local group offered to help me out with modifying and mounting my ARB Winch Bumper (ARB Part#: 3434040). Now this bumper is the correct shape, but the mounts are a little different as they're designed to work with the 1997-2000 Pajero GLS. From what I've gathered the Pajero GLS has a slightly narrower frame "horns" at the very front of the frame. These "horns" are what the bumper would mount to, but in US-spec Montero's it seems that there are extra brackets that have been welded onto the frame horns by Mitsubishi which widen the horns by about 1/2".

This means the bracket's on the ARB Pajero Winch Bumper (3434040) are the correct width on the outside, but the width between the two inner brackets is too narrow so it has to be widened for the 3434040 to work with a Gen 2.5 Montero.

You can solve this problem in your own way, but what we decided to do was to cut the inner parts of each bracket and widen then with new material. It was fairly simple, but time consuming. It took us 12 hours (including lunch and a run to the hardware store for Grade 8 bolts) to completely finish. I will say that if you are using a Warn winch, then it will take you about 1-2 hours less time, since ARB's are built to use a Warn, though any winch can be used.

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The finished product.

 

[MrGalantguy]

Nice progress so far man!

 

[Se7en62]

I was having trouble getting one of the Rugged Ridge manual hubs to engage/disengage. I removed the hub, took it apart, cleaned it with silicone lube and then reassembled with white lithium grease. It's now about 90% easier to turn by hand than before with pliers.

Now, I'm sure the 4WD system and rear air locker work flawlessly. Next job is going to be to replace the fluid in the differentials, transfer case, and transmission and clean the tranny filter.

 

[rajin cajun]

That is a very nice clean Montero. Congrads! There is a lot of knowledge on these forums. I learn something new every day. Please post some pics after you install the stainless steel skid plates! How do they compare to OEM? Will be ordering some myself. Patience patience patience, I keep telling myself....

Cheers,

RC

 

[raysobi]

Rad!! Love the color of your Montero!


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[Se7en62]

Thank y'all! I really like it and it grows on me more and more every day.

Knocked out the transmission drain and fill. I just removed the drain plug and drained 1-gallon of old transmission fluid out, then refilled through the dipstick with 4-quarts of fresh Mitsubishi Diamond SP-III fluid.

After that, I wired the ARB's bumper lights up to the factory wiring harness for the foglights, since they aren't being used anymore. Then I rebadged it as a Pajero with some badges I bought online. I think it all came out pretty good. I am on the fence about the spare tire cover though. It may grow on me more...Thoughts?







I still need to wire up the side markers to run in unison with the running lights and turn signals. I'll do that after I find a connector that I can use to make a wiring harness. I think I might have some luck at the Wrench-a-Part if I pull some bumper lights out of an Eclipse.

 

[Se7en62]

After several times reading through his thread, I decided I'd follow ImNoSaint's lead on replacing the dim factory reverse lights. I went the exact same route he did in his thread (here) with the Nilight 18W LED Flood lights. Following his guide, it only took me about an hour and half to finish the install. Honestly, the most tedious part was tightening the hardware on the backside, since I have a tow hitch installed that blocks the inner most nuts.

For $19/pair, the result are reverse lights that light up my neighbors house across the street like a spotlight.

These tools, plus the angle grinder or die-grinder are all you need:


MORE DETAIL ON IMNOSAINT'S 2.5 THREAD

My finished product...


Today is also FINALLY Pajero Plate Day! Which means I can get rid of my Montero's horrible (sorry folks) Cali plate and get it fitted with the plates of my native Texas homeland. It finally passed inspection after having to clear the EGR code and unplug the battery for a day to reset everything. The EGR did come back on afterward, so I'll still be diagnosing that soon. Has anyone ever run SeaFoam through the EGR's vacuum lines?

 

[Se7en62]

Here's a couple of quick updates: I was able to get my new Texas Tags, which I'm really happy about. The next thing that I wanted to address preemptively was to flush the coolant system with the same solution I used on my Jeep. I just followed the directions on the bottle for a 6-hour deep cleaning.

Not surprisingly, the solution found a leak. After a little advice from the Montero group on FB I just swapped out the line for a new section of 3/8" heater hose. I also ordered an Edelbrock inline fuel filter to install here to help catch any particulates in the cooling system after I finish the flush. I'll make another post once I throw that inline filter on.

After attempting the front brakes twice only to run into barriers (tools, skillset, etc.) I dropped it off at a local shop to let them knock out the Hart front brakes and Timken bearings. I'll update this post with a picture of the new rotor up front behind the wheel, because it looks pretty rad. The shop also threw installed my updated Mitubishi Crank Bolt as well.

After I got it home, I wen ahead and finished replacing the rear brakes as well. That only took me about 20 minutes per side. These pads and rotors are from Hart Brakes. The rotors are their Black Slotted rotor and the pads are carbon-ceramic. The black color on the rotor is an anti-corrosion layer of zinc. These brakes performed really well during my brake-in session and didn't show any noticeable fade until about the 9th round of 60-15mph emergency braking. The brake pad material transferred well to the rotor and I could see the grayish dust collecting in the slots as well.

 

[Se7en62]

As she sits today. I still have quite a bit to do in terms of overland prep, but I'm nearing the end of the major maintenance. So far, I've put about 4k on it and really like it.

I am thinking it will get a K&N filter soon and if someone makes a phenolic manifold spacer then I'll do that, but performance wise it's going to remain stock. A swap to 4.90 gearing is likely though, but probably after our return to the CO BDR in July.

Next up will be to drain the brakes and replace with fresh fluid to stiffen up the pedal feel. I'll get to that tonight, as well as replacing the rear diff fluid and removing the tow hitch before we go hit the trails tomorrow.

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[zerodrift]

Progress is looking good! Are you on stock gearing currently?

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[Se7en62]

Progress is looking good! Are you on stock gearing currently?

Yes, I'm on the factory 4.27's. The 33's are fine with this gearing on the highway, but in stop and go traffic they make it a little slow off the line. I should really be looking at the 4.63's from an SR since I don't plan to go to a 35" tire, but the 4.90's are just easier to come by from an AWD Sport.

 

[reversecaoboy]

I think PajEvo over on ADD forums is selling a set of 4.63's

 

[Se7en62]

I think PajEvo over on ADD forums is selling a set of 4.63's

Nice! I saw them and am considering shoehorning them into my budget sooner rather than later. Thanks for the heads-up.