1991 montero 4m40 swapped offroad/overland build

Made some more progress today. Pulled the trans, flex plate and engine plate off, then pulled the timing cover and accessories off.

It appears the type 73 used the single row timing chain like the l200. I'm guessing only the pajero got the double row timing setup. I will say it is impressive looking at all the gears as this is the first time I've peaked inside one of these engine. They seem fairly well built.

It's looking like my parts wont be in until tomorrow. I think I will be setting up the popup.
 

Attachments

  • 20210129_161403.jpg
    20210129_161403.jpg
    896.6 KB · Views: 18
  • 20210129_161413.jpg
    20210129_161413.jpg
    926.6 KB · Views: 19
  • 20210129_161417.jpg
    20210129_161417.jpg
    770.4 KB · Views: 17
Time to post some updates. My transmission came in from the uk. Im still waiting on a clutch and some other misc parts. Right now I've pulled the engine back out. Removed the trans, removed the timing cover and have been working with my engine mounts. Sadly I think my only option is to cut the drivers side mount off the frame and weld it in about a half inch higher. Ive been dealing with the ac pump interfering with the steering linkage, and the pulley is so close, I can't actually change the belt with the box connected. So thats one project going on at the moment.

The next which I'm really excited about. I actually managed to get the secondary battery tray and sheet metal from a first gen diesel pajero, so I've been working on getting that welded in.. as you can see I had to drill grind and cut the piece off the original inner fender. They welded it all over!.

Whats cool is the holes for the battery vertical mounts are actually stamped. Mitsubishi used silver tape to cover them up. The only thing they didn't do is tack in the nuts. Thats something I will do.

Some other pics of my new sexy transmission. Unfortunately I will have to wework my crossmember and driveshafts.

And of course my pics are too large to upload. Ill probably put them on my server this evening and edit
 
Some pictures of progress. the engine out and partially torn apart for the pajero timing cover and backing plate. THe new transmission, drive shafts, the difference between a type 73 engine plate and a pajero engine plate, timing cover as well.

Last, the installation of a oem pajero secondary battery tray sheet metal I cut off a first gen pajero.
montero43.jpg


montero44.jpg
montero45.jpg
montero46.jpg
montero47.jpg
montero48.jpg
montero49.jpg
montero50.jpg
montero51.jpg
montero52.jpg
 
Managed to get the new clutch installed, transmission bolted up and the new timing cover and front main installed along with the vac pump and some other misc tidbits. I pulled the drivers side engine mount back off as well. I need to do some more work on it. if the weather is decent tomorrow I may get the engine back in, but we will see.



One of these days I will get around to resizing these images as well.


montero53.jpg
montero54.jpg
montero55.jpg
montero56.jpg
 

PacS14

Adventurer
Congrats! I can't see any of the pictures in your last two posts. Either way glad to hear you are making progress!
 
Been awhile since a update, I had a busy last 5 months at work, but im back home finally and back at it with the montero build.

I'll try and post some pics, and probably do some videos eventually on youtube.

As of today. I just dropped the driveshafts off again to be made for the manual trans. The rear had to be lengthened and the front shortened. I think I may actually get them back tomorrow.

I had to do quite a bit of cutting on the transmission crossmember to get the manual trans mount to fit. It's about 90% done. I have it sitting roughly where I want. I just need to make 2 tubular spacers to weld into the crossmember that space it up enough.

Lets see what else? I ended up having to cut both engine mounts back off, ditching one of the oem, making one that wouldnt work, then realizing I could salvage one of the originals, then fabricating an entire new one. All this to make the ac compressor clear the steering box. the engine now sits nicely in the chassis with plenty of clearance. Unfortunately I somehow broke the ac pump, so I need to source a new one. I think I can use one off a usdm montero, but im not 100% sure yet.

I ran into a snafu with my welder, it was shipped electrode negative and setup for flux. I did quite a bit of crappy welding being pretty disapointed. I finally lost it doing the engine mounts then realized after doing some research you could switch them. I went to look at it, and sure as hell they were reveresed. WIth that being fixed it welded beautifully. I'll probably grind out the winch plate welds and redo them.

So after the engine being installed and taken out many times, I pulled the trans so I could more easily mock up the new engine mounts. While reinstalling the trans I managed to break a tab off the stupid pull style throwout bearing cage/lock. Well I couldnt even find a part number for it, so I ended up buying another brand new clutch for what seems to be a 2 dollar piece of flimsy metal.

I picked up a redarc bcdc50d and did some solar panel testing. I ended up going with some solid newpowa 100w panels. I have 2 currently, but I may run a third as I dont plan on using the upper rack space for much else.

Tomorrow I will be buying another yakima load warrior rack extension to run the entire lengths of the rig. I'm also shopping for some used gutter mounts. I think I will shoot for 4 cross bars. I'm also looking at more lighting for the rack.

Other fun things I just snagged is a high lift jack attatchment for jacking the arb bumper. I'm excited to check that out.
 
Here is a quick update with some pics.

Drive shafts were made. I think the front is a bit short as I only have 2 inches of engagement, and it had about 3" stock. The rear could have been maybe a half inch longer but I believe its plenty good.

Clutch setup is drilled and installed. Mitsubishi actually had the factory underdash brace in place for the clutch pedal! all I had to do was drill out the holes for the master and studs from the clutch pedal.

The engine should be back in for the final time, new oil seals installed, clutch reinstalled, I do need to install the transmission mount, which is a matter of coming up with 2 bolts. No biggie.

I installed the yakima roof rack I had that was already extended once with another extension. Fits the roof perfectly I think. It was a chore doing it as I had a high lift and axe hanging off the side, that all came off and I broke it down into piece. I still need 2 more cross bars as one of mine is bad.

I also picked up 5 quarts of gl4 oil for the trans and transfer case. Hopefully it's enough. I think one is 2.4 and the other 2.3.

Taking a break for the day227103752_10226553995737548_7953239761128219136_n.jpg227971375_10226554002417715_6894182516186049615_n.jpg228708350_10226554003857751_3495143560876048323_n.jpg229332853_10226554002937728_5719612816302982620_n.jpg230400722_10226554358706622_3969472732029478218_n.jpg231420310_10226553996577569_5986354007910561956_n.jpg231604563_10226554360306662_5293785573950200458_n.jpg232053566_10226554359906652_4156877807525675804_n.jpg233699525_10226554003457741_3152367772486507357_n.jpg227103752_10226553995737548_7953239761128219136_n.jpg227971375_10226554002417715_6894182516186049615_n.jpg228708350_10226554003857751_3495143560876048323_n.jpg229332853_10226554002937728_5719612816302982620_n.jpg230400722_10226554358706622_3969472732029478218_n.jpg231420310_10226553996577569_5986354007910561956_n.jpg231604563_10226554360306662_5293785573950200458_n.jpg232053566_10226554359906652_4156877807525675804_n.jpg233699525_10226554003457741_3152367772486507357_n.jpg
 
Last edited:
I havent done much for updating, but I had to pull the timing cover off and replace the camshaft. My fault, apparently I didnt get a shim reseated when I was reshimming the valves. Anyhow to do the timing I had to pull the cover as my crank pulley had no mark to lineup the timing. While I was in there I installed a new tesnioner and chain which really wasnt needed, but what the heck. I got the valves somewhat close, as good as I could as half the shims are NLA from mitsubishi. I had 2 valves with .002 clearnace before, that definitely needed to be addressed. This was a few weeks of waiting for parts from all over the country.

Other things, well I had this 2000rpm rattle that I had first thought was the valves, well I think it was a fuel knock or something. It ended up being a dirty fuel filter. I had bought 2, but sat on them and had no gotten around to replacing one yet. The replacement and purge of the new filter seemed to fix it.

I've done a few janky temporary wiring jobs to some not so important stuff as I just havent been motivated to wrench on it much as it's been running good and I'm in the middle of a transmission rebuild on my mighty max with a bearing puller thats nla... I ghetto rigged the intercooler fan so I can run it when im doing longer trips. It definitely helps, even without a hood scoop. Then We went night wheeling the other day and I hadnt wired up the hella 700ffs yet so I had a few minutes before my friend was ready and I just ran some temporary wiring to run them. I'm definitely glad I did, they worked awesome for plane ol halogen.

My house battery setup is only slightly done and mounted. The battery mounting is done, just not tied down in the pic. I need to build a small encasement for my power, that ill be on the list when I build a sleeping setup/fridge setup in the back. Right now everything is good and safe, just not pretty. I also had to run a temporary locker power wire from the aux battery when we went wheeling. Another wiring thing that will take awhile to get sorted. I've got 2 switch panels to wire up as well, along with an entire relay box. I'll probably get into it later this week, but I needed a break from this. I wasted my entire summer working on it, and basically missed summer. Now im stuck with ************ fall oregon weather, and waiting on a fishing boat that was suppose to be delivered over a month ago.

As of now, I'm basically just racking up miles on the rig to make sure everything is good. I just picked up an entire front end rebuild from sankei 555. all tie rods, idler arm, pitman arm, lower ball joints with spare, and a spare set of uppers as they are already new oem installed with the second gen oca,. Oh and I will put new lca bushings in as well. That will probably happen next week or when we get a few dry days.

The thing needs taller gearing. with 4.625 and 35s with the diesel v5mt3 transmission im turning 2200rpm at 60. it sounds good, but the 2/3 shift is brutal up hills. You gotta rev it way out to get it into boost on on the upshift, otherwise it falls on it's face. I will be turning the pump up and the boost up even more. Probably shoot for 14 to 15lbs, and I'll open up the fuel a bit pre boost and on boost. I just need to run my new egt probe and get a boost gauge setup.

I was going to upgrade to a second gen radiator and clutch fan shroud, but the new radiator I bought from mitzybitz came in broken. the overflow nipple was broke and gone, and it was suppose to be a koyo radiator and they sent me a nissen... I'm still dealing with that, pretty frustrating there, My current radiator is a older 2.5 brass that has a partially rotted out cooling fin core. it climbs up temps pretty good when pulling a hill, especially with a light boat, and even worse in the summer. It's just not up to the task and I wanted a proper sized radiator for the 4m40. The stock second gen 4m40 seems like a good fit. I thought it would be too big but width wise it seems fine. I should double check the height now that I think about it.

Other fun stuff. I need to put a hole in my hood and some sort of scoop or louvers to get better airflow through the intercooler. I really dont feel like trying to do a front mount right now. I've been trying to get dave from above to sell me his turbo hood, but hes not having it :)

There is a bunch of small stuff to finish up, but for now I just wanna enjoy it a bit. I absolutely love this thing!


20211025_150053.jpg20211025_150100.jpg20211025_150112.jpg20211025_150124.jpg20211025_150254.jpg20211025_150320.jpg20211025_150344.jpg20211025_150221.jpg20211025_150145.jpg
 
We went out the other day for a little night wheeling. I almost rolled it sliding into a 3ft deep rut. I dont remember it being nearly that deep this summer, and it was just that one. that was fun. Anyhow here are some pics of us throughout the night. hes in my old 94 sr on 33s. I think he got stuck about 8 times lol. I managed to get stuck twice, once between a steep hill and a gravel road, and then in the pics.
 

Attachments

  • Resized_20211017_2049281.jpg
    Resized_20211017_2049281.jpg
    581.9 KB · Views: 7
  • Resized_20211017_2049491.jpg
    Resized_20211017_2049491.jpg
    505.2 KB · Views: 8
  • Resized_20211017_2048071.jpg
    Resized_20211017_2048071.jpg
    577.7 KB · Views: 8
  • Resized_20211017_1924481.jpg
    Resized_20211017_1924481.jpg
    640.5 KB · Views: 8
  • Resized_20211018_0259131.jpg
    Resized_20211018_0259131.jpg
    526.2 KB · Views: 8
  • 20211018_021059.jpg
    20211018_021059.jpg
    3.9 MB · Views: 8

Forum statistics

Threads
185,533
Messages
2,875,612
Members
224,922
Latest member
Randy Towles
Top