I'm making a wish list for my 90 montero. I understand that some of the Gen 2 parts are considered upgrades. I don't have easy access to a gen 2. Best deal I've found on one was $600 for a non running SR thats got everything but the cat converter on it. Its like 2.5-3 hours from me and I would have to pay/find a way to get it home. Second "deal" on one was an hour farther, the guy would only sell parts not as a whole. If I wanted the rear end he wanted $300 for it and me to pull it <img src="/forums/images/graemlins/zombie.gif" alt="" />

Anyway, I'd like to put gen 2 brakes on the front and I have read through a lot of info on here so far but just want to make sure I get a good option cost and performance wise. I noticed the 95 SR rotor is different then the 95 LS and found different part numbers for the calipers too. Is one option better then the other? Its said the bolts to mount the SR rotor need to be shorter then the Gen 1 is that true for the Gen 2 LS rotor as well?
Ill probably be ordering the parts online, I doubt napa would take a signal piston caliper for a core when buying a dual piston caliper..

Gen 2 UCAs
I know the ball joint design is better when it comes to changing them. If I don't go with much bigger tires then 235s and don't give it much lift is it still ok to put the gen 2 UCAs on? My concern is if I still be able to get a decent alignment.

Gen 2 Ideler arm
Can anyone comment on how the Gen 2 idler arm has held up on a Gen 1? Worth doing? Has the pitman arm from the gen 2 been used too?

My montero will be used for general commuting most of the time. Occasional towing and will take it on camping and hunting trips. Don't plain on doing any major off-roading.

Thanks for any help and advise in advance

That far away, u-haul rents p/u and tow dollies. Good alternative

If you're just using it for commuting, camping, etc., my question is: Why bother?

John B.

I'd do the Gen 2 brake upgrade, but like JB mentions - skip the rest.

Point taken.

John B.

Keep it stock as long as you can. Someday you'll have one of the few non-modified Gen 1s and it'll be worth a fortune to a collector!

My 2 cents: I worked my way thru the gen 2 upgrade list for the most part. I was rebuilding a Gen 1 with 225K miles and only upgraded the parts that were shot - which was all of them. ? I use it as both a daily driver and expedition rig. I also tend to wheel alone and go places I probably shouldn't when solo so i want my rig to be as capable as possible because i'm too lazy to walk 50-100 miles back to a road. That said, given your intended use I agree with the earlier comments to do the front brakes and call it a day. Bone stock Gen 1s are more than capable for how you intend to use your rig. I'd drive it 'til something wears out. At that point if the part is upgradeable then go for it. In the meantime enjoy your rig and save your time and money.

In case you're wondering how much the upgrades will improve your rig. here is a list of mine and the reasons why for reference.

1. Front brakes. Stopping power for 33's and steep hills
2. Upper control arms. a bit more travel but mostly easier to maintain.
3. Torsion bars - heavy bumper and big winch (combined weight of over 220 lbs) aren't so great for the stock suspension and the rig feels front heavy. bigger tbars provide a much better ride and road feel by compensating for extra weight, not to mention a stiffer ride off road. WIth a stock bumper the stock t-bars were plenty.
4. SR rear end. I did this mod as much for the disc brakes and bigger trailing arms as for the locking diff. And the coils are nice for a bit more lift. I've only HAD to lock it up twice but it was worth having when i needed it.
5. Steering box. the tighter turning radius has come in handy - especially when i was trying to pick my way up a goat trail in a Baja canyon. <img src="/forums/images/graemlins/shiner.gif" alt="" />
6. Idler and Pitman arms - Required for the gen 2 steering box.
7. Wheels.
8. Seats. Comfort and arm rests, period.

HTH <img src="/forums/images/graemlins/cheers.gif" alt="" />

I'm pretty sure that the rear trailing arms are a direct swap too. Once read here that the Gen2 trailing arms were a bit beefier.

Also read here ages ago that Gen2 coil springs were desired and also a direct swap. In the Gen1's they were said to have provided a little extra lift (about 0.75 to 1.5" lift) without having to install an actual lift kit.

Thanks for the info guys. Welcome back Mi_Mitsu <img src="/forums/images/graemlins/kewl.gif" alt="" />
I do plain to do some maintenance in the front end and getting an alignment done soon.
Any info on the different part number for SR and other gen 2 caliper? Would there just be different pistons lengths depending on the rotor thickness and they preform the same. Do you need to put in shorter bolts to mount the rotors?

I used these Gen 2 SR calipers:

RAYBESTOS Part # RC10687
RAYBESTOS Part # RC10688

They come with the brackets.

I did use shorter bolts to mount the rotors to the hubs, I think it depends on the rotors... The SR versions are slightly thinner in the mounting flange to hub area being there is an ABS ring back there as stock in these as well that you won't be using in the Gen 1.

There has been a lot of discussion about SR being larger or not, the conclusion I believe is that there are 2 different Gen 2 rotors. LS/RS 276mm dia. x 24mm & SR 276mm x 27mm thick.

If you do calipers, do the matching rotors. I used the 3.0 GEN II stuff for convience since they were the easiest to get. When I did the upgrade, I used the old rotors. The first hard stop warped them good. Now I do matching rotors and calipers. Don't forget that you have to trim the backing plates to make them work and the little bracket on the caliper that holds the short metal line.
I had an issue with using new bolts on the hub was that I really couldn't get my socket in to hold the bolt. I used socket cap bolts instead.
Gen II rear springs do give a slight lift. I feel that they handle better with the newer Coils and it tows better too. I feel the Gen II UCA's make it ride better, but if you don't lift it or do bigger tires, I would leave it. My current Gen I has 265/75R16 and still has plenty of room.