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Re: 1999 Montero Sport Limited 3.5L crawler build [Re: Ian Sharpe] #1078681
08/14/15 10:52 PM
08/14/15 10:52 PM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
Quote
Hey ES,

I had this kit put in mine last year. What would be the difference from the one above.

http://www.ebay.com.au/itm/A340E-AW4-REP...=item4cff3c118c

cheers


Hey, Ian.

The A340 is the Toyota version of the AW4. When I asked the trans guy about putting the kit above in the Mitsu A/T, he said that would work just fine, that they're all the same. So, looks to me like the only difference is the box.

OK. I take it back. Yours is an SK-340 kit. The one I'm looking at is the 340-HD2 kit. They're for the same transmissions but the SK kit doesn't have the lock in 1st feature. Also, the instructions in the HD kit detail a bunch of modifications to change several things for different uses. Looks like a much more comprehensive kit than the SK.

Quote
This will fit all 1985 and Up Aisin Warner Models below

A340 / A340E
A341 / A341E
A343 / A343E
AW4


So, that would also include the 30-43LE.

Whoohoo! Got a tail shaft housing and an output shaft. smile

Edward

Last edited by ES_97Sport; 08/14/15 11:02 PM.
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Re: 1999 Montero Sport Limited 3.5L crawler build [Re: ES_97Sport] #1078682
08/17/15 09:27 PM
08/17/15 09:27 PM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
Ok. Got a line on a transmission. I had the dealership check the VIN and this is what came up ...

1997 Montero Sport 4WD A/T
Aisin AW 30-43LE
96M E 67472

If anyone knows of why this wouldn't work, let me know ASAP. Planning on going down to pick it up tomorrow morning otherwise.

It comes with the torque converter but no flex plate. I'm not sure if the flex plate the '99 currently has would work or not. ???

There used to be a place here in Denver that sold beefed up lower stall torque converts. That was a LONG time ago and I don't have clue who that was anymore. Worth looking into?

Edward


'97 Montero Sport LS 5-Speed 3.5L conversion
SAS Dana 44s & ARBs, 35" Yoko Geolandar M/Ts
NP231 B4R doubler/Terra Low231/RP 5.38 229:1
'99 Montero Sport Limited 4WD SAS 3-link project
'03 Montero Sport Limited AWD
'97 Montero Sport LS 5-Speed 4WD
Re: 1999 Montero Sport Limited 3.5L crawler build [Re: ES_97Sport] #1078683
08/18/15 12:41 AM
08/18/15 12:41 AM
dannytuned  Offline
Mudrunner
Joined: Oct 2006
Posts: 391
St. John, IN
You will need the starter, flywheel, flywheel bolts, pilot bushing, torque conv. bolts, and the plate that sandwiches between the motor and trans.


2001Sport 3.0-Headers-Cage-RoofChop-NP231/D300-D44/ARB-Ford9/Yukon/3Link-37's+H1's-PSC Assist-108:1
Re: 1999 Montero Sport Limited 3.5L crawler build [Re: ES_97Sport] #1078684
08/18/15 12:44 AM
08/18/15 12:44 AM
dannytuned  Offline
Mudrunner
Joined: Oct 2006
Posts: 391
St. John, IN
Quote
Does your cruise control still work?


Never had cruise on mine.

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


2001Sport 3.0-Headers-Cage-RoofChop-NP231/D300-D44/ARB-Ford9/Yukon/3Link-37's+H1's-PSC Assist-108:1
Re: 1999 Montero Sport Limited 3.5L crawler build [Re: dannytuned] #1078685
08/19/15 01:30 AM
08/19/15 01:30 AM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
Quote
You will need the starter, flywheel, flywheel bolts, pilot bushing, torque conv. bolts, and the plate that sandwiches between the motor and trans.


Got the torque converter w/ the transmission. Starter isn't a problem.

I got the PN# for the dipstick stuff and flex plate.

I'll have to talk to the dealership to get PN# for the T/C bolts and the flex plate bolts.

I wasn't aware there was a 'pilot bushing' on an A/T. Do you mean the Crankshaft A/T Drive Plate Adapter? The big round do-dad with all the holes that fits between the crank and flex plate?

I'm putting the AW behind a '99 3.5L. I had to use the 3.5L cylinder block plate from an '02 A/T on my M/T because the '97/98 plate wouldn't work with a 3.5L. I remember that from the 3.5L conversion. (along with the correct starter and flex plate (flywheel, in that case)

In addition, I'm going to need a different shifter. Mine has a an extra position so ....


Quote
Never had cruise on mine.


No worries. I did a some research. The PCM connection for the cruise over drive cancel signal (B+). I believe from what I've seen of the PSC docs, this signal can be supplied by the TCU. For what precious little I use cruise I'm not sure its even worth my time to connect. smile


I picked up the '97 Sport AW this morning. I'm getting read to leave for Moab on Thursday so I'm kinda crunched for time. I dug through what I could to find what I was missing + Danny's stuff above. I could only confirm a few of the parts I have below. I'll get this to the dealership so they can figure it out while I'm gone. I will clean this list up ASAP.


1997 Montero Sport 3.0L 4WD A/T "AW4"

Auto Trans (Dipstick) Tube Filler Tube (tube & o-ring seal)

MR246816 (9-1-96 thr 5-3-98) (correct)

MR410582 (6-1-98 thr 5-3-99)


Auto Trans (Dipstick) Filler Tube O-Ring

MD951878 (9-1-96 thr 5-3-98) (correct)


Guage, A/T Oil level (dipstick)

MR246817 (9-1-96 thr 5-3-98) (correct)


Flex plate

MB919250 (9-1-96 thr 5-3-98) (correct)

MR305191 (6-1-99 thr 7-3-03)


Torque converter bolts (flex plate to T/C) 6pcs

MD950120 (9-1-96 thr 5-3-98)

MD713228 (6-1-98 thr 5-3-99)


Flex plate bolts (flex plate to crankshaft adapter) 8pcs

MD113400 (9-1-96 thr 7-3-03)


Adapter, Crankshaft A/T Drive Plate

MB919252 (9-1-96 thr 5-3-98)

MR222860 (6-1-98 thr 7-3-04)


Bolt, T/M Connecting (dip stick bracket - lower)

MF244878 (9-1-96 thr 5-3-98)

MF301372 (6-1-98 thr 5-3-99)


Bolt, Oil Strainer (dip stick bracket - upper)

MF244849 (9-1-96 thr 5-3-98)


Cable, Gearshift

MR246422 (9-1-96 thr 5-3-98)

MR470205 (6-1-98 thr 5-3-99)


Clip, Gearshift Link (shift cable retainer clip)

MB484289 (9-1-96 thr 5-3-98)


Pin, Gearshift Link

MF472040 (9-1-96 thr 1-3-97) 2x25, split

MF472026 (9-1-96 thr 1-3-97) 1.6x20, split

MF180738 (9-1-96 thr 5-3-98) 3.6x23.2, snap


Washer, Gearshift Link

MF450005 (9-1-96 thr 5-3-2000


Plate, Cylinder Block, RR (engine to A/T plate) 3.0L

MD309626 (9-1-96 thr 5-3-98) 3.0L

MD348329 (6-1-99 thr 7-3-03) 3.0L

Cover, Engine Oil Pan Bolt Hole 3.0L

MD347355 (4-3-00 thr 7-3-03)


Plate, Cylinder Block, RR (engine to A/T plate) 3.5L

MD337494 (6-1-98 thr 7-3-04)

Cover, Engine Oil Pan Bolt Hole 3.5L

MD309349 (6-1-98 thr 7-3-04)

MD347355 (6-1-98 thr 7-3-04)


Edward


'97 Montero Sport LS 5-Speed 3.5L conversion
SAS Dana 44s & ARBs, 35" Yoko Geolandar M/Ts
NP231 B4R doubler/Terra Low231/RP 5.38 229:1
'99 Montero Sport Limited 4WD SAS 3-link project
'03 Montero Sport Limited AWD
'97 Montero Sport LS 5-Speed 4WD
Re: 1999 Montero Sport Limited 3.5L crawler build [Re: ES_97Sport] #1078686
08/20/15 12:12 AM
08/20/15 12:12 AM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
Pulled out the Montero Sport FSMs ...

1997 -
R4AW3 - 2WD
V4AW3 - 4WD

1998 -
R4AW3 - 2WD
V4AW3 - 4WD

1999 -
R4A51 - 2WD
V4A51 - 4WD

1997 & 1998 use the AW4 A/T; in '99 Mitsu switched to a completely different A/T


1997 & 1998 transmission gear ratios ...

1st - 2.804
2nd - 1.531
3rd - 1.000
4th - 0.754
rev - 2.393



My new transmission ...

1997 Mitsubishi Montero Sport LS 4WD
Aisin AW 30-43LE
96M E 67472

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]


1991-2001 Jeep Cherokee XJ Aisin AW4 A/T adapter housing ...

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]


1998-2001 Jeep Cherokee XJ Aisin AW4 A/T 23 spline output shaft ...

[Linked Image]
(not a Mitsu part, just a handy stand for photos <img src="/forums/images/graemlins/smile.gif" alt="" /> )


Misc required parts (if they didn't come with the transmission; I'll post pics as I get this stuff) ...

Auto Trans (Dipstick) Tube Filler Tube (tube & o-ring seal)

MR246816 (9-1-96 thr 5-3-98)

Auto Trans (Dipstick) Filler Tube O-Ring

MD951878 (9-1-96 thr 5-3-98)

Guage, A/T Oil level (dipstick)

MR246817 (9-1-96 thr 5-3-98)

Flex plate

MB919250 (9-1-96 thr 5-3-98) (correct)


Edward

Last edited by ES_97Sport; 09/01/15 11:48 PM.
Re: 1999 Montero Sport Limited 3.5L crawler build [Re: ES_97Sport] #1078687
09/02/15 09:45 PM
09/02/15 09:45 PM
Ian Sharpe  Offline
Mudrunner
Joined: Jun 2002
Posts: 315
Braidwood NSW, Australia
My unit leaked atf from the Jeep tailhousing once installed.

Bit of googling said i should have used a seal extension in the Jeep tailhousing. Anyway I sealed up the oil hole & its all been good so far. Just didnt want to pull it all out again, but I did buy the extension & will put in it (if I need to take it apart again). I'm no too fussed about fluid transfer between the 3 units (if there is any) as all 3 , ie tranny, doubler & NP242 are all running atf.


cheers


97 Exceed, 3.5l SOHC auto, 4.90 gears, ARB front locker,rear Harrop E-Locker, Magnum winch, dual transfer cases also 2008 NS swb Pajero, front bar & winch
Re: 1999 Montero Sport Limited 3.5L crawler build [Re: Ian Sharpe] #1078688
09/03/15 06:44 PM
09/03/15 06:44 PM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
Quote
My unit leaked atf from the Jeep tailhousing once installed.

Bit of googling said i should have used a seal extension in the Jeep tailhousing. Anyway I sealed up the oil hole & its all been good so far. Just didnt want to pull it all out again, but I did buy the extension & will put in it (if I need to take it apart again). I'm no too fussed about fluid transfer between the 3 units (if there is any) as all 3 , ie tranny, doubler & NP242 are all running atf.


cheers


Do you have a pic or link for this? I did some googling but I'm not even sure what I'm looking for so I don't know if I found it or not.

Edward


'97 Montero Sport LS 5-Speed 3.5L conversion
SAS Dana 44s & ARBs, 35" Yoko Geolandar M/Ts
NP231 B4R doubler/Terra Low231/RP 5.38 229:1
'99 Montero Sport Limited 4WD SAS 3-link project
'03 Montero Sport Limited AWD
'97 Montero Sport LS 5-Speed 4WD
Re: 1999 Montero Sport Limited 3.5L crawler build [Re: ES_97Sport] #1078689
09/03/15 10:12 PM
09/03/15 10:12 PM
Ian Sharpe  Offline
Mudrunner
Joined: Jun 2002
Posts: 315
Braidwood NSW, Australia
The extension can be used when here is not a correct seal between the housing & the doubler input shaft because the input shaft may not be quite long enough. You may no have this problem. The extension housing comes with a seal. The seal is Timken 710058

http://www.jeep4x4center.com/teraflex-automatic-seal-extension-tf-2904400.html


97 Exceed, 3.5l SOHC auto, 4.90 gears, ARB front locker,rear Harrop E-Locker, Magnum winch, dual transfer cases also 2008 NS swb Pajero, front bar & winch
Re: 1999 Montero Sport Limited 3.5L crawler build [Re: Ian Sharpe] #1078690
09/03/15 11:55 PM
09/03/15 11:55 PM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
Quote
The extension can be used when here is not a correct seal between the housing & the doubler input shaft because the input shaft may not be quite long enough. You may no have this problem. The extension housing comes with a seal. The seal is Timken 710058

http://www.jeep4x4center.com/teraflex-automatic-seal-extension-tf-2904400.html


Ok, now I understand. This replaces the factory seal in the A/T extension housing and seals around the transfer case input snout where it sticks into the extension housing (over the A/T output shaft).

If I understood correctly, Nathan's docs said the short nose t-case snout was needed. I can't figure out if that meant for HIS, or in general to attach to the AW4. I thought I had this figured out but I've found Jeep posts where they say the leak is because you have the wrong snout length.

I've seen a few NP231s - AFAIKT, the only thing that changes there is the snout length. There isn't a difference in the bearing/planetary plate depth. So, ...???

Edward


'97 Montero Sport LS 5-Speed 3.5L conversion
SAS Dana 44s & ARBs, 35" Yoko Geolandar M/Ts
NP231 B4R doubler/Terra Low231/RP 5.38 229:1
'99 Montero Sport Limited 4WD SAS 3-link project
'03 Montero Sport Limited AWD
'97 Montero Sport LS 5-Speed 4WD
Page 3 of 14 1 2 3 4 5 13 14

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