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Re: 1999 Montero Sport Limited 3.5L crawler build [Re: dannytuned] #1104238
03/07/18 08:31 PM
03/07/18 08:31 PM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
Originally Posted by dannytuned
Originally Posted by ES_97Sport
..decided to use King coil-overs front and rear...Anti-wrap bar in the back.


Nice!

With the atlas/pro rocks, sounds like a starter kit for a race rig...


Oh, good God! Don't even THINK it! laugh laugh laugh I could see my business partner's face if I told him I was gonna start racing. LOL!!

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
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Re: Transfer case and crawl box [Re: ES_97Sport] #1104255
03/15/18 10:43 PM
03/15/18 10:43 PM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
Originally Posted by ES_97Sport
... Atlas t-case -

Gear Ratio: 10.34:1
Drop: Left hand drop (Driver Side)
Input Spline: 23 Spline short
Tailhousing: Standard Tailhousing (w/ speedo provission)
Speedometer: Electronic Speedometer Module
Rear Yoke: 1350 CV
Front Yoke: 1350 CV
Site Tube: Yes Please ....


[Linked Image]

The Atlas 4-speed transfer case showed up last week with the electronic speedometer module included as ordered. The same part is available separately from AA under "300640 : TJ SPEEDOMETER HOUSING KIT".

TJ Speedometer Kit (PDF)

[Linked Image]

Since I've already wired up one Dakota Digital SGI-5 for converting VSS signals and have all the appropriate documentation, I figured I'd get this documented so the guy doing the work wouldn't have to recreate the wheel.

[Linked Image]

Advanced Adapters Electronic Speedo...ital SGI-5e for 1999 Montero Sport (PDF)

Dakota Digital is up to 'e' on their SGI-5. If I remember correctly, I used the SGI-5c when I did the NP231 swap into my black SAS'd 1997 Sport. From a wiring perspective, nothing has really changed there. I originally used Tera's VSS from their NP231 ultra-short SYE which will accept 12v, but Advance Adapters VSS only accepts 5v. That required a change in the wiring configuration. Not a big deal. If anything it makes it easier to understand. smile

Again, the plan is to located the SGI-5 under the console right behind the shifter where it's well protected and easy to get to when configuring. One hole through the floor with a grommet and a LOT of silicon sealer. smile

Code
Dakota Digital SGI-5e -> Mitsubishi Speedometer -

Male connector (SGI side):
A - Red			Power 12v DC (SGI - POWER)
B - Black		Ground (SGI - GROUND)
C - Yellow		Sensor Signal Out (SGI - OUT1 or OUT2*)

Female connector (Mitsu side):
A - Black/White		Power 12v DC (key switched)
B - Black		Ground
C - Yellow/White	Sensor Signal (to speedometer)


AA Electronic Speedometer (VSS) -> Dakota Digital SGI-5e -

Male connector (VSS side):
A - Orange		5v Sensor Power (SGI - SENSOR PWR)
B - Black/Blue		Sensor Ground (SGI - SENSOR GND)
C - White/Orange	Sensor Signal In (SGI - SIGNAL IN)

Female connector (SGI side):
A - Red			5v Sensor Power (SGI - SENSOR PWR)
B - Black		Sensor Ground (SGI - SENSOR GND)
C - Orange		Sensor Signal In (SGI - SIGNAL IN)

* If OUT1 doesn't work, use OUT2.


According to the Advance Adapter tech, there's another way to do this with different parts, but I KNOW this works well with the Mitsu speedometer and sends a reliable sensor signal to the PCM which is pretty important. smile

Now I have to figure out how to get the 2WD/4WD switch part working on an Atlas. smile

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: Transfer case and crawl box [Re: ES_97Sport] #1104260
03/22/18 11:13 PM
03/22/18 11:13 PM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
Corrected diagram for the VSS and Dakota Digital SGI-5e. Correct labeling on the signal wire to the speedometer.

[Linked Image]

The Atlas 2 & 4 speed transfer cases (now) will accept up to two open/closed switches - exactly the same functionality as the Mitsubishi transfer case switches from 1997-2001. Installing two Atlas Low Range Switch Kits (#300378A) maintains the "2WD/4WD Detection Switch" and "Low Range Switch" functionality. Soft of. There is no switch for the doubler on the 4 Speed Atlas so something creative would have to be done there. AA suggests a toggle switch. Sigh.

Given that I'm replacing the transmission and TCM, all of this is somewhat academic, but I want to keep the 4WD indicator on the dash functional and I also want to minimize the amount of stuff going into/out of the PCM that has been disconnected or will now be non-functional. (the switches in the diagram are shown in the positions they need to occupy to function correctly)

[Linked Image]

Waiting on the axles still. frown I had to hunt all over to get a 4 PPR reluctor ring for the AW4. I can't believe how expensive the sensors are. sick

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: Transfer case and crawl box [Re: ES_97Sport] #1104262
03/24/18 01:04 AM
03/24/18 01:04 AM
TOASTY  Offline
Trail Leader
Joined: Jan 2002
Posts: 6,126
Mesa AZ, US. *****
Looking good Edward, Think you'll make it to the Sierras this August?

Also i'm planning on switching to an Atlas 4, the Rocktrac is kind of crappy and wasn't worth the effort. I need something at least stronger than the stock Mitsu case, the worst part is that what I spent on the Aussie 3.15's then the Rocktrac, I could have almost bought an Atlas to begin with and be done. Good Call.


1999 Montero Blizzard package

2005 Montero Limited

2015 Mirage with antifreeze Sparco wheel package
Montero Sport & Jeep A/T Output Shaft [Re: ES_97Sport] #1104264
03/26/18 08:43 PM
03/26/18 08:43 PM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
The five pictures below show the 1997-1998 Montero Sport V4AW3 transmission output shaft with the Mitsubishi 4 PPR reluctor ring. Note the keyway in the second picture. Don't do what I did and buy a shaft without the key (or loose it). I'm still looking for a replacement. smile
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]

The three pictures below are of the 1998-2001 Jeep Cherokee 4WD 4.0L AW4 transmission output shaft and 4 PPR reluctor ring. Chrysler shipped a 4 PPR and a 16 PPR reluctor ring (at least that's what I've been told). I haven't seen a 16 PPR reluctor ring, so .... smile
[Linked Image]
[Linked Image]
[Linked Image]

Shown in the picture below is the difference between the Jeep output shaft on top and the Mitsubishi output shaft on the bottom. The '3rd', outer lock ring groove is missing on the Mitsubishi output shaft (see red arrows).
[Linked Image]

I have a pre-1998 Cherokee output assembly and I'll post pictures as soon as I have time. The differences between the pre-1998 and 1998-2001 Jeep assemblies were not clearly pointed out by anyone (or I'm just dense), so in a nutshell ...

The pre-1998 AW4 output adapter housing, output shaft speed sensor and reluctor ring:

1) The (Jeep) output adapter housing bolt patterns are the same on both sides, but the output shaft speed sensor and reluctor are totally different from their 1998-2001 counterparts. The parts are not interchangeable in any way. If you have a pre-1998 housing, you have to use the corresponding pre-1998 sensor and reluctor.

2) The pre-1998 output speed sensor/reluctor assembly is a 1 PPR setup, while the 1998-2001 sensor/reluctor assembly is a 4 (or theoretically 16) PPR setup.

3) The pre-1998 output shaft speed sensor and reluctor ring are completely different from later versions, and as far as I know are not even of the same type.

So, for anyone that's thinking of doing this, you need the following, all from a 1998-2001 Jeep AW4 (short snout 23-spline) ...

1) 23-spline AW4 output shaft with the third lock ring groove (and the half moon key)
2) Output adapter housing
3) 4 PPR reluctor ring and corresponding output shaft speed sensor (Chrysler calls this a 'Vehicle Speed Sensor', BTW. IT IS NOT the same as the actual VSS on the transfer case tail shaft housing.)

If there's no intention of using the output speed sensor stuff, the correct 23-spline output shaft and adapter housing are probably it. smile Since I'm going to use a TCM (the PCS unit mentioned further up), I kinda need the output speed sensor functional. smile

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: Transfer case and crawl box [Re: TOASTY] #1104265
03/26/18 09:01 PM
03/26/18 09:01 PM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
Originally Posted by TOASTY
Looking good Edward, Think you'll make it to the Sierras this August?

Also i'm planning on switching to an Atlas 4, the Rocktrac is kind of crappy and wasn't worth the effort. I need something at least stronger than the stock Mitsu case, the worst part is that what I spent on the Aussie 3.15's then the Rocktrac, I could have almost bought an Atlas to begin with and be done. Good Call.


Unfortunately not this year. I'm not expecting this to be done until June and then we have a lot of tuning to do. Both with the suspension and transmission TCM. Unless a miracle happens, I'm not expecting that to be finished until the end of summer. sigh If you all are still going up next year, though ... laugh

Eeak! Well, that's good to know. I was actually looking into that option but I couldn't find one. I couldn't even find a used junkyard one here.

Not a very good call. frown I wish I would have decided on the Atlas before building an entire NP231 setup I probably won't ever use.

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: Master Brake Cylinder Upgrade [Re: ES_97Sport] #1104266
03/27/18 09:59 PM
03/27/18 09:59 PM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
Originally Posted by ES_97Sport
Long time between updates but the project is still moving forward.

Brake master cylinder -

Raybestos MC390426 1 1/4" bore. This BMC is - ALMOST - a direct replacement. The flare fittings are a different size than Mitsubishi but that's easy enough. The unit is about 3" longer than the Mitsubishi BMCs. This means that the Group 65 battery will not fit in the standard location with this BMC installed. frown ....


The new BMC with a Group 34 battery. I lined the new BMC up as close as I could to where it will actually mount. There's about 3/4-1" between the BMC in my black Sport and my Group 65 battery. The gap here is about 3/4". There wouldn't be more than 1" between the new BMC and this battery - which is significantly shorter than a Group 65. smile
[Linked Image]
[Linked Image]

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: Transfer case and crawl box [Re: ES_97Sport] #1104267
03/27/18 10:14 PM
03/27/18 10:14 PM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
Originally Posted by ES_97Sport
... The Atlas 2 & 4 speed transfer cases (now) will accept up to two open/closed switches ....


Two switch kits from Advance Adapters for the 2WD/4WD switch and Low Range switch. Note that these are the 300378 -A- parts for the post 8-2014 production transfer cases.
[Linked Image]

Advance Adapters speedometer gear for the Atlas transfer case. This is the 'short' (p/n 300637) speedometer gear for the Atlas electronic speedometer housing. (the mechanical speedometer housing uses different gears) This is the 39 tooth for a vehicle with 37" tires and 5.38:1 axle gears. It doesn't make all that much difference in my case because I'm using the SGI-5 speedometer converter from Dakota Digital and I could have ordered any gear and made all of the adjustments to correct the speedometer using the SGI-5, but I starting out in the ballpark is a good idea. smile
[Linked Image]

This is the last of the pieces for the transfer case. Everything is here and ready to go. STILL waiting on the axles ... sigh.

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: A/T Transmission Control Module [Re: ES_97Sport] #1104268
03/27/18 11:41 PM
03/27/18 11:41 PM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
Wiring diagram for the resistors that need to be installed in place of the transmission solenoids that will disappear when the original transmission is removed. These will keep the PCM from popping trouble codes for the missing solenoids.
[Linked Image]

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: A/T Transmission Control Module [Re: ES_97Sport] #1104269
03/28/18 08:48 PM
03/28/18 08:48 PM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
Originally Posted by ES_97Sport
Wiring diagram for the resistors that need to be installed in place of the transmission solenoids that will disappear when the original transmission is removed. These will keep the PCM from popping trouble codes for the missing solenoids. ....


[Linked Image]
Advance Adapters Electronic Speedom... Montero Sport Speedometer ECM/PCM (PDF)

[Linked Image]
Advance Adapters 2WD/4WD & Low ...7-1999 Montero Sport Transfer Case (PDF)

[Linked Image]
1999 Montero Sport A/T V4A51Solenoid Bypass Resistor Wiring Diagram (PDF)

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 12 of 14 1 2 10 11 12 13 14

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