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Re: A/T Transmission Control Module [Re: ES_97Sport] #1104272
03/31/18 12:36 AM
03/31/18 12:36 AM
TOASTY  Offline
Trail Leader
Joined: Jan 2002
Posts: 6,126
Mesa AZ, US. *****
That looks like the Dodge pickup BMC, I think Napa has the conversion fittings for you.


1999 Montero Blizzard package

2005 Montero Limited

2015 Mirage with antifreeze Sparco wheel package
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Re: A/T Transmission Control Module [Re: TOASTY] #1104274
04/02/18 08:51 PM
04/02/18 08:51 PM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
Originally Posted by TOASTY
That looks like the Dodge pickup BMC, I think Napa has the conversion fittings for you.


Yep. I have the fitting sizes written down here somewhere but I think they do, too. I bought new flare fittings and brake line a few months ago since the ABS stuff is all coming out and the front will need to be completely re-plumbed anyway. Figured that was easier than trying to make the old stuff fit. smile

Dynatrac says the axles go into assembly the 26th of next month. frown Pushes us out another month. frown frown At least it gives me time to mock up the Winters shifter assembly and do the wiring diagram for the TCM, shifter and transmission. Getting impatient to see something actually happen. 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: Montero Sport & Jeep A/T Output Shaft [Re: ES_97Sport] #1104275
04/02/18 09:24 PM
04/02/18 09:24 PM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
AW4 A/T output adapter housing - pre-1998 on the right and 1998-2001 on the left. You can see the differences in the bosses for the output shaft speed sensor.
[Linked Image]
AW4 A/T output adapter housing pre-1998 with the retainer clip for the output shaft speed sensor.
[Linked Image]
AW4 A/T output adapter housing pre-1998 with the output shaft speed sensor installed.
[Linked Image]
AW4 A/T output adapter housing pre-1998 internals - 1 PPR reluctor ring installed on 23 spline output shaft.
[Linked Image]
Inside view of AW4 A/T output adapter housing pre-1998 with the output shaft speed sensor installed.
[Linked Image]
AW4 A/T output adapter housing pre-1998 output shaft speed sensor and reluctor ring installed on 23 spline output shaft.
[Linked Image]
AW4 A/T output adapter housing 1998-2001 with the Jeep output shaft speed sensor (and a replacement connector/pigtail) installed.
[Linked Image]
AW4 A/T output adapter housing 1998-2001 with the 1997-1998 Mitsubishi Montero Sport V4AW3 output shaft speed sensor installed.
[Linked Image]
AW4 A/T output adapter housing 1998-2001 internals - 4 PPR reluctor ring installed on 23 spline output shaft.
[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: Montero Sport & Jeep A/T Output Shaft [Re: ES_97Sport] #1104276
04/02/18 09:25 PM
04/02/18 09:25 PM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
AW4 A/T output adapter housing 1998-2001 Jeep output shaft speed sensor.
[Linked Image]
AW4 A/T output adapter housing 1998-2001 Mitsubishi Montero Sport V4AW3 output shaft speed sensor.
[Linked Image]
AW4 A/T output adapter housing 1998-2001 - Jeep 1998-2001 output shaft speed sensor and Mitsubishi Montero Sport V4AW3 output shaft speed sensor comparison.
[Linked Image]
AW4 A/T output adapter housing 1998-2001 Jeep output shaft speed sensor replacement connector pigtail.
[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: AW4 shifter [Re: ES_97Sport] #1104285
04/11/18 12:56 AM
04/11/18 12:56 AM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
I think I'm finally done with the wiring diagram for RADesigns' Winters Rock Shifter. This is a little more complicated then Rory's intended shifter setup, as I need P, N, R, D (4), 3, 2, L (1) signals to control the PCS TCM.

If this wiring works as I think it should, the Winters shifter will generate 1, 2, 3, and 4th. P, N, R are generated by the OEM switch on the PS side of the V4AW3. These signals will be fed into the PCS TCM and also back into the OEM wiring to the PCM. Feeding the signals to the existing PCM will maintain (I'm pretty sure) existing functionality like backup lights, brake cut off for the cruise control, cruise control, the selector position in the dash cluster and anything else that would normally be affected by the OEM shifter.

The nice thing about this setup is that - with the help of the PCS TCM - I will have full manual 1, 2 and 3rd like Rory's setup with the shifter and switches, only without the switches. D (4th) will behave just like D normally does with OD and TC lock-up. I won't have manual control 4th or TC lock-up but I think I can live with that. smile

Wiring the shifter and TCM into the existing infrastructure is a lot easier than if I were trying to do this with a '97-98. The '97-98 only has L (1-2), 2 and D as noted in the diagram below. The '99 wiring matches up perfectly with the shifter and PCM, making this a straight 1 to 1 wiring job. smile

A couple days ago I found a wiring diagram on PCS' site for the Mitsu AW3. laugh Definitely not rocket science. I had Boomslang send me another harness for the '99 PCM so the half dozen connections to the PCM can be wired into the Boomslang harness, leaving the OEM PCM harness intact. Now onto building the spreadsheet for the transmission, shifter and PCM connections. Not too bad. Only about 35 connections. smile

[Linked Image]
1999 Mitsubishi Montero Sport Limit...ams V4AW3 RADesigns Winters Shifter v3.4

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: AW4 shifter [Re: ES_97Sport] #1104311
05/01/18 12:28 AM
05/01/18 12:28 AM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
Whoohoo! The axles are shipping this week! Finally! smile

I spent the last week and a half working on the wiring and I'm almost done. I have a hangup trying to determine how the transfer case 'range detection switch' works as the FSMs seem to contradict themselves, but hopefully I'll be able to figure that out tomorrow.

I got the wiring diagram for the old 2000 PCS TCM translated to the new 2800 and cross referenced to the Winters shifter and Sport's PCM. I stumbled across a PCS-2000 wiring diagram for the old European AW3 from the Eclipse which helped a LOT. Other than cross referencing a about 40 wires and one call to tech support to clear up the wiring on the transmission output sensor, it was pretty painless. Very time consuming but painless. smile (The PCS diagram was for the old AW3 with a reed switch, rather than the magnetic A/C sensor that the newer Jeeps, Mitsus and Toys used. The reed switch needs a +5v pull-up where the magnetic sensor doesn't. Which I already knew but had forgotten. Doh!)

The Toy A340E and the Mitsu Turbo AW3 use a line pressure solenoid instead of the mechanical 'throttle cable' setup to regulate transmission line pressure. The line pressure 'throttle cable' is the cable visible on the DR side of the transmission in earlier transmission pictures. It is -- NOT -- a 'kick down' cable as is erroneously reported in numerous threads on the internet.

Having a mechanical line pressure 'regulator' is a good thing and a bad thing. If like me you are replacing the TCM and have to program a new TCM, not having to figure out line pressure is a huge plus. That's where 99% of the issues come in - and also where you're most likely to trash a transmission, I am told. The three remaining AW3 solenoids are not 'linear', they're strictly on/off - there's no position(s) in the middle like newer transmissions. The FSMs contain detailed shift and TC charts and information so its very clear how to program the tables for the three solenoids.

The downside to having the mechanical throttle cable setup is that the 3.5L throttle bodies don't have the second attachment point for the transmission throttle cable. The 97-99 3.0L throttle bodies do, but they are not quite the same animals. After spending several days researching this, I've come up with some possible avenues -

1) Install the cruise control box from the old style cruise with the separate vacuum control. This is basically the box on the '97 Sport bolted to the firewall that all the cables run into. Run the cable from the pedal and the throttle cable into the box and the accelerator cable out the box to the TB. The same way it worked originally. smile

2) Change TB from the 3.5L to the 3.0L. I know they'll bolt up because I have a 3.0L TB on a '02 3.5L manifold and it works peachy. I just don't know if the IAC will work. I seem to remember that the two IACs are not the same. But, if the plugs and electronics are the same, this would be the simplest solution. All that would be required is a 3.0L accelerator bracket or to fab up a bracket.

3) Figure out how to put the second cable attachment on the 3.5L TB. I'm waiting for a new generation 3.0L TB with the cruise built onto the TB to see if this is even remotely possible. The TB comes with both attachment points but ... there are a lot of 'buts' in this possibility. smile

I'm keeping my fingers crossed for #2. laugh

I was really impressed with PCS' tech support. Very helpful. This is unfortunately going to be a one-off thing, though. PCS kindly informed me that I shouldn't have even been able to buy their controller. Apparently, they don't sell their controller if they don't have a CAL file for the TCM. I ended up with mine because of an error on the part of one of their sales channels. I'm not going to go there right now, but once I get this all working satisfactorily, I'm gong to see if I can pester them into selling me a spare for emergencies. smile

Anyway, the axles should be here late this week or early next. Then its time to drop everything at the shop and get started.

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: AW4 shifter [Re: ES_97Sport] #1104324
05/08/18 12:06 AM
05/08/18 12:06 AM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
Whoohoo! The axles are in! I'll stop by the shop latter this week and get pics. The Sport goes in the week of the 28th. Finally!! laugh

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: AW4 shifter [Re: ES_97Sport] #1104327
05/09/18 10:35 PM
05/09/18 10:35 PM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
Danny, Toasty, anyone? Does anyone know if the throttle cable (transmission line pressure cable) reaches the throttle body? Danny, I found a post where you were wondering the same thing but I couldn't find a post where you said yea or nay. Like Danny said, the 3.0L TB has the second slot for the cable but I'm not sure the cable actually will reach ok.

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: AW4 shifter [Re: ES_97Sport] #1104329
05/10/18 12:46 PM
05/10/18 12:46 PM
dannytuned  Offline
Mudrunner
Joined: Oct 2006
Posts: 391
St. John, IN
Originally Posted by ES_97Sport
Danny, Toasty, anyone? Does anyone know if the throttle cable (transmission line pressure cable) reaches the throttle body? Danny, I found a post where you were wondering the same thing but I couldn't find a post where you said yea or nay. Like Danny said, the 3.0L TB has the second slot for the cable but I'm not sure the cable actually will reach ok.

Edward


Yes it reached and fit right into the slot on the tb.


2001Sport 3.0-Headers-Cage-RoofChop-NP231/D300-D44/ARB-Ford9/Yukon/3Link-37's+H1's-PSC Assist-108:1
Re: AW4 shifter [Re: dannytuned] #1104330
05/10/18 07:22 PM
05/10/18 07:22 PM
ES_97Sport  Offline OP
Rock Warrior
Joined: Jul 2003
Posts: 850
Colorado, US *****
Originally Posted by dannytuned
Originally Posted by ES_97Sport
Danny, Toasty, anyone? Does anyone know if the throttle cable (transmission line pressure cable) reaches the throttle body? Danny, I found a post where you were wondering the same thing but I couldn't find a post where you said yea or nay. Like Danny said, the 3.0L TB has the second slot for the cable but I'm not sure the cable actually will reach ok.

Edward


Yes it reached and fit right into the slot on the tb.


Thanks Danny!!! I was starting to freak out a little as my other options were not looking like they'd work. smile Looks like I'll be working on throttle bodies this weekend. laugh

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 13 of 14 1 2 11 12 13 14

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