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3.5L 6G74 into a Gen 1 #995323
04/29/10 05:41 AM
04/29/10 05:41 AM
SRTNate  Offline OP
Getting the Wheeling Fever
Joined: May 2008
Posts: 97
Tucker GA
I am currently swapping a 3.5L out of a '95 SR into my '89 Gen 1. I'm not too terribly far into the process, but I'm feeling good about how things are going, and thought it was about time to start documenting it. Overall, it's been fairly straightforward...there are some fitment issues, but I consider them minor. I haven't yet run into any "show-stoppers".
[Linked Image]

The only firewall clearance issue I've run into so far is just to the left of the brake booster (facing it). The doubler for the steering column needs to be trimmed a bit, and the firewall needs to be hammered back...though, there is nothing behind it, so it is a pretty easy task. It's pretty ugly, but I figured I'd make sure everything fit before I made it pretty...even though it will be impossible to see.
[Linked Image]

The next clearance issue is with the oil pan. It hits the front axle, and the axle-crossmember mount. For now I have just cut out the interfering sections, and will weld in patches later. This too was easy, neither location interfered with the oil pickup. At the moment this picture only shows the first cut, but I will get an updated pic posted.
[Linked Image]

Neither the Gen 1 or Gen 2 engine mounts will work, so I'm currently working on making a hybrid of the two. I've cut the Gen 2 mounts and am just using the plate that mounts to the engine, and I'm using all of the Gen 1 mounts EXCEPT the plate that mounts to the engine. I haven't finished this yet, but the test fit looks good, and I just need to weld them together.
[Linked Image]
[Linked Image]
[Linked Image]

I don't have any pictures of the exhaust yet, but I've test fit the 3.5L Y-pipe and it appears that it'll work with no, or minimal modification. It seems to line up with the stock catalytic converter location and may or may not need to be shortened.

I've only done a minimal amount of work to the wiring so far. I pulled every last bit of wire out of the 95 donor, but I'm not sure how, or if, I'll use it all. At the moment all I've done is eliminate the ABS and Airbag wiring. There's some decisions to be made regarding how I'm going to go about the wiring, but really it's what I consider "the easy part"...getting the engine to physically fit seemed to be a far bigger problem.
[Linked Image]

Last edited by SRTNate; 04/29/10 05:44 AM.

1989 Mitsubishi Montero SWB 0.0L (3.5L soon?) Auto, Front LSD, Rear SR Locker, Aisin hubs, Safari Snorkel, ARB Front Bumper, Warn M8000, Bushwacker Flares
1984 Mitsubishi Montero
2005 Dodge SRT-4
1970 Plymouth 'Cuda (in pieces)
...and a few others less interesting.
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Re: 3.5L 6G74 into a Gen 1 [Re: SRTNate] #995324
04/29/10 06:38 AM
04/29/10 06:38 AM
justice  Offline
Roll Me Over
Joined: Feb 2000
Posts: 3,269
So Cal, USA *****
Awesome! I've been hoping someone would do this swap! <img src="/forums/images/graemlins/kewl.gif" alt="" />


99 Gen 2.5, fixing blown head gasket
89 SWB- 33's, ARB Front locker, SR rear locker/axle, SR F brakes, winch, WST Offroad Armor all Around, 2.85 Aussie T-case Gears (SOLD)
Sold: (2) 95 SR's, 86 SWB, 90LWB, 91 LWB
-Can Change a timing belt in my sleep..
Re: 3.5L 6G74 into a Gen 1 [Re: justice] #995325
04/29/10 06:53 AM
04/29/10 06:53 AM
Angrybooger2  Offline
Getting the Wheeling Fever
Joined: Dec 2009
Posts: 84
Nipomo,Ca
Really awesome!


88 Dodge Raider
1.5" lift
32"X11.5" A/T tires
15X10 vintage enkei's
Re: 3.5L 6G74 into a Gen 1 [Re: SRTNate] #995326
04/29/10 01:54 PM
04/29/10 01:54 PM
MontyMcV  Offline
Trail Leader
Joined: Jun 2003
Posts: 7,340
Cleve-burg OH USA
That's going to be one cool(er) ride when you're done! <img src="/forums/images/graemlins/kewl.gif" alt="" />


Big Truck: 00, 3.5, Endeavor, 5-Spd drive line in hand!
Little Truck: 87, 2.6T I/C, MT, LSDs, Tonneau Top
Her Truck: 03, 3.8, 20th Anniv, 65k
Daughter's: 06 Eclipse, Keeping it Mitsu!
FSMs: MitsubishiLinks.com
Re: 3.5L 6G74 into a Gen 1 [Re: MontyMcV] #995327
04/29/10 03:46 PM
04/29/10 03:46 PM
JAVYPRO  Offline
Body Damage is Cool
Joined: Feb 2001
Posts: 1,966
Buford, GA USA
Coincidence. We are going on vacations to Puerto Rico for the whole month of June and since car rental prices are insane, ($4,000 for Jeep and $800+ for a little sardines can), I was talking to my brother about finding an SUV and he told me about this guy that sold his GEN I LWB with a 3.5 transplant for just $1,900.

I was a day too late. <img src="/forums/images/graemlins/scared.gif" alt="" />

Great project.<img src="/forums/images/graemlins/kewl.gif" alt="" />
Javy


88 red Montero with the Dakar Special Edition decals, 438,000 miles (As of 7/23/2012) some occational blue puffing but still strong and counting!!! I am going ppsshhh (turbo), Stay tuned =) ...
Re: 3.5L 6G74 into a Gen 1 [Re: JAVYPRO] #995328
04/29/10 08:10 PM
04/29/10 08:10 PM
fasteddy  Offline
Web Wheeler
Joined: Jan 2001
Posts: 13,649
Helen , GA *****
Will the 3.0 pan fit the 3.5? I didn't think they changed the blocks that much. I knew the 3.5 was 19mm taller in deck height.

Are you going to use the 95 or gen1 tranny?

I saw the 95 hull for sale on CL with the shogun in the edge of the pic...


Not responsible for advice not taken...
Re: 3.5L 6G74 into a Gen 1 [Re: fasteddy] #995329
04/30/10 12:31 AM
04/30/10 12:31 AM
SRTNate  Offline OP
Getting the Wheeling Fever
Joined: May 2008
Posts: 97
Tucker GA
Quote
Will the 3.0 pan fit the 3.5?


I'm not entirely sure...
I was eyeballing it, and it looks like the bolt pattern is the same. When I take the pan off all the way, I'll double check. But, the Gen 2 pan looks nice and stout, with a nice solid gasket surface. Also it looks as if the Gen 2 pan is meant to be the lower support to the engine regarding how it mounts to the transmission...basically eliminating the two Gen1 engine-to-trans brackets. I won't miss them. Plus the 2-piece oil pan makes it easy to clean the sump if one so desired.

Quote
Are you going to use the 95 or gen1 tranny?

That's probably going to be a "phase 2" of the project. To help keep my options open, I did this...

[Linked Image]

So I could save this..
.
[Linked Image]

The transmission/transfer case out of the Gen 2 is quite a bit longer than the Gen 1. I measured, but forgot, but I'll measure again.

[Linked Image]

The Gen 1 SWB rear driveshaft is so short already, that I think I'd have to fashion a slip yoke eliminator and get a telescoping driveshaft to be able to use the Gen 2 Trans.

The whole "transmission question" also contributes to the "wiring question". I want to find a good way to do the wiring so I don't have to do a bunch of chopping and grafting now, only to undo it later to return it to it's original state.

Last edited by SRTNate; 04/30/10 03:35 AM.

1989 Mitsubishi Montero SWB 0.0L (3.5L soon?) Auto, Front LSD, Rear SR Locker, Aisin hubs, Safari Snorkel, ARB Front Bumper, Warn M8000, Bushwacker Flares
1984 Mitsubishi Montero
2005 Dodge SRT-4
1970 Plymouth 'Cuda (in pieces)
...and a few others less interesting.
Re: 3.5L 6G74 into a Gen 1 [Re: justice] #995330
04/30/10 01:20 AM
04/30/10 01:20 AM
KB2IAW  Offline
Mudrunner
Joined: Dec 2003
Posts: 363
Otsego Co. N.Y.
Thats quite an undertaking ...looks good so far , btw did you get the money order for the parts ??? should have arrived by now .


1994 montero SR 3.5 v6

City Of Hills Oneonta N.Y. FREEDOM HAS A TASTE,AND FOR THOSE THAT HAVE FOUGHT FOR IT, THE TASTE IS SO SWEET , THE PROTECTED WILL NEVER KNOW .

VENI VEDI DECI <oneontasportsmenclub.net>
Re: 3.5L 6G74 into a Gen 1 [Re: KB2IAW] #995331
04/30/10 01:28 AM
04/30/10 01:28 AM
W
willwinchforfood  Offline
Rock Warrior
Joined: Sep 2008
Posts: 508
Tucker, Ga
Why is this taking you so long? More Monster less sleep.


SOLD!!: 91 LS 95 SR Rear LSD front 95 LS front brakes Dons Bumper 10k Gorilla/Promark winch Safari Snorkel Dual bouncy 31's

1991 Chevy Suburban 33's. All other stock.
Re: 3.5L 6G74 into a Gen 1 [Re: willwinchforfood] #995332
04/30/10 02:11 AM
04/30/10 02:11 AM
SRTNate  Offline OP
Getting the Wheeling Fever
Joined: May 2008
Posts: 97
Tucker GA
Quote
Why is this taking you so long? More Monster less sleep.


All Monster Energy Drink donations are welcome.


1989 Mitsubishi Montero SWB 0.0L (3.5L soon?) Auto, Front LSD, Rear SR Locker, Aisin hubs, Safari Snorkel, ARB Front Bumper, Warn M8000, Bushwacker Flares
1984 Mitsubishi Montero
2005 Dodge SRT-4
1970 Plymouth 'Cuda (in pieces)
...and a few others less interesting.
Page 1 of 13 1 2 3 12 13

Moderated by  Macka, Mudraider, off-roader, PajEvo, rxinhed 

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