I thought I would post this in here because this build will be much different than other Montero's in the Mitsubishi section here at Pirate 4x4. My plans are to build an expedition rig and daily driver. I don't need a rock crawler, that's what my 1985 Mitsubishi Pickup TD is for. I just want to build a rig that will haul the whole family on expedition style adventures across Utah's vast desert country. The 1991 Montero was the last year for the boxy first generation Montero's. I have always been a huge fan of the boxy styling of the first gens. I purchased this rig out of southern California because I wanted a rust free ride. Oh yeah, I forgot to mention it just recently had a $5600 engine installed. Who knows how it will turn out, but it will make for a fun project. For the most part it appears to be in really nice shape. The rear bumper has a ding and the drivers bouncy seat has seen better days, but over all it's really nice.


What I have to work with:

-1991 Mitsubishi Montero LS, V6, Automatic, Rear LSD, Sunroof, and no rust.


My Plans:

-1.5" OME Lift and a slight torsion bar adjustment to level it out.

-1" body lift

-Airflow Snorkel

-Front and rear ARB Lockers

-4.89 differential gears

-2.85 Crawler gears

-Front heated seats

-New leather seats, door panels and carpet

-Aisin manual locking hubs

-Ladder for the rear door

-ARB Touring steel 2200mm x 1250mm Roof Rack for mounting my RTT

-Mombasa Roof top tent

-ARB Bullbar and Warn M8000 Winch

-Custom drawer system

-31x10.50x15 Hankook Dynapro MT's

Here she is, she has the extremely rare 2 tone paint job and rare alloy wheels.
http://farm6.static.flickr.com/5220/5487209052_af0ed5c5f7_z.jpg
http://farm6.static.flickr.com/5131/5505082887_1906873d10_z.jpg
http://farm6.static.flickr.com/5056/5505678460_dc341429b8_z.jpg
http://farm6.static.flickr.com/5099/5505678536_7d96c039d7_z.jpg

Bouncy Seats?

Bouncy Seats?

I definitely plan to go with dualing bouncies:bounce::bounce:

Sounds like a cool project, everyone needs a expedition style build to go with their rock crawler. I like to have a truck for all occasions :D


I don't need a rock crawler, that's what my 1985 Mitsubishi Pickup TD is for.


I think we would all like to see some pics of your pickup out on the rocks:smokin:

I think we would all like to see some pics of your pickup out on the rocks:smokin:


I would too, but were all snowed in here in northern Utah. Hopefully the snow will all melt and I can get it out on the rocks here over the next month or two. I took it for a spin around the block the other day an she rides pretty nice but I still need to do a few things before she is ready for the rocks. I need to fabricate a new tunnel to house the tranny and atlas shifters. I also need to lower the seats about 2".

With the stock alloys, why not some 33x10.5s or 34x10.5s? Even an expedition rig needs more clearance. With the gears you desire, the 31s will spin high rpm...:confused:

You really don't need the lift and 4.88s with 31s. I'd find an airlocker rear to save money on an ARB, plus it will have disc brakes.



Hell, all it need are 31" mudders, winch, and plenty of extra gas cans. :D

With the stock alloys, why not some 33x10.5s or 34x10.5s? Even an expedition rig needs more clearance. With the gears you desire, the 31s will spin high rpm...:confused:
You really don't need the lift and 4.88s with 31s. I'd find an airlocker rear to save money on an ARB, plus it will have disc brakes.
Hell, all it need are 31" mudders, winch, and plenty of extra gas cans. :D

Because these Montero's originally came with 28.9" tires (235/75/15) I would need to add the 4.89 gears to return it back to stock if I ran a tire that is 30.6" tall. Most 31x10.5x15 are about 30.6" tall so they should be perfect. To go with 33-34" tires, I would need to change my gearing to 5.29 according to the calculator.http://www.accuautoparts.com/calculatorfin.jsp Changing the gearing would guarantee I will still have adequate power and my speedo will be accurate.

I am not really looking for the cheapest buildup, I am just looking to build the most functional and reliable vehicle possible. Because these Montero's are low on power to start with, I really don't want to further handicap it by adding too large of tires with out correcting the gearing. I really have no need for anything larger than 31" tires, that's what my pickup is for. The little pickup will tackle the toughest of trails with ease, I am looking for something much different with this buildup. I want this to be more of a sleeper ride.

Brian (bs) from the Wire has the 34" Swampers on his 91 Montero, warmed up engine and stock gears ='d no problems trail riding with us a few years ago. To correct the speedo for a tire size difference, just replace the speedo drive gear. I merely suggested the larger diameter tires to go with the other hardware you're proposing, as the 3.0L V6 isn't really underpowered when compared with the 2.6L.

Brian's LS:
http://i236.photobucket.com/albums/ff112/rxinhed/Silverfork%20Road%20Trip%2010-2009/100_8598.jpg

With my 4-cyl Raider, I successfully wore out two sets of 33" tires, some 1/2worn 32s, and a set and a half of 31s. All my approximately 100K miles were stock, no added low gears or lockers, no lift. Most every day included 500 plus pounds of tools, rock, and boxes in the back, sometimes hauling my little trailer and 110-gallon water tank too.

I realize you've been around the Mitsubishi block, but expedition rigs sometimes need just that little extra for terrain negotiation...I was not presuming the Rubicon as this type of truck running, but places like Tea Kettle Junction and Race Track, geologizing around the Henry Mountains in UT, hunting fossils in Wyoming, etc.

How much lift(body and Suspension) would be needed to run 33" tires, and would I need to do any fender trimming. I really don't want to do any fender trimming.

Slight trimming on the front bumper ends, no cutting in the fender wells or fenders. There is a short length of metal in the leading edge of the front wheel wells that can be moved forward with gentle persuasion of a rubber mallet, again no cutting.

http://i236.photobucket.com/albums/ff112/rxinhed/Dodge%20Raider/130_9369.jpg

In the picture above, my front bumper is removed to make way for my tow bar. The little bit of metal that I mention along the leading edge of the front inner fender well is located under the valance. Trimming of bumper end is about 1/2" to 3/4" and is unnoticeable after a few rain storms.

I really have no desire to trim or bend the sheet metal. I live in the rust belt and if I trimmed out the fenders, they would rust away immediately.

There's no need to trim any sheet metal to runn 33's. Theres a splash shield in front of the front tires that you can bend slightly by hand if you need to. No need to take a hammer to it. The bumper end he's refering to are the black plastic end caps, so no rust to worry about.

If your dead set on 31's more power to you, but if going this route I would recommend you nix the body lift plans. The montero has big wheel wells and the truck will look gay (for lack of a better word), lifted with little tires. The Suspension lift will be enough to compensate for being loaded down with camping gear while on expedition.

I recommend the following:

Gen 2 SR rear axle. You will wan this upgrade for the the disc brakes as well as the locker, you can still put the 4'90's in it. You will find the Gen 1 rear drum brakes to be weak, especailly on the LWB loaded with camping gear and bigger tires.

Swap out the front brakes to Gen 2 dual piston Calipers. If you plan to daily drive, you will like these mods. Search the wire for details on both these.

Where are you guys finding aftermarket gears for these? I just picked up a 87 Dodge Raider and I cant find any aftermarket supplier, nor any info as to what axles are under the thing. I have the automatic 2.6 and I want to go lower with both the axle gearing and the transfer case?

The axles are Mitsubishi, parts are Mitsubishi, gears are Mitsubishi.

Transfer case can reportedly be switched to a Dana D300; otherwise, lower gears can be found with some guys at 4x4wire.com (US) and outerlimits.com (AUS).

thanks man, its been years since I had my jeep and im just now getting into wheeling again