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My Montero Sport Build

124271 Views 178 Replies 38 Participants Last post by  toasty
10
2001 Montero Sport ES 3.0L

I bought it new, and it did daily driver duty till 2006, at which point it got 4.90 gears, a rear ARB locker, 2"rear coils/2" body lift, and 33's.





I wheeled it for a year like that, then the SAS started.




Got my Dana44 from a 79 F150 and installed 4.88 gears and another ARB.



Used the wedge parts of the Ford radius arms, and spliced them to 2"x.250"DOM with some .250 gussets and 1" heims on the end. These arms ended up being 6" longer than stock. I located the axle an inch forward from the IFS centerline.




Had to modify the trans xmember to clear the arms. Now it bolts to the inside of the framerail instead of under it.


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Hi Raole Duke,

Just read your build thread. Your Montero build is awesome! Thanks for sharing!

/John
Thanks John. Looking forward to seeing your build.
Thanks John. Looking forward to seeing your build.
Looking forward to posting it. I'm not a fan of daily forum updates, I'm one of those that wants to try it out before posting. So sadly its gonna be some waiting. :smokin:

Hey, just noticed, you're from St.John? Thats quite close to Chicago, is it not?
I'm (obviously) from the other side of the "big pond" but I have lots of IRL friends in the Detroit area. Visiting every year. Perhaps taking a detour next time if I'm welcome :D
Got a few questions on your rig by the way. Perhaps better taking that in pm?


/John
Any updates...progress??? I need some more motivation to buy some shit! :flipoff2:
Any updates...progress??? I need some more motivation to buy some shit! :flipoff2:
Nothing major. Two biggest things on the list for this winter, a winch and second battery, and tube bumpers.

Here's a vid from a few months ago, I put it on the Wire but it should go in here too.:D

Badlands - July 2011 - Scott, Quarry - YouTube
And a flex pic.



Seems like since the rear lost the trailing arms, and got links, now the front doesn't flex as much. Thinking about going with xj springs in the front and ditching the EB's.
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What size xj springs do you have to use to match the 5.5" EBs?
Not sure yet. I still havta look into that.
7
Been workin on the rear bumper for the last few weekends.

First, some of the body got cut out. Shooting for a good departure angle so I wanted everything to tuck in as much as possible.



Some 4"x4"x1/8"(it was free), some 1.75x.120dom(cage leftovers), and a HF hitch tube.



Some more dom for the ends. Tried to fill the recess in the body for the plastic factory bumper.



Skinned the ends with some 11ga.(another freebie)





Painted it today. I'll get some pics outside soon.



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Bumper looks sweet
Thanks!

Here's a couple new videos from this past weekend.

Montero Sport @ Haspin Acres - YouTube

Montero Sport Climbs Devil's Backbone - YouTube
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A couple new things.
Military take-off 37x12.50/16.5 Goodyears on recentered H1's with PVC inserts.



5.43 ring and pinion, pinion guard, and a Yukon locker for the nine inch.



I put about 150 miles on the new setup this weekend. Mostly highway miles, the Sport finally has plates again. The 5.43 ratio is much more friendly to my tired ol 3.0, especially now with a 125lb wheel. Ran just under 2250rpm at 55mph Still have to install the 5.38 gear set in the D44, before I can hit the trail.
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I know you don't have ABS, but are you running the stock booster and master cylinder?
I know you don't have ABS, but are you running the stock booster and master cylinder?
Still have the stock master and booster. The master goes to a Summit adjustable proportioning valve, instead of the ABS pump. The brakes work good but could be a lil better.
You can swap on an 80's dodge fullsize pickup master cylinder with some line adapters from NAPA, that will give you more braking power to feed the bigger calipers.
You can swap on an 80's dodge fullsize pickup master cylinder with some line adapters from NAPA, that will give you more braking power to feed the bigger calipers.
I will remember that, thanks. About a week ago I took the front calipers off and re-bled them by tapping them with a rubber mallet in many different positions and got a couple bubbles from one side, so the brakes have gotten better but could still use help.



Took the Sport to a Cat scale the other day.
4,840lbs with: me, 3/4tank of gas, spare tire, tools, and extra fluids.



I was expecting well over 5,000, so was pleased.:D
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What did it weigh before?
What did it weigh before?
I've never weighed it, but curb weight for a 2001 Montero Sport is 4,205, so not that much gain, all things considered.

The 5.43 r+p have been a huge help getting that weight moving on the street. The 3.0 is over 100k, all hard miles, too. It is tired and runs hot. I've been on the lookout for a 3.5 to swap in.
looking good man btw welcome to the H1 wheel club
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looking good man btw welcome to the H1 wheel club
Thanks, been a while since i've seen pics from you, post some up. So far I have not had luck with the h1's at highway speeds. That might just be the military Goodyears. Still have yet to off-road this setup, but I did have to see what zero psi looked like.





Here's what i did to the rims after i got them.

rebar rock rings in and out.



lightened the PVC inserts, 10 lbs total.



Golf ball balance.:homer:



:beer:
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