SO i found out the hard way that on a Gen 2 with the 12v 3.0 there is not enough space between the transmission and the the crossmember for 2 NP231's. So i can't run Dual NP231's like NathanC did, I did install a single NP231 just for a temporary low range upgrade (2.72:1). The cool thing about putting that case on an early Gen2 is that you don't need to change the pulse sensor or the tail housing of the trans This will make the Speedo stuff super easy. Doesn't really matter to me since i will be getting rid of the 231 as soon as i find a Dana300 so that i can run duals and use my Atlas shifters!
Transfer case garbage aside I did another long travel test on saturday. This time with awesome results, I didn't run out of travel at all! The extra travel in the rear kept the IFS on the ground at all times. Shock angles are perfect, coils retained and landed in the lower buckets perfect. I need to lower the bump stops maybe an inch, the uptravel is barely too much and the caliper hits the frame with the rubber line fitting and eventually cracked the fitting. Also if anyone wants bolt on coil retainers let me know I think the price will be $30 maybe less i forgot.
Here's some pics and i haven't maxed it out yet <img src="/forums/images/graemlins/kewl.gif" alt="" />

Dude, that is some crazy friggin travel? <img src="/forums/images/graemlins/cheers.gif" alt="" />

Awesome. Keep up the good work!

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

...and has new meats! Suhweet!! <img src="/forums/images/graemlins/smile.gif" alt="" />

"No aftermarket support"
haha Boo Hoo!!


Nice work dude!!

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

Looking good. <img src="/forums/images/graemlins/kewl.gif" alt="" /> So you are running a Gen1 3.0 in that?
BTW, the pulse sensor is for Gen2+ transmission. Nothing to do with the speedo.

Toasty, more on the the 231 swap in please. I was thinking of putting one in my 91 LWB....Should I get the tail-housing off a 92/93 Trans? or will the 231 bolt to the gen 1 auto tail-housing as is? How did you work out the drive shaft? I was thinking going 231 with SYE with a mechanical speedo hookup for the gen 1 speedo...TIA

He's running a 2.4 NA gas engine.

John B.

Thanks Nathan! like Johnny said its got a 8v 2.4L. What does the pulse sensor actually do? I thought it was something that worked with the speed sensor? I'll have to re read your write up again. This Montero is a 1995 (DEC '94) but it came with a 12V 3.0, So it has a AW2 trans with a odd 6 bolt pattern. The NP231 still lined up on 5 holes on the tailhousing adapter though.





The 231 will mate to a gen 1 perfectly, but if your '91 ends up like my truggy and one hole is off don't worry about that too much it's easy to drill or forget about (i just left mine 5 bolt). If you have the odd style like me you will have to drive out the dowel pin too. The case you need will be a short shaft NP231 (Mated to an AX-15) you can get the long shaft but you'll need to have it cut down.
The drive shafts i made myself, the front drive shaft i used was a cherokee front double cardian setup with the u-joint end switched to the montero U-joint to the diff. For the rear i wanted something heavier since it takes more abuse on hill climbs and stuff pluss it has to travel with the axle where the front doesn't. I used the standard Gen 2 V6 shaft with F-350 slip joint, I have the yoke for the 9.5" SR pinion flange on the bottom and the 9" pinion flange on the t-case side. Drive shafts are really easy to DIY i found out, just have to know what you're doing. I also made my own SYE, mine turned out fine but i don't recommend doing it because you need a special kind of welding wire + pre-heat/post heat garbage. Also the wire costs more than an SYE kit so if you don't already have it it's definately not worth doing.

If you want you can call me this weekend and i can tell you what you need to make your own drive shafts.

So Toasty how do you like the 2.4 gas motor ?...I've installed a few as you know ...Just wondering on a nother view point ... Truck looks good I most say ...