I'm thinking Input shaft bearing, and counter shaft bearing. I bet the rest of it is OK.


You're gonna need to flush the crap out of it though.

Also... go ahead and source yourself come GL4, and whatever you do, don't put GL5 in it no matter who tells you it is OK.

What's involved with the automatic Aisin replacement instead of simply putting in another V5MT1-x? Doesn't that involve a new ECU, all sorts of pumps, hoses, etc?

stick with the MT. That is one tough trans and it was used in cabovers and buses in the 3rd world from what I've heard.
The 89-94 should bolt in. The only differences were internal, basicly synchro changes. 95 and after had a different input shaft and different counterbearing( probably lighter duty for the mass soccermommobile market of those days).
I haven't had to do my trans yet but it's alway in the back of my brain as it has 255K on it.
Ats ae not for me...

This. Rebuilding a manual trans seems vastly easier than converting to an automatic. Was the transmission that just failed the original? If so, getting 210,000 miles out of it doesn't seem so bad.

Not sure if it is the original, I bought the truck with 90K. I presume it is however.

I wasn't really thinking about a conversion, but someone did mention it above. I prefer using manual gears anyway.

OK, another question: How big is the transmission/TC assembly? How much does it weigh (that is, can I stuff it into a VW New Beetle with the passenger seat folded forward, or do I need to rent a trailer to move it from a boneyard?)

It's been a while since I've had the "pleasure" <img src="/forums/images/graemlins/rolleyes.gif" alt="" /> of wrestling around with one of those. Are you going to bring the trans/TC home from the junkyard as a unit (i.e., together)? If so, I wouldn't put them in a Beetle. If you separate them, and take them home one at a time, I *think* it would work. (The whole job is a bit of a PITA, by the way.<img src="/forums/images/graemlins/pfft.gif" alt="" /> )

Well... The transmission itself is pretty short. So If you got one with the bellhousing, and tailhousing still on....with the transfer case removed I'd say it'd fit easy. Pro'b fit in the passenger seat, and even buckle in. I'd want carpet scraps, and stuff put down so it did not puke, or grime my carpet up. Trans alone... Heavy. like.. I could lift it myself (good handles inside the bell and tail housings) and put it in the trunk of a car. I'd estimate 100-120 lbs. With the transfer case installed.... f'ing heavy heavy. You'd better get a competent helper to help you load it to keep from dragging it all over paint / trim / bodywork / interrior. With a helper to load it, and lots of blankets, and carpet scraps, I think it might fit. I'd estimate weight at ~250 all assembled. And Wonky. Not easy to install into a vehicle alone, though I've done it several several times.

OK, found a transmission with TC off a relatively low mileage (120K) 1990 pickup, pretty nearby, for a good price.

The boneyard guy warns me the transfer case won't work on the Montero. Is this so?

Can I just unbolt the TC off my transmission and bolt it onto the new one? What's involved? I'm planning to go get this tomorrow.

Dude... Pop that old one apart first. It's not difficult to put in bearings. <img src="/forums/images/graemlins/kewl.gif" alt="" />

As far as the transfer case not working... No idea.

To swap the transfer case, IIRC you've got to punch out 1 roll pin, and then unbolt it, and it comes right off.