Ive done a bunch of searching and have a bunch of links bookmarked, but I wanted to get as much of my project up in one place, both for my own sanity and for advice, tips and suggestions...

So first off, the issues...
after startup, at idle speed there is a small, "maybe" valve knock, it goes away after it warms up, going to try the 3000rpm-15 sec cycle and see if that clears it up

Seccond,
Slight inconsistency of idle, will drop from idle for just a monent, no pattern, not regular, totally random, not sure where thats coming from at all...

Third
need to replace rear shocks, not sure what brand yet, KYB on the front, so probably same.

4th
the rear end bottoms out when fully loaded so maybe some overload springs... though new shocks may handle that

fifth
rear lug studs sheared off, tried to work on this already and discovered that the anti-lock sensor-disk blocks the studs from being removed easily. One shop I took it to suggested that they may have to remove the rear bearings...

sixth,
was looking into information about the electric suspension control, just because mine doesn't have it... was it removed or never had it?

seventh,
whats up with the butterfly valves in the intake... one person posted that they pulled then with no ill effects, there was mention of a refit for them that eliminates there danger...ect. So how do I check if thats been done and so on.

8th
whats a good roof rack, it has the cheezy stock roof-rack,
and with that HUGE moon roof I cant use all that much of it.

9th
want to get a wench... need a bull bar for said wench...

10th
going to build a bed shelf, the one over the wheel well's, have seen the links and have them bookmarked.

Ok, Have a bunch of plans, including lights, getting Hi-jack, internal 12v air system and pump, getting tires, 31-33, pros and cons... and on and on and on...
I will post pics soon of its current incarnation, I believe it has a 2" body lift.

Got her and promptly took her on a trip out to deathvalley national park and went a bunch of places, no paved roads for 2 weeks of camping and fun. now to fix what we found, and to start planning the upgrades.

Constructive tips criticisms and comments...please, this is my first real 4x4... Im not counting my 82 subrau brat here. So IM really excited, though this will be the usual as its affordable build.


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

1. I'm assuming you mean valve ticking, not knocking, as that would indicate a more serious issue. Ticking lifters are common on these and many other Japanese engines of the same time period that used a similar lifter design - the oil passage holes are small and get partially clogged over time. You could retrofit with newer 3mm oil hole lifters, but it's somewhat pricey for what is essentially just an irritating noise. Using quality oil and filter seems to help, and people have had luck with adding ATF or Seafoam to the engine oil a few hundred miles before changing the oil in order to help unclog the oil passages.

2. Could be symptoms of an idle control valve that's failing - not uncommon on these engines - or a vacuum leak (vacuum line or lower intake plenum butterfly shaft are the likely candidates).

3. KYBs are popular on the Monteros and seem to work nicely with the stock spring rates. I've got OME shocks and can't recommend them highly enough - I've beat the crap out of them with rock crawling, high-speed rally style driving, and street driving for 100k miles now, and they are still in good condition. They cost a bit more, but I'll buy them again for my SR when my current set is worn out.

4. Get some fresh shocks on there, that should help. If you still have issues there are aftermarket springs available which can give you additional lift and more spring rate to prevent bottoming - airbags are another option but can restrict the amount of suspension travel you have.

5. Not a good thing. In order to replace the studs, the axle shaft has to be removed, the bearing retainer has to be cut off in order to disassemble the axle shaft and replace the studs, then a replacement bearing retainer has to be pressed on. Mitsubishi dealer for the part and a machine shop for the labor. Don't ask me how I know this.

6. If your Montero has or had it, you'd have a selector switch on the center console. Only the factory shocks are adjustable (there's a round electric actuator on the top of each OEM shock) and they are $$$ - you've got KYBs on the front already so if you had them they've been replaced already.

7. The lower plenum issue has been beat to death on this forum - use the search function to read up on it. The short version is that if you have a loose butterfly shaft you need to address it soon or you could suffer significant engine damage if one of the butterfly valves gets swallowed by the engine.

8. Again, the search function is your friend (maybe not a good friend, but a friend nontheless) - read the info post on how to use it first and you'll get much better results.

9. Whatever kind of serving woman you have in your home is your own business, but if you're looking for a winch then you just need to use the internet. There are numerous options and quality levels limited only by what your budget is. There's a nice space on your Montero behind the front bumper that you can mount a winch via a plate welded between the frame rails. Off-road bumpers for the Montero are very limited and fairly pricey - I'm not even sure if the ARB is still available for them amymore. The most common method is to find a used one from a Jeep or other SUV with similar dimensions and fabricate some custom adapters to make it fit the Montero.

10. Search for Scottie2113 - he's done some extremely nice fabrication to set his Monteros up for expedition-style wheeling and camping.


Saying that this Montero is your "first real 4x4" is a statement that many Jeep owners would concur with if they were to break away from the overly-hyped "trail-rated" vehicles they own. The fact that a virtually stock Montero can do some serious 4 wheeling without breaking drivetrain or suspension parts is something most other 4x4's know nothing about, and you've got arguably one of the best model Monteros to start 4 wheeling with. Get some pics posted up so we can all see what you've got. <img src="/forums/images/graemlins/smile.gif" alt="" />

When you say it bottoms out when fully loaded, do you mean just sitting there its bottomed out? Or bottoms out going over bumps?
If its the second new shocks will certainly help. Kyb Gas-a-Just will give a nice controlled ride.

Mine bottoms out when its loaded, too. I could probably use the heavier duty OME springs. While new shocks will help with control, they can't change the spring rate.

I made a platform for the back of my '95. I used two pieces of 3/4" plywood by cutting the appropriate length, measured with the front seats all the way forward, then using pieces of 4x4 cut to length to serve as vertical supports. One set of supports is under the rear of the sheets, near the cargo door, one set is in the rear seat footwells. You can sink a screw through the plywood and into the legs to hold them in place. When I want to break camp and drive, I just put one sheet on top of the other so I can move my driver's seat back. When it's set up, a full size air mattress fits, but there's not much room between it and the headliner to maneuver. Nice bonus is the view through the sunroof at night.

You could make variations on this. Make the sections right in back of the front seat hinged, for example, and you could leave the wood in there and not lose front seat functionality, for example. I just did it the simplest way that I could to make it work for me.

John B.

thanx for all the imput, ya need a wench... want a winch <img src="/forums/images/graemlins/smile.gif" alt="" />

running out to work, but... so ya bottoms out when I hit a bump, or a washout when fully loaded, thinking about progressive rear springs, or somthing of the sort.

out near death valley, a week after buying her... next trip should be even more fun.

Welcome to the 'wire! Seems the group has you sorted on your various questions.

If you're not doing anything over the new years holiday, maybe join a bunch of us in a drive down to Anza Borrego (east of San Diego) for my Hangover Avoidance 4x4 Run. <img src="/forums/images/graemlins/cheers.gif" alt="" /> <img src="/forums/images/graemlins/kewl.gif" alt="" />

Which KYBs? Gas-A-Just or MonoMax or Gas-A-Just Monotubes?

Their most basic shocks are fine (<$50 ea).

Gas-A-Just Monotube. The Monomax work good too though. Stay away from anything twin tube

Not sure why KYB gas-A-Just would be listed twice. It is a mono-tube and is pretty darn good. There is a better KYB shock for the SR models with the adjustable damping: That would be the stock shock from the factory and a set of four will run you about a thousand dollars. I'm not even kidding.

John B.