Dug up this old thread for an update. The swap went smooth, and to recap here's what I needed to get the NP231 into my 2001 Sport(should be the same for all 2000-04 Montero's and Sports).
-Trans, flywheel+bolts, pilot bushing, starter, and the plate that goes between motor and trans, from a 1999 Sport.
-Transfer case adapter, and NP231 from a 2001 Cherokee.
-AW4 shift controller. I shift the trans and engage TC lock manually, and there would be a lot more involved to get the trans to shift automatically again, but I'm pretty sure it's doable(I like my switch mounted on the shift lever:D)
-I shift the 231 with a modified cable shifter from my old 91 Eclipse, and the Dana300 has twin sticks that come through the factory hole in the floor.
Here's the part I just finished. The swap caused five trouble codes, the failure of the five solenoids inside the V4A51, which is no longer in the truck, ES_97Sport did research on this for his sport and figured out that a 3ohm 50Watt resistor can be substituted for each solenoid and make the PCM happy again. See
THIS thread.
I still have no speedometer but others have used a Dakota box to convert/modify the signal. I just haven't had the time or cash to tackle that project yet, need to finish the rear swaybar and get tires first.
Thanks for everyone's help, the Wire always comes through for a guy!
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