Auto to 5spd conversion?

[jessef]

Yes. It's that simple.

Remove used front and rear 4.625's out of a US montero and put on 30" tires coupled with the 5-spd is a hard combo to beat.

The reason why you don't hear much about these things is t because people assume L300's are unique. They are not. They are based on the same 1st generation montero/Pajero and share most driveline components (diffs, axles, brakes, 4wd parts, etc...)

As for gear ratio's on the highway, you guys are confusing people.

The driveline gear ratio's (gears in the front/rear differentials) in the US is 4.625 and 4.636

In JDM Mitsu's, they are 4.875 and 5.29

If you simply swap out the JDM gears (5.29/4.875) with the US (4.625's), you will have a 5psd that can cruise nicely at 70mph under 3k with good mpg.

If you can get a 5spd for your trip, do it.

Now you've spiked my interest...
I got a 5 speed L300 as well because I hate autos and I am doing some towing but I sure wish it would cruise a bit faster at lower RPM on the highway. It's the first time I read something about this conversion opportunity and I'd like to hear more about it.

Have you done it yourself?
Am I correct in my understanding that you just need some bits from the front and rear diffs of a US Montero to fix that? I'd like to hear someone confirm this as it sounds quite easy so I am surprised no-one here mentioned it before.

[john n]

Anybody know where I can find those Montero differentials?

[jessef]

Almost every auto wrecker in the US.

Start just across the border in WA. There's plenty.

[Airwick]

Hmm,
Going to Seattle Friday... maybe I should try to stop by a couple wreckers and see what I can find.

Just to clarify, would any second gen Montero (91-99) work or are there only some years that are compatible? Also, would they all have the 4.625 ratio or are there some odd ones; and if so is there a way to check (by looking at the part numbers or whatnot?)

Thanks,

[Mr. Flibble]

Are there similar conversions for the L400? Is anyone aware of the gear ratios on the L400s?

I have my heart set on an L400 because of the engine and chassis!

[jessef]

For the L300 you want up 90 Montero with the 4cyl for the front diff f
gears and rear. The 2nd gen montero's with V6 have larger axles in the front.

L400 have two different diffs.

9 & 9.5 in the rear . 9" is one all L400's unless it has the factory upgrade option. LSD or winter pack. All royal exceeds have the larger 9.5" rear end.

You can tell the difference. 9.5" the splines go from the pinion all the way back to the 3rd member housing while the 9" diff the splines stop a few inches before the 3rd member housing.

The only montero's that have the 9.5" large rear diff are the 1994-1998 SR models with the 3.5L. 99% of them also have the factory rear diff locker which will fit right in.

You'll need the ECU which is behind the drivers side rear panel where the 3rd row jump seats are located. 20'some odd screws to remove the panel.

Trace the wiring loom under the floor to the compressor which sits under the rear bench seat on the drivers side.

Since L400's never came with diff locks, you'll have to install an aftermarket switch to turn the compressor on/off.

L400's have 4.875 diff gears so you'd have to swap out both sets front and rear.

L400's take the 2n gen montero 92+ 3L V6 front diff gears.

[jessef]

And swapping diff gears, axle shafts, etc should be done by a shop that has experience in setting up differentials. Special gauge tools are required.

Not cheap and definitely not for a backyard mechanic.

Forgot to mention the rear locker has a shorter left side axle so you'll need that as well.

[Mr. Flibble]

And swapping diff gears, axle shafts, etc should be done by a shop that has experience in setting up differentials. Special gauge tools are required.

Not cheap and definitely not for a backyard mechanic.

Forgot to mention the rear locker has a shorter left side axle so you'll need that as well.

So, would swapping out the parts for the L400 give it a better highway ratio similar to that of the L300 if the swap is made? While I would like the locking rear diff, I would not go through all that trouble to make the change unless it had an impact on highway speed. I just drove down from Mt. Washington in my 89 4unner - and passed a few Deli L300s. I would like to see a similar highway speed in an L400 if at all possible. (And, as this thread mentioned, with a Manual Transmission).

Thanks jfarsang!

[Green1]

I would like to see a similar highway speed in an L400 if at all possible. (And, as this thread mentioned, with a Manual Transmission).

The L400 holds it's own quite well on the highway, much better than an L300, and with no modifications required to get there. Might be worth trying it before deciding that you need to modify it.

[jessef]

You don't need to modify an L400.

Bone stock, you can cruise at 120km/hr and still pass on the highway. Same goes for uphill.

For reference, my L400 has more grunt than my old 4runner with the V6.

It's a completely different animal than the L300.

[SquamptonRyan]

awsome info everyone, thanks!

Jfarsang you're right on the money with my desire for a 5 speed coming back to the ability to limp to civialization. The simple solution for me would be to sell my current van and pick up a 5 spd, but after 3 years of small preventative maintenance jobs and a very recent new head, my van is currently running like new and I'm a little afraid to start fresh!

I do have faith in my auto tranny, and in reality if you're on a road, your not that far from civialization, but I've just always been a beliver in the physics of the 5 speed.

So, now the million dollar question. If I can find a 5 spd tranny, and am willing to re-locate the second fuel tank, can it be swapped for the auto? or is this just wayyyyy too big of a can of worms?

seriously thanks for all the info guys. Especially Jfarsang, you should start charging a consultion fee!

Ryan

[loki]

awsome info everyone, thanks!

Jfarsang you're right on the money with my desire for a 5 speed coming back to the ability to limp to civialization. The simple solution for me would be to sell my current van and pick up a 5 spd, but after 3 years of small preventative maintenance jobs and a very recent new head, my van is currently running like new and I'm a little afraid to start fresh!

I do have faith in my auto tranny, and in reality if you're on a road, your not that far from civialization, but I've just always been a beliver in the physics of the 5 speed.

So, now the million dollar question. If I can find a 5 spd tranny, and am willing to re-locate the second fuel tank, can it be swapped for the auto? or is this just wayyyyy too big of a can of worms?

seriously thanks for all the info guys. Especially Jfarsang, you should start charging a consultion fee!

Ryan

just bring a spare auto tranny with you lol

[marsgal42]

So, now the million dollar question. If I can find a 5 spd tranny, and am willing to re-locate the second fuel tank, can it be swapped for the auto? or is this just wayyyyy too big of a can of worms?

This is a big job. There is a certain element of "if you have to ask, the answer is no".

At a minimum you will need to swap the flywheel/clutch assembly, sort out the mountings, figure out the shift and clutch linkages and make sure the rest of the driveline (transfer case, drive shafts) match up. Such a swap is rarely economic unless you have a complete donor vehicle to cannibalize for parts, all those little bits and pieces that go with such work.

Five speed Delicas are rare. Ones that have sound drivelines but which are otherwise junk are rarer still, especially on this side of the Pacific. You might cannibalize a junk Montero, but that too is a fairly tall order.

...laura