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Post by ES_97Sport on Mar 15, 2018 15:50:45 GMT -5
I'm not going to try to recreate the 4x4Wire thread here, so here the link ... 1999 Montero Sport Limited 3.5L crawler build"The Plan": Dynatrac Pro Rock axles - Dana 44/60 Hybrid front & Dana 60 rear (ARB air locker F/R) Atlas 4-speed transfer case w/electronic speedo Rebuilt and beefed up V4AW3 w/TransGo shift kit RADesigns Winters 'Rock Shifter' PCS (Powertrain Control Systems) TCM (transmission control module) Alcan (very) custom rear leaf springs King coil-overs front, King shocks rear Anti-wrap bar rear Extended 'Jeep style' radius-arms front ARB bull bar front Custom bumper/carrier rear All-Pro Extreme (DOM) rock skids 1 1/4" BMC (and a bunch of other hardware) for the huge Dynatrac brakes Custom steel 17x9" Stockton Wheel Series 22 w/custom rock rings Yokohama Geolandar M/T G003 37x12.5x17 tires Edward
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Post by nugget on Mar 17, 2018 4:31:24 GMT -5
That's Awesome, is an understatement.
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Post by vr4madness on Mar 18, 2018 22:53:12 GMT -5
I am excited to see how this turns out!
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Post by ES_97Sport on Mar 19, 2018 18:45:08 GMT -5
So am I! The transmission and TC are done. I pick those up tomorrow. The Mitsu tech finished a few little things on '99 and I picked it up this morning. There's just a few misc little pieces left to trickle in. We're just waiting for the axles to start. The transmission turned out to be much easier than I expected. I didn't need the Jeep 23-spline output shaft. The '97 AW3 already had the 23-spline shaft - in fact, it was EXACTLY the same as the late '90s Jeep shaft I bought for the swap. The OEM Mitsu output speed sensor and tone ring (that came on the transmission) fit perfectly in the Jeep output adapter housing as well. The only thing that doesn't fit is Mitsu the shifter cable bracket. There's no bolt bosses on the housing for the bracket like there is on the Mitsu housing. Fabing a different bracket that uses the bolts for the t-case will probably take care of that. I don't know if I miss-read Nathan's and Danny's (and everyone else's) threads or the Sport '97-May '98 AW3 comes with the 23-spline shaft, but I swear I thought I had to change output shafts, output speed sensor and tone ring and the output adapter housing. If that's incorrect and all that has to be changed is the output adapter housing, make a new shift cable bracket, install a SGI-5 to convert the speedo signal, and re-hook up two t-case switches, that would make it really, REALLY easy to replace the Mitsu t-case with an NP or Atlas. In fact, that could all be done without even removing the transmission from the vehicle.Ok, I thought I understood Danny and Nathan correctly. I picked up the transmission today and the tech cleared that up. I must have miss-heard what he was telling me on Friday. The OEM Mitsubishi output speed sensor and output speed sensor tone ring fit in the Jeep output adapter housing, but the output shaft will not rotate because the tone ring hits the end of the output speed sensor by .180". So the tech re-installed the output speed sensor and tone ring from a donor Cherokee 23-spline AW4 (and tested it to make sure he got signaling). The issue here is that, as Nathan pointed out ages ago, the Mitsu tone ring is a four pulse unit, while the Jeep Cherokee is something else. Pre-98 appears to be 2-pulse, but 98+ is something else. Mine is 1 pulse per rotation (ppr) and some are 4 ppr. Obviously you can't just feed a 1 or 2 ppr signal to the TCM/PCM expecting a 4 ppr signal. 4x4Wire - who on here are running Mark's transfer case gears, or other transfer case options?Anyway, not a problem for me with the PCS but not just a simple straight across swap with stock electronics. Edward
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Post by ES_97Sport on May 7, 2018 19:22:14 GMT -5
Whoohoo!!!! The axles arrived last Thursday at the shop! I'll stop by later this week and get pics. And, I finally have a firm start date - I drop the vehicle off the week of the 28th. I actually put it off a week to finish up a few things. I'm putting the finishing touches on the wiring diagrams for the transmission, transfer case, VSS and TCM. Basically just clean-up of the labeling. A few electrical parts are still outstanding - they won't be in until the 15th. Sigh. I still have to figure out the throttle and accelerator cable thing. The V4AW3 uses a 'throttle' cable to control line pressure in the transmission, unlike the A51 in the 1999+ models. Previously there was two setups for this - #1 used a second attachment at the throttle body (just like the accelerator cable), and #2 used a completely separate 'bell crank' box where the cables all ran into that and then one cable went to the throttle body. The difference between the two is the former was the new style cruise control with the vacuum diaphragm on the TB and the latter was the old style 'remote' cruise control. Thankfully the '99 3.0L with the new style cruise uses the two attachment points at the TB, because the 3.0L TB and 3.5L TB are not interchangeable. Completely different TPS and IAC. I haven't gotten this far yet, but it looks like I can transplant the cable control parts from the 3.0L to the 3.5L with one or two minor modifications. I hope so, otherwise its back to the old style box setup. I still have to build the CAL file for the TCM. That's the only major piece left that has to be done before they start. That'll probably take up the next two weeks, but it'll be worth it if it all works as I hope. Edward
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Post by aetro on Mar 9, 2024 12:59:06 GMT -5
Whoohoo!!!! The axles arrived last Thursday at the shop! I'll stop by later this week and get pics. And, I finally have a firm start date - I drop the vehicle off the week of the 28th. I actually put it off a week to finish up a few things. I'm putting the finishing touches on the wiring diagrams for the transmission, transfer case, VSS and TCM. Basically just clean-up of the labeling. A few electrical parts are still outstanding - they won't be in until the 15th. Sigh. I still have to figure out the throttle and accelerator cable thing. The V4AW3 uses a 'throttle' cable to control line pressure in the transmission, unlike the A51 in the 1999+ models. Previously there was two setups for this - #1 used a second attachment at the throttle body (just like the accelerator cable), and #2 used a completely separate 'bell crank' box where the cables all ran into that and then one cable went to the throttle body. The difference between the two is the former was the new style cruise control with the vacuum diaphragm on the TB and the latter was the old style 'remote' cruise control. Thankfully the '99 3.0L with the new style cruise uses the two attachment points at the TB, because the 3.0L TB and 3.5L TB are not interchangeable. Completely different TPS and IAC. I haven't gotten this far yet, but it looks like I can transplant the cable control parts from the 3.0L to the 3.5L with one or two minor modifications. I hope so, otherwise its back to the old style box setup. I still have to build the CAL file for the TCM. That's the only major piece left that has to be done before they start. That'll probably take up the next two weeks, but it'll be worth it if it all works as I hope. Edward Any chance we can get a copy of this 4x4 wire thread now that they are gone?
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