ES_97Sport
Rock Warrior
Reged: 07/19/03
Posts: 554
Loc: Colorado, US
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RE: Mitsu Montero Sport 5-speed manual transmission transfer case to NP231 w/Terra Low 231 & the super short SYE conversion
I made the last trip to the shop today to start coordinating schedules and they wanted to know if this is going to be a one-off or if there will maybe be a need to make more in the future. So, I figured I'd let everyone know what's going on in case someone else is interested.
This is the only info I currently have regarding the swap so far:
Machine a new extended trans->t-case adapter 7-8 inches or so longer - enough to fit the shifter platform; retain the stock trans shifter location/height; t-case shifter location stays the same but will be raised up bit - enough for the cable conversion
Machine a trans output shaft adapter to t-case input
Retain the existing trans/t-case mount so I don't have to modify my cross member
Transfer case shifter will be machined to accept the clevis end for the shift cable
Thanks to Nathan for the spedometer solution (the SYE kit uses the new electronic sender)
I'm going to use the Terra Flex super short SYE so I don't need to worry about serious drive shaft length changes and geometry changes
Don't have a solution for the front drive shaft yet; waiting to get everything built and installed before dealing with the trivial mods:-)
Misc bracket fab for the cable shift
Misc bracket fab for the Mitsu roll-stop
Edward
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'97 Montero Sport LS 5-Speed 3.5L conversion
SAS Dana 44s & ARBs, 35" Yoko Geolandar M/Ts
NP231 B4R doubler/Terra Low231/RP 5.38 228:1
'03 Montero Sport Limited AWD
'97 Montero Sport LS 5-Speed 3-link/SAS project
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AlphaMale
Wheeler
Reged: 12/19/07
Posts: 159
Loc: indiana
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I would be interested in any available information about putting a 231 on an auto trans... but im guessing you dont care much about that since you've got a manual... 
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87 Montero SWB (31's), 95 Montero SR (35's), 97 Sport SAS project (37's)
76 Galant Sedan, 73 Galant Wagon turbo
77 XS400 cafe, 77 XS400 street tracker
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ES_97Sport
Rock Warrior
Reged: 07/19/03
Posts: 554
Loc: Colorado, US
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I think it's easier for you since you have an automatic than for me with a 5-speed manual. NathanC did the dual t-case conversion on his '94 SR and that mated to an automatic. If you're just looking for a single NP231 on your Sport all you'd need is the information he's posted about hooking the first NP231 up - the one that actually bolts to the tranny. There are a couple places that make cable shifters for t-cases - probably get one from Klune, Advanced Adapters, Atlas or Stak4x4 - but I'm sure there's an alternative. Nathan needed a dual cable, you wouldn't. Find a cable shifted auto transmission and steal the shift assembly. I've seen these converted to t-case shifters so I know it'll work. The only reason I'm using the factory t-case shifter is because I already have the shifter and I'm making the adapter so I can make it however I want; might as well integrate the original shifter since I already have all the parts except the $30 shift cable.
NathanC's conversion:
http://www.4x4wire.com/forums/showflat.php?Cat=&Number=989569&page=&view=&sb=5&o=&fpart=1&vc=1
You probably wouldn't need the super short SYE for the NP231 either since you don't need to extend anything up front like I do but you will need someone's SYE. The Terra Flex kit uses the electronic sender like Nathan was talking about so the Dakota thingy for the spedo should work.
Drive shafts are cake and you can have those built at any decent drive train shop. There's nothing special involved. Mine are about $300 each at a shop locally and that's the same price they were originally 7 years ago.
Honestly, Nathan will probably have to correct me 'cause I glazed - automatics do that to me:-) - over on some of the Advanced Tailhousings and Output Shafts 300 level posts. Since I'm building an adapter for the output shaft as well I don't need to worry about what output shaft fits what or from what year, etc. The only thing I needed to check was which Terra Flex Low231 kit had the strongest input so I could build the correct shaft adapter.
If Nathan's stuff doesn't work on the Sport, though for some wierd reason, once I'm done with mine I'll take a look at the auto.
Edward
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'97 Montero Sport LS 5-Speed 3.5L conversion
SAS Dana 44s & ARBs, 35" Yoko Geolandar M/Ts
NP231 B4R doubler/Terra Low231/RP 5.38 228:1
'03 Montero Sport Limited AWD
'97 Montero Sport LS 5-Speed 3-link/SAS project
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ES_97Sport
Rock Warrior
Reged: 07/19/03
Posts: 554
Loc: Colorado, US
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I updated the t-case conversion page at 4x4 Extreme Sports and posted a bunch of pictures of all the preliminary stuff. Undercariage, V5MT1 transmission, adapter housing, Mitsu t-case, NP231 and some other stuff.
http://www.4x4extremesports.com/transfercase_conversion.php
Please forgive the REALLY bad quality on some of the pics. Forgot my camera and had to use my phone.  I'll get new ones on Monday.
And, no the t-case damper didn't fall off. I scraped it off on the Golden Spike trail year before last. 
Edward
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'97 Montero Sport LS 5-Speed 3.5L conversion
SAS Dana 44s & ARBs, 35" Yoko Geolandar M/Ts
NP231 B4R doubler/Terra Low231/RP 5.38 228:1
'03 Montero Sport Limited AWD
'97 Montero Sport LS 5-Speed 3-link/SAS project
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MontyMcV
Trail Leader
Reged: 06/04/03
Posts: 7068
Loc: Cleve-burg OH USA
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I'll ask, in case I'm not the only one who doesn't know... I love the AWD of my Gen IIs for where we live. Weather that includes snow and deep rains, and trips on the highway through it at times.
Is the NP231 4WD only, or does it have an AWD mode?
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Big Truck 2: 00, 3.5, Endeavor, 94k, stock for now
Big Truck 1: 95, MT, >Gone<
Little Truck: 87, 2.6T I/C, MT, LSDs, Tonneau Top
Her Truck: 03, 3.8, 20th Anniv, 29k miles!
FSMs: MitsubishiLinks.com
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PartyTruck
Body Damage is Cool
Reged: 05/12/03
Posts: 1083
Loc: Iceland
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It's like the older monty's it has 2WD, 4WD and 4Lo. The NV242 has a similar setup like the mitsus.
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1996 Pajero 2.5 TDI on silly big 38" tires and 14" wide rims. Stock rear locker, 50mm body lift, 1" rear axle shift and fender flares from hell.
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MontyMcV
Trail Leader
Reged: 06/04/03
Posts: 7068
Loc: Cleve-burg OH USA
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If I had to guess it would have been 4WD only. Wouldn't think that there would be such a hard core aftermarket for AWD enabled.
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Big Truck 2: 00, 3.5, Endeavor, 94k, stock for now
Big Truck 1: 95, MT, >Gone<
Little Truck: 87, 2.6T I/C, MT, LSDs, Tonneau Top
Her Truck: 03, 3.8, 20th Anniv, 29k miles!
FSMs: MitsubishiLinks.com
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ES_97Sport
Rock Warrior
Reged: 07/19/03
Posts: 554
Loc: Colorado, US
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Quote:
... Is the NP231 4WD only, or does it have an AWD mode?
Yes. The NP/NV242 is 2WD/4WD H-L/N/AWD. The link below has more information on t-cases.
http://www.offroaders.com/tech/jeep/transfer-cases-factory.htm
I was actually looking for a NP242 for mine until I found out that there officially aren't any gear options for it. At least one person has adapted a TerraLow 231 kit to a NP242 apparently but I have no urge to go there. The shop I bought my 4:1 kit from and the other shop I spoke to both said that your're pretty much stuck with the stock 2.72:1. And this is WAY too much trouble to go through to go take two steps backwards.
A couple people sugested calling TerraFlex directly re: the NP242. Maybe they've got something they're not advertising.
Also, as the shop guys pointed out, if it's bad enough to be in 4WD on the street then there's no point in AWD 'cause you could just be in 4WD. Duh. I couldn't argue with that reasoning. 
Edward
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'97 Montero Sport LS 5-Speed 3.5L conversion
SAS Dana 44s & ARBs, 35" Yoko Geolandar M/Ts
NP231 B4R doubler/Terra Low231/RP 5.38 228:1
'03 Montero Sport Limited AWD
'97 Montero Sport LS 5-Speed 3-link/SAS project
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PartyTruck
Body Damage is Cool
Reged: 05/12/03
Posts: 1083
Loc: Iceland
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Quote:
Also, as the shop guys pointed out, if it's bad enough to be in 4WD on the street then there's no point in AWD 'cause you could just be in 4WD. Duh. I couldn't argue with that reasoning.
Dumbass reasoning if you ask me, the AWD option on the 242 and the superselect T-cases is excelent when driving gravel roads and light snowy roads. It combines the drivetrain smoothness of 2WD and traction of 4WD. This is the thing I love second most on my pajero (first being the stock rear locker) and use it frequently when offroading.
This spring when I start work on my Grand Cherokee I will be puting in a NP-242 to have this inbetween option of 2WD and 4WD.
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1996 Pajero 2.5 TDI on silly big 38" tires and 14" wide rims. Stock rear locker, 50mm body lift, 1" rear axle shift and fender flares from hell.
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ES_97Sport
Rock Warrior
Reged: 07/19/03
Posts: 554
Loc: Colorado, US
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Quote:
Dumbass reasoning if you ask me, the AWD option on the 242 and the superselect T-cases is excelent when driving gravel roads and light snowy roads. It combines the drivetrain smoothness of 2WD and traction of 4WD. This is the thing I love second most on my pajero (first being the stock rear locker) and use it frequently when offroading.
I think you're comparing apples and kiwis.
First, I don't know how you're Pajero is outfited but I don't need AWD or 4WD to drive on a gravel road or a 'light snowy road'. It isn't even worth the time and effort to get out and lock the hubs. All AWD would do for me is suck gas.
Second, mine is locked front and rear and I RARELY use the lockers even though I'm resonably sure the trails I do are somewhat more technical than what you're use to. I use the lockers MAYBE once or twice a year off road and most of the time its just to cycle things and make sure everything still works.
My point is I think you're making a performance compareason between two COMPLETELY different vehicles and I think the shops were thinking more of my Sport when they said that.
Anyway, I was reading my docs on the Low231 kit. TerraFlex DOES have something for the NP/NV242 but they explicitly say to call TerraFlex for information.
Edward
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'97 Montero Sport LS 5-Speed 3.5L conversion
SAS Dana 44s & ARBs, 35" Yoko Geolandar M/Ts
NP231 B4R doubler/Terra Low231/RP 5.38 228:1
'03 Montero Sport Limited AWD
'97 Montero Sport LS 5-Speed 3-link/SAS project
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