4x4Wire's TrailTalk Forums: Ranger - Montero Diesel Swap thread

I'm working through the flywheel and clutch fitment.

Here is the new 86 Ford Ranger diesel Clutch cover placed on the resurfaced stock Ford Ranger diesel flywheel:

Here is the stock 87 Mitsubishi Montero 2.6 Gas clutch cover placed on the stock 2.6 flywheel:

Notice the Ranger has raised curved teeth vs. the Montero's flat teeth. The pilot bearings are also different between the two flywheels. They both fit the input shaft but they are not interchangeable in the flywheel. Here are specs for the two clutch kits from NAPA:

86 Ford Ranger 2.3 diesel
NAPA # NNC MU478011C
# Clutch Disc Splines : 23
Clutch Cover Type : Diaphragm
Contents : Clutch Disc, Cover Assembly, Pilot Bushing, Alignment Tool, Hydraulic Line Tool
Cover Size : 8 7/8"
Disc Hub I.D./Input Shaft Size : 1"
Disc Material Type : Organic

87 Mitsubishi Montero 2.6 Gas
NAPA # NNC MU621A
# Clutch Disc Splines : 23
Clutch Cover Type : Diaphragm
Contents : Clutch Disc, Cover Assembly, Release Bearing, Pilot Bearing, Alignment Tool
Cover Size : 8 7/8"
Disc Hub I.D./Input Shaft Size : 1"
Disc Material Type : Organic

So this tells me that the clutch discs are pretty much the same. The input shaft size is the same and the cover size is the same. Based on this analysis and looking at the release bearing design, here is what I think needs to happen to make everything fit:

1. Use the flywheel from the Ranger so you can reuse the diesel starter.
2. Use the pilot bearing for the Ford Ranger diesel in the Ford Ranger diesel flywheel.
3. Use the clutch disc from the Montero 2.6 or the Ford Ranger diesel. They appear to be the same. I think I'm going to use the Ranger disc since I already own it.
4. Use the clutch cover from the Montero 2.6 and have the holes drilled into the flywheel to fit. Use the alignment pins from the Montero flywheel (bring with Ranger flywheel to machinist)
5. Use the Release bearing for the Montero 2.6 tranny. This should fit both the input shaft of the tranny and the clutch cover for the Montero 2.6

Since I bought a complete Ranger clutch kit, I'll need to buy a Montero release bearing and clutch cover. Should I buy the NAPA clutch parts or go with something better like Luk?

-Pmontero

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'87 Montero Diesel
'98 Porsche Boxster Electric
and more...
Greasology
NotPetroleum

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