1995 montero sr diff lock

[iceman]

So i found a 95 sr at the crash yard that is diff lock equipped, does anyone know what I need to pull from it to get it to work when i go to install on my truck?

[pennyman1]

the whole rear - it is a 9" rear and unless your's is a 9" it won't fit in the axle of the truck

[Acuta73]

Is it a non-ABS with discs?

You don't need THAT..send it to ME! :grin:

And Penny is right, will need to do an axle swap, not just a 3rd member/Diff swap.

[iceman]

Sorry i should have been more specific haha. I know that i need the whole rear end which is okay because i wanted the disc brakes off of it anyway. My question was what components do I need to make the whole setup work? For the disc brakes I need the proportioning valve and possibly the master cylinder? But for the diff lock do i need any of the wiring or can it be rigged to work?

[Acuta73]

I'd dig around in that truck for whatever actuates the locker. Probably just a small pump, but might have a small tank, too. Strip and use what you can, IMHO.

You WILL need a larger res for the brakes...not sure about the Master? I know the discs use more volume.

Probably gonna have to have a brake shop make you some new hard lines. Only other issue I could see would be gear ratio being radically different for the front and rear?

[pennyman1]

the rear axle in the montero is 4.63 - if you can find them mitsu made 4.22 and 3.91 for them. I have also seen posts saying it is a copy od a ford 9" only stronger and the gearsets fit, but I have no proof of that. That is an air locker, so you need an air supply and a solenoid to switch it in and out.

[iceman]

So I went back over there took some measurements and found the air pump, expected something much bigger. It is about the size of a small fish pump but i grabbed the bracket it was housed on so it should be pretty easy to mount. For anyone who might be wondering it was mounted in the jack compartment under the middle row of seats. I will see if i can get some pictures when I go over there later today. If it is the same as a ford 9 that would be sweet.

[iceman]

Alright gonna update this today and ask a few more questions. So after three trips to ecology I have come up with a few problems and when I go back tomorrow or Wednesday it would be nice to grab everything and be done. The first problem is in relation to the brakes I spent the better bart of an hour and a half tracing brake lines and drawing diagrams on this montero with abs and another 95 without abs trying to figure out how the system works. here is what i came up with and please correct me if it is wrong: I will need the master cylinder off of the montero because it has no residual valve where our trucks do and the valve would trash the read disc brakes very quickly. As far as a proportioning valve goes I was looking for something close to the master cylinder like the fords but it wasn't there, instead there was that load sensing valve by the rear axle so that is needed. Last thing does anyone know if the rear end is the same length as the mighty max and is the mounting the same? I know that it has coil-overs in the rear but will it be possible to use the same u bolts or will I need to make new brackets for mounting it up? It wont be possible for me to measure that until the rear end is off. thanks for all the help guys.

[pennyman1]

you will need the mounts off the old axle to mount the new axle - ldk if the axle width is the same, but it should be close. Don't forget, if you change the rear to 4.63 and your truck is 4wd, you need the front diff gears also to match front to rear. hope you also got the e brake cables to hook the ebrakes up.

[iceman]

Alrighty guys so here is what i got. using crude instruments I have determined that the montero axle is somewhere between 1/4 and 1/8 of an inch bigger so new U bolts are going to be necessary, that shouldn't be a problem i can make that work the mounting on the MM is pretty simple. However the mounting on the montero is very complicated, anti roll bar, rear coil overs, and different shock mounts now the problem is that it is all welded to the axle so to mount it to the mighty max will take some persuasion with the plasma cutter and grinder. Then there is the gear ratio problem so it is turning into a bigger than anticipated project.

[camoit]

Can you put up a picture of the rear end with some shots of the parts you are talking about? If you need spring perches you can get them from rough stuff. (http://www.google.com/url?sa=t&rct=j&q=rough%2Bstuff&source=web&cd=1&cad=rja&ved=0CCsQFjAA&url=http%3A%2F%2Fwww.ruffstuffspecialties.com%2F&ei=EFbGUb5updSLAo7cgZgF&usg=AFQjCNHTxomSXxE5-vJBf7oNCIxc8vVyFA&bvm=bv.48293060,d.cGE)

[iceman]

Yeah no problem, i will post some tomorrow or monday when i can get them off of my camera.

[iceman]

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alrighty so here you can see my very poor quality photographs and can see what has to be cut off, the mounting for the trailing arms shock mounts and spring mounts as well as the anti roll bar on the drivers side. then new mounts have to be made for attaching it to the leafs and shocks on the mighty max since the axles are different sizes. hopefully the universal is the same size and i also have to workout the brake issues.

[iceman]

http://i720.photobucket.com/albums/ww202/hamstrung2/D50%20MiniRam/cd2.jpg

here is a reference picture of a mighty max rear end assembly only without shocks

[camoit]

You can't just steel the drop out and swap the gears instead of all the cutting. Because that a bunch of grinding.

[iceman]

it is a different rear right? so wouldn't that be not compatible? I guess i didnt follow you there.

[pennyman1]

yes the 95 monte rear is a 9" and the truck is an 8" - no center chunk swap here

[TOASTY]

The '95 Montero is actually a 9.5" axle the 9" is found in Mitsubishi trucks with a 3.0 V6, any with the 3.5 V6 got the bigger axle. I have swapped the SR axle and it's Montero Sport/Triton counterpart into every configuration of Mitsubishi 4x4 so far. I wish i had found your post sooner as I may have been some help.

Personally i like to just the Sport/Triton variation of this axle for swaps under the leaf sprung Mitsus, The Sport axle '97-99 is a near direct swap depend on the year and drivetrain of the recipient. For example a v6 Mighty Max in most cases will just take the Sport axle like it was made for it. There are some exceptions like yoke to pinion flange bolt spacing is sometimes different but the center bore is the same so it's easy to DIY new holes without worries of the shaft being off center.
Putting the V6 axles into the 4cyl powered 4x4's is a bit tougher because the centering bores are very different and the yoke bolt pattern is really close to the flange radius. What i do is machine a spacer to fit (interference fit actually) the ID of the flange and the OD of the yoke then once it's pressed together i face it on a lathe.

I did the whole chop off all the SR coil sprung brackets and swapped that axle in a spring over leaf setup. It wasn't bad, took me a few hours to prep the axle and a couple more to set it up under my pickup. Totally worth it, where else can you get an air locker for a couple hundred dollars? not to mention the beefy axle it's attached to.

As far as Ford 9" compatibility goes it's a cut and retube operation, the splines on the Mitsu 9" match the splines on the Ford Small bearing 9" and the shafts on the Mitsu 9.5" match the big bearing Ford 9". The Ford splines are a rougher cut so sometimes you need to polish them up with a scotch write pad or fine sandpaper.

[Chargerx3]

The '95 Montero is actually a 9.5" axle the 9" is found in Mitsubishi trucks with a 3.0 V6, any with the 3.5 V6 got the bigger axle. I have swapped the SR axle and it's Montero Sport/Triton counterpart into every configuration of Mitsubishi 4x4 so far. I wish i had found your post sooner as I may have been some help.

Personally i like to just the Sport/Triton variation of this axle for swaps under the leaf sprung Mitsus, The Sport axle '97-99 is a near direct swap depend on the year and drivetrain of the recipient. For example a v6 Mighty Max in most cases will just take the Sport axle like it was made for it. There are some exceptions like yoke to pinion flange bolt spacing is sometimes different but the center bore is the same so it's easy to DIY new holes without worries of the shaft being off center.
Putting the V6 axles into the 4cyl powered 4x4's is a bit tougher because the centering bores are very different and the yoke bolt pattern is really close to the flange radius. What i do is machine a spacer to fit (interference fit actually) the ID of the flange and the OD of the yoke then once it's pressed together i face it on a lathe.

I did the whole chop off all the SR coil sprung brackets and swapped that axle in a spring over leaf setup. It wasn't bad, took me a few hours to prep the axle and a couple more to set it up under my pickup. Totally worth it, where else can you get an air locker for a couple hundred dollars? not to mention the beefy axle it's attached to.

As far as Ford 9" compatibility goes it's a cut and retube operation, the splines on the Mitsu 9" match the splines on the Ford Small bearing 9" and the shafts on the Mitsu 9.5" match the big bearing Ford 9". The Ford splines are a rougher cut so sometimes you need to polish them up with a scotch write pad or fine sandpaper.
Is the 90+ 3.0l 4x4 mighty max the same rear differential as the mid 90's monteros? Being either a 9" or 9.5" I have a 90 MM 3.0 4x4 and it's center pumpkin looks just like my 95 montero sr pumpkin. I want to pull the locker pumpkin in the montero and drop it into my mighty max. Is those doable?

Also are ford 9" ring and pinions able to swap in with no issues?

[TOASTY]

Your '95 has a different rear axle, you need one from a 3.0 powered Montero.

[Chargerx3]

I'm worried you might be right. Does That also mean the locker would not interchange too?

[TOASTY]

Does not interchange 28 vs 31 spline. Also the axles with the locker have one short axle shaft so you would need to have some machine work done to make it work in your truck with your original axle. The easiest thing to do is find a 97-99 Montero Sport with a locker and swap the whole thing in (these are leaf sprung and will bolt up) otherwise just swap a Montero axle in if you know how to weld. Plus getting the newer axle will get you disc brakes.

[Chargerx3]

Thanks for responding. I wonder if I can just pull the axle shafts then on my 95 SR, cut off the excess length (hopefully there is enough spline)and install the pumpkin or locker into my MM 8" axle. Not really looking to swap in a 3" wider axle at this point if I don't need to. The discs look to bolt up on my axle as well.