Merrill's 4G64 DOHC.

[Merrill]

Let's cap this swap off!!

So I left off with the brake lines. Well you may have looked at the pics and discovered that everything was done under the hood. Since the interior was done, that means only the engine and trans need to go back in for me to roll!

Amazingly, this build suffered only ONE bolt casualty during dis-assembly that required my attention - the exhaust manifold stud.

Final assembly was on Christmas eve. There was no place to find a new or used exhaust manifold, and there was no way in hell the rest of the broken stud was coming out. Solution - weld a new stud on...

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Problem solved...

Next is the engine.... simple enough to do...

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Finally - the trans. This one seemed to be a pretty big hit on Facebook, so here is the list

How to Build a Hydraulic Hybrid Transmission


If you noticed before, I have swapped to a hydraulic setup. This is what you need to make it happen.


97+ Montero Sport 2.4 2WD 5 speed transmission
97+ Montero Sport clutch pedal assembly with bracket
97+ Montero Sport Slave cylinbder, hard line, and rubber line (or you could bend your own)
Mighty Max 4x4 Clutch master cylinder


This is not rocket science at all. Simply remove the tail housing from the MM, and mate it to the MS transmission.


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Here is one issue you will have to fix. There is an accessory casting for a bracket, or some option for the MS. It will hit the tunnel of the MM when installed. Just trim it off.


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I am sorry about the darkness of the first pic - my flash wasnt working... Look closely and you will see the trans parts making contact with the trans tunnel.

The tab for the hard line to rubber line is already on the truck. Just use it as it is meant to be used.


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And there you have it. I highly recommend getting a damn good alignment after you are finished with the swap. You'll be doing yourself a huge favor with that...

I must make one thing very clear about all of this. Everything I have written and updated here is NOT by any means intended to be a write-up so you can go do it yourself. This job is for the professionals. I don't want to sound rude, but if you "need" a picture perfect write up on how to do a right hand drive swap - you have no business doing it.

Please do not attempt this swap if you have no professional experience in this field.

If you have any questions or comments - Post up of PM me!