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Ok so I am pleased to announce that IT LIVES! But is far from done... As per the usual here is a wall of text.
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If you are thinking of attempting this build I will once again outline what I needed to do so, just to do it.
This rig needed two donor vehicles, one if you get a running V6 ram/mighty max to tear apart (why would you do that though?)
In my case I had a running Montero 5 door donor(fully loaded), and a junkyard V6 Ram 50 at my disposal.
Engine:
A 6g72 from a first gen Montero/Raider will drop right in with no modification. Take the radiator while you're at it, as it is slightly larger, but in order to make it fit you will need the power steering lines from a V6 2nd gen. The engine bay fuel lines could be done custom, but it's easier to take some from the aforementioned 2nd gen (and then done custom back to the tank, fuel injection's a bitch). The exhaust I have now is temporary in my case, but to get it running I was forced to use the y-pipe from the junkyard ram, which is frighteningly close to one of my brake lines (which are different in the V6 models) my line has showed no sign of failure or fatigue, but I would have preferred to get some more breathing room. If you felt so inclined you could take the whole booster and line system from a V6 model to make the clearances more relaxed. I'll update with a picture of the engine bay tomorrow morning. The MAF is clunky and awkward to fit, but given my new harness I was able to move the radiator overflow and washer fluid reservoir elsewhere to make room. When the turbos go on I will be converting to a MAP and megasquirt III ECU.
Transmission:
I used a V5MT1-1 from a raider, but was forced to use the cross-member from my donor Ram. I fit right into place after that without any fab work, even put the sticks right where they aught to be. I had to expand the hole in my tunnel to fit the gear shift lever, but that is only relevant if you had an auto in the first place
Wiring:
I used the ENTIRE harness from the Montero. This had pros and cons.
pros: It allowed me to use all of the cool gizmos from the Montero (cruise, intermittent wipers, headlight cleaners, power everything, and a whole bunch of extra circuits), and made the dash swap possible.
cons: Using this harness required a complete reroute of the harness to fit the truck, extending the hot lead to the battery, made some tom foolery with the taillights, and forced the dash swap, but if you use a 2nd gen V6 mightyram harness you will be fine. Ground everything that was grounded and label your wires well and it will work just fine. Certain components needed special attention, but I'll cover that in a minute.
Fuel:
You will need a high pressure pump, and the stock tank won't allow you to put one in it. If you get the tank from a fuel injected 2nd gen this is a non issue. In my case I simple put the pump above the frame next to the tank and ran all of the lines needed. This allows you to upgrade it later if needed as a plus. Unfortunately, the damn thing is quite loud, and will need to be more isolated from the frame in the future.
Driveshafts:
These were a bit of a pain, but in the end I was able to use both of them from the donor Ram, and for the rear I had to take the flange from the Montero's 9.5 (which I will be salvaging at a later date). The rear is a two piece w/ carrier bearing (your truck has the brackets for it even if it has a one piece), and I will be swapping to a custom one piece driveshaft when I swap to the 9.5.
Dash:
This one is only for those who really like it, as it was a nightmare to make work. The Montero/Raider dash is set such that it needs quite a bit of trimming to even fit, and once it does you have to fabricate a brace for the steering column as the stock pipe support is simply in the way (the wheel needs to be moved to the left anyway if you want it to look right). To get it to fit you have to flatten out the beveled section on the windshield side such that the dash goes straight forward from the defrost vents (you will know what I mean when you have one in front of you). Once that is done you will need to trim that section back to where the ark of the windshield is met and it juuuust barely touches the indented section where the defrost vents are. At the corners of the dash bordering the front take a cut straight down 90 degrees to the ground. It wont be very long. There are two brackets on the side that need to be removed from the cab carefully, and the dash will need some small nips on the sides to make room for a few needed brackets, such as the bracket for the steering column. These are all hidden. The Dash has two kicker braces in the middle by the heater core that need to be reattached to the top of the dash by whatever means you find. The top mounts (there are three) will need to be made from scratch, as will the side mounts. The center console needed to have the bottom most cubbie trimmed off, but fits perfectly without it, so there are no uncomfortable gaps. to make it's support fit simple undo the bottom bolts and flip the bottom bracket over. The vents need extensive work to fit, and I have yet to make them work. All in good time. The steering column is straight out of the Montero, and as such need the floor mount from the ram. It's a prick to swap given the grommet, but a little oil and patience will see it off. The parking brake needed a hole cut for it to clear the face of the dash. Don't ask how I got it out in the first place...
After all of that I gained a sweet new dash, the only one to ever be put in a Ram or Mighty Max, as well as an appropriate speedo, tach, oil pressure gauge, volt meter, that goofy "inclinometer", plus a bunch of real estate for the aftermarket gauges that I will be running (boost, fuel-air, water/meth level, Intake air temp, and maybe EGT and that AEM meth failsafe gauge).
Special Fixes:
The vent blower, wiper motor, fuel pump, and rear end harness needed some extra TLC to get working. To get the wipers working I needed the whole motor out of the Montero. The stock wiper motor will plug into the harness, but it will go constantly at low speed, regardless of wiper setting. Putting the Montero's motor needed only a new mounting plate and it works fine. On the bottom of your blower unit you will see two components screwed into the housing. One is the actual motor which has a triangular plate, and the other is a small rectangular component that the harness plugs into. Take the rectangular component from the dash's home vehicle blower and swap it into the project car. Viola the blower will work. The fuel pump needed a hot wire that is activated in the 'on' position. I used a wire which I now believe is the rear defrost circuit lol. This wire is NOT hot when the starter is running so cold starts may be a bit pesky, usually needing a crank or two in my experiance so far. At least it gives me a light on the switch to indicate that it is on (not that the constant whirring wasn't enough)... Lastly, the rear end harness from the Montero is incompatible. In my case the junkyard ram would have given me no advantage, so I reverse engineered the wiring harnesses and spliced them right under the passenger seat. Once you have that done properly, swap the brake pedal button for the Montero's (it has four wires as opposed to two), and remove the blinker wires from it, replacing at least one for a new wire which is routed to the green wire on the ram's rear end harness. If you don't do that your amber lights will turn on with the brakes and the red brake lights will always stay dark. This is because the Montero had all-red taillights which simply used both blinker circuits simultaneously as 'brake' lights. Our trucks, of course, have dedicated blinkers and brake lights.
The road forward:
As of now I have a completely rebuilt N/A motor with a tad over 300 miles on it, and a complaining 5 speed (I'm going to try out a few fluid recommendations before I attempt a swap or rebuild).
Endgame I am looking at:
-Swapping the ECU to a Megasquirt III (which I have read is super easy with these motors), and converting to MAP.
-Swapping out the rear end for a limited slip Mitsu 9.5" with plans to toss in the 2nd gen Montero's Air locker, and swapping out my front for the 8" in the donor Ram, moving my limited slip guts over from my current rear end.
-Fabricating the turbo headers, re-clocking my TD04 turbos, and running full 3" dual pipes from the turbo outputs clear to the back end, with an X-pipe in the Y-pipe's old spot so I can bung in a wideband O2
-Replacing the Injectors with 3SX injectors of in-determinant size.
-Porting the heads as wide as they will go, and upgrading the rockers and spring according to this guide: http://www.3si.org/forum/f36/sohc-above-beyond-mod-bible-476200/.
-Replacing the pistons with VR4 pistons, to handle the boost and heat. (I've been told that the stock crank can handle about 500hp, not that I will be seeing those numbers... Oh, and our trucks weigh less than the 3000gts. Go figure)
-Plumbing an intercooler in place of the AC condenser and running an inline oil pump and dual oil coolers for the turbos.
-Getting the water for the turbos from... somewhere, not sure yet, but there are two ports in the block already. Not sure if they are sufficient yet.
-Adding a water/methanol reservoir in the spot currently occupied by the MAF, and adding the necessary parts to allow it to function.
Here are the turbos btw. Sorry for the crappy picture, just took it a second ago.
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-Upgrading to a ceramic clutch ($500, ouch... Not that the stock replacement is much better at $300)
The supercharger dream isn't dead just yet, and I have a few ideas kicking around...
To make one work, I figured I would need a fairly large one to make it work less hard and thus produce less heat (that's the idea at least). As such I am looking at an Eaton M112 from a wrecked 03 Mustang Cobra, which run about $800 used. To put it on I will need to do the following:
-Obtain a custom air/water intercooler core to fit between the stock fuel rail, and making a new manifold to fit it that replaces both stock intake manifolds and allows the mounting of the Eaton and all of the needed fluid lines
-Moving the water/meth injectors to said manifold to avoid putting water/meth through the blower, and moving the MAP and boost sensor to get accurate readings.
-Praying that I don't generate a disgusting amount of intake air heat.
-Reworking the intake before the blower such that compressed air flows from the turbo's intercooler, past a large blow off valve, through the throttle-body, and into the blower (yes, I know that that will "double compress" the air, but the alternative would be a nightmare to make work properly)
-Tuning everything to only ever allow 20lbs of boost (this setup will absolutely generate more than that), including wimpifying the turbos and over-driving the blower.
-Praying that the trans will handle it.
-Driving the blower with the alternator's serpentine
-Possibly cutting a hood scoop for blower clearance
-Adding yet another heat exchanger to the front of the vehicle for the supercharger's liquid intercooler (at this point I would have a radiator, two oil coolers, a large standard intercooler, and the aforementioned liquid intercooler).
-Praying that the whole frame doesn't just bend at the bed to cab seam.
-Praying for strength.
-Relocating a few components for clearance, such as the coil.
-Upgrading the injectors and fuel pump yet again.
...and If it worked I would be looking at close to 500hp with a super unique power curve and wicked sound (quintessential mustang blower whine, followed by turbo spool and a heavy blow off at closed throttle, all with a lovely unrestricted V6 growl to round it out).
Anyhow just thought that I would update the thread with my progress and future plans. Don't be discouraged if you are looking to swap, it was worth it. Any advise and constructive criticism is welcome, I'm still learning the ropes.
C'mon people, I feel like I'm talking to an empty room here, a few replies would be nice, even if you think it sucks or want help with a personal swap. Either way I'll keep this thread updated as progress is made.
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