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Showing posts from 2017

Transfer Case Shifter Replacement

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When I first tested this Monty it shifted into 4 and 4l without any issues, even the rear locker kicked in just fine. After purchase I took it out to wheel more aggressively to baseline its suspension and it wouldn't shift into low range and that's when after a bit of research I learned of this drivetrain's Achilles' heel. In the image of my shifter above, surrounding the lever that engages the transfer case forks is a brown plastic articulating ball or at least what's left of it.

While this particular plastic outlived Mitsubishi's warranty, it went to pieces later in many a Montero/Pajero/Shogun. The fix is not a new aftermarket part - none exists that I could find - but to score a junkyard find of a previous iteration found in earlier vehicles that have a white plastic ball instead of brown.

I swapped mine the other day after sourcing a white-balled shifter from a local Montero enthusiast who picks them up from local pick-a-part yards. The job is pretty stra…

A Couple of Generations

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Rear Door Mod

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With the platform insert there aren't many ways to stow flat rigid items and yet there are two that are indispensable to our travels, a folding step and a folding table. The step is used around the rig when packing the roof rack and it gives my dog a literal leg up in hopping into the back.

The table is an 18X20" GCI compact camp table that's just right for dining for two of us or to get gear off the tent floor.


With the previous mod of the utility shelf eliminated it opened some real estate on the rear door where these items could be stowed. It all works around the Camillus hatchet/door handle well and the placement still kept a window to access the interior door lever. Quick Fists are the greatest kit out there for this kind of arrangement.


ARB 1250 Awning

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Shade is a commodity like water where we amble. Trees are sparse in the land that we travel and we've depended on an awning for the decade we've been doing this.

This is our third awning, our second ARB and I was surprised to find some improvements in the product when I slipped it out of its shipping tube.


Gone is the envelope design of the case. This one is tailored, boxed at the ends to better fit the rolled awning with an inverted pouch on both ends to keep the zipper tabs.


Nothing else has changed and doesn't need to. The friction cams on the legs lock tight, the channel material and junction hardware are machined to tuck away and stay put.


The awning is mounted to the Apex Roof Rack using four 3/4 inch rubber lined zinc plated clamps on the vertical stanchions and two 1" clamps on the top rail, under $7 for a solid mount.

Apex Roof Rack

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The Franklin Rack didn't work out for our needs; too small, not rigid enough. It's found a new home on my son's Gen 3. I replaced it with this Apex Rack, a larger, more rigid platform with parallel vertical posts where a rear awning could be mounted.


The rack builds with a lower base with a welded basket and an upper rail attached with vertical stanchions. The way it comes together; the rack can be separated into two halves, front and rear, with some questionable hardware that clicks the tubes together - nothing that can't be remedied with stainless hardware. It fits well on the stock roof rails with enough rear overhang to mount an awning.


The rack mounts with four U-bolts with thumb bolts. There's plenty of room for recovery gear, Rotopax fuel and water containers, and our Kodiak tent.

Rocker Blackout and Pinstripe

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I used Duplicolor's Spray Truck Bed Coating to black out the rockers and bumpers. I made the mistake of using their rolled on product to begin with, resulting in bad surface continuity.


The coating was sealed at the seam to the factory finish with 1/4" pin striping in signal orange as a nod to the Montero/Pajero's history with the Camel Trophy.


Platform and Drawer System

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If you've been reading along on this build you know that there was a dog deck and a folding utility shelf installed, neither of which worked as well as I would have liked. Add to that one of the reasons I went with this 2.5 is its room to create a sleeping platform, and I decided to do a do-over, making this Interior Modification, Part 2, combining a platform with a drawer systems. 

I studied a number of DYI systems on Expo and other build threads, making decisions on materials and dimensions, but keeping all this driven by our overland history of what has worked and what we wish we had. The driving need here for us was to have the ability to pull over, level out, roll out pads and bags and go to sleep. 
We've done the RTT route and have a Kodiak ground tent, both with pros and cons. Being able to sleep in the Monty seems to be the best compromise for us; easy set-up and access, great weather protection and climate control, off the ground away from critters and more of a chal…