Living out of the Nomad




















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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...
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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 system.  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...
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Reverse Light Upgrade

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The back-up lamps on the 2.5 are more of a suggestion of light than actual practical illumination, so I decided to do quick and inexpensive upgrade. I've had good luck with CREE style LEDs previously, as long as I replaced all the hardware with stainless. I came across these NiLight 18W flush mount flood lights and thought I'd roll the dice and give them a try. Eighteen bucks, why not? The install required trimming a bit of the opening for the stock lamps since the NiLight height is about a quarter inch taller. Remove the housing. Then remove the lamp from the housing. I clipped the the socket off from the wires. Before fitting clean the area around the opening to remove the footprint from the previous housing.  I used a jig saw with a metal cutting blade to score the bottom edge of the opening, creating "teeth" that will be pulled to match the height requirement of the new housing. Using a pair of ViseGrips, grab a tooth and slowly mo...
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