Project Delica - Swapping 8" & 9.5" diff into '96 Delica

[VR Trooper]

Hey, I'm just starting plans for a new project I hope to do next spring/summer.
I'm looking for info on driveline specs and model compatibility for 96-03 Challenger/Montero Sport, 00-on Pajero/Montero, and 94-06 Delica if anyone here has experience with any of these.

I have a 1996 Mitsubishi Delica that I'll be putting an '03-06 Pajero/Montero 5spd Sportronic transmission into, and I'm planning to upgrade to 4.30 Ring & Pinion from the same.
But the Pajero is a 8" front and 9.5" rear, while my Delica is a 7.25" front and 9" rear.
Requiring me to do a whack of homework to ensure the swAp is possible and that I get the right parts.
Currently I'm at the tail end of a 3.8L Mivec transplant into my Delica and I'm gonna start searching for the tranny components for this next project.

I searched OuterLimits a few months ago and still have more digging to do.
Bitsamissin has helped me greatly on the Challenger/Montero sport specs, and I'll be looking for 00-on Pajero/Montero Sport specs.
I'll have to re-read my notes, but everything looked doable, but my only option was to either swap a Challenger/Montero Sport rear axle into my Delica, or weld the core of a Challenger/Montero sport into my Delica rear axle. Both have their challenges...
I also am looking to find info on LSD options. I've been told the best option is 01-03 Challenger/Montero Sport Hybrid LSD. Hope to figure out identifying markings on diff housing.

Any advice or knowledge you can offer would be greatly appreciated.
I always try to give back as much as I can, in sharing my knowledge.

Cheers,
Ryan

[OGJON]

giday Ryan
delica uses all coil rear end gen 2 pajero engine & running gear/diffs & suspension

my current daily driver '95 NJ lwb pajero has the larger diffs 8" front & the rare 10" rear lsd diff & has the 4.623 diff ratio

it would be easiest to just put the whole diff & housing in/under your van.

don't forget to post lots of pictures for us

[VR Trooper]

Thanks OGJON,

But be careful of what you wish for... lol...
On my 3.8L conversion I took about 500 pictures and posted nearly 200 on my thread on delicaclub.com
Lots of people have helped me with info, advice and specs on that project.
So I figure I'd lay the thread out as a somewhat instruction manual for anyone curious or wanting to do a similar job.
I'd do the same here.

[VR Trooper]

Also, I can't post pics til I post a couple more...

[VR Trooper]

I plan to have the entire project finished by the end of next year. (hopefully sooner)

The entire project consists of a 3.8L Mivec 265hp 230ft/lbs torque, with 5spd Sportronic transmission, 4.30 final drive and paddle shifters.
The engine is complete other than final ECU programming and exhaust.
Paddle shifters are already mounted, as part of my commitment to making this transmission project happen. (maybe a daily reminder as well... lol...)

Here's a link to the thread on Project Delica - L400 3.8L Mivec 5spd Sportronic w/Paddle shift
http://delicaclub.com/viewtopic.php?f=30&t=32008

[VR Trooper]

I believe the following is a 94 Pajero rear axle, which looks a bit different than my Delica axle.
I'll do a closer comparison this weekend, but the trailing arms and shock mounts look to be different.
Not impossible to change...


is this a 94 Pajero Rear axle?




Compared to my Delica axle

[VR Trooper]

My paddle shifters, mounted last weekend

Without the transmission, I'm thinkin maybe I should hook the paddles up to my stereo volume, overdrive switch, high beam dimmer, sunroof, maybe my horn, or a bright F-off light on my back bumper!

[-Scott-]

Welcome to Outers.

Sounds like an interesting conversion you're planning.

Go the 9.5" diff. It's larger to handle the increased torque of the larger engines. If people can put solid axles under the front of a Pajero I'm sure you can fit the 9.5" rear under your Delica.

Good luck - I look forward to watching your progress.

[VR Trooper]

Thanks Scott,

The only 4.30 R&P I can find available for this transplant is from late model Pajero/Montero 9.5" rear, so it looks to be the only option I have.
I'm not too worried about welding the diff housing into my Delica rear axle, or welding Delica brackets onto a Pajero or Challenger rear axle.
I just want to do all the homework I can before ordering parts.
With my 3.8L Mivec swap, I had to order many parts from all over North America to pull off the transplant.
I managed to only waste a couple hundred bucks getting parts I didn't need or didn't fit.
I learned early on, to spend the extra time getting it right the first time.
I live in the middle of nowhere small town with a total of 3 Mitsu's... lol..
So my tranny and axles will likely come from the USA, 3000-4000km shipping.... Ouch!
Looks like the parts should be $2000-3000 + $500 shipping + duties and taxes. $4000.
More than I paid for my 3.8L engine, headers, tuning software and all necessary parts for the swap.
And almost as much as I paid for the van. haha!

[OGJON]

mate gen 2 pajero & delica run exactly the same diffs so no need to weld anything, just unbolt your entire rear housing & bolt in the other housing

[VR Trooper]

mate gen 2 pajero & delica run exactly the same diffs so no need to weld anything, just unbolt your entire rear housing & bolt in the other housing

I'd like to confirm if the pic of above is of a '94 Pajero rear axle assembly.
My Delica axle is a totally different beast compared to that picture.

I certainly don't want to cause any problems or upset, but all the information I've been given from some experienced Delica owners that my rear end is a 9", which wouldn't matter at all if the Pajero bolted in.
But from the picture of the '94 Pajero rear axle (above), the two axle housings has different mounting brackets, different trailing arms, and my Delica lower spring seat is part of the trailing arm, not on the axle itself.
Not impossible to make it work, but doesn't appear straight bolt in. Unless that picture is not of a Gen 2 Pajero rear axle.

I have no access to Pajero's or Pajero parts where I live. I have to rely on pictures, documents and members' advice.

Essentially, I'm looking to put in a 9.5" rear end with Limited Slip Diff.
I've been advised by Bitsamissin and a couple members on other Mitsu forums that I'd probably want a Hybrid LSD from a 00-03 Challenger/Montero Sport.

[VR Trooper]

Anyone here familiar with the north American montero sport / challenger rear differential options/years?
I'm trying to confirm if the hybrid diff is the best/one I want, what year it came in and what label I'd be looking for to confirm that I am ordering the right one from a wrecker. Again, this axle might be shipped across north america so I wanna get it right.
Your opinions and knowledge are very mch appreciated.

Cheers,
Ryan

[VR Trooper]

Just picked up my Transmission Package.
Tranny 100K km
w/transfer
wiring and ECU's
shifters, console,
front and rear diff carriers 4.30
front and rear axles
front half shafts
and a whack of other parts to do the conversion!

Oh, the work I have to go do now...

[-Scott-]

Good luck - and remember we want pics!