Ok, so heres the story....
After blowing thru 3, yes 3, automatics, I decided to finally go for the 5 speed swap.
For those of you that have been around a while, I would have done this swap long ago, if I had not been misinformed by "know-it-alls" on here claiming that this exact swap just was NOT possible!!!
After a bit of research, I concluded that I could indeed use the AR5 out of a newer Trooper. The Trooper, with the manual option, was only availble with a standard style transfer case, (No TOD) So...I needed to mate this tranny up to my stock TOD transfer case.
This is a DIRECT bolt in swap!!!!
All parts are OEM!!!! EVEN the DRIVELINES are the SAME!!!!
Here is a list of needed items....
AR 5 manual 5 speed (1998-2001 Trooper)
Isuzu 3.5 Flywheel (3.2 will work if you have it turned)
New flywheel bolts OEM
Trooper clutch set (preasure plate, disk, T. O. Berring) OEM ONLY!!!!
Trooper input shaft pilot berring
New clutch preasure plate bolts OEM
Isuzu Rodeo Clutch master cylinder (1998-2001)
Isuzu Rodeo clutch pedal assembly (98-01)
Isuzu Trooper clutch slave cylinder (1998-2001)
Clutch hydraulic lines.
Trooper computer (manual tranny model 98-00)
Trooper shifter boots
Reccomended... New rear main seal
Optional...Trooper manual tranny exhaust system
Remove your old auto and transfer case, T. Converter, flexplate, pilot bushing from crank, and drivelines, exhaust, computer, shifter assembly...ect...
Remove blocking plate frome firewall (2 bolts) where clutch master cylinder will go.
install master cylinder, clutch pedal, hydraulic lines.
Install rear main seal, input pilot berring, Flywheel, disk, preasure plate
On the shifter assembly in the TOD transfer case, The metal top cover with 4 bolts will need to be removed and clearanced 1/4".
As you try to slide the AR5 into the TOD case, you will see where the shifter hits just slightly. This is the area that needs to be "trimmed" just a small amount. (I used a 4" angle grinder) took me 5 minute to remove 1/4"...
After that, you will be able to slide the two cases together..bolt cases together using the old TOD bolts you removed.
Install the Throw out bering in the input shaft...(do not remove wedge collar!!!) Do not install T.O. Berring on preasre plate!!!!
Install new gearbox and TOD unit as one...install slave,crossmember,drivelines,exhaust...ect..hook up computer...You will have to re-route some fuel lines. (bend and re-attach to tranny)
Have someone help bleed out the hydraulic system
On the old wiring harness, you will have to cut into the plug that used to go to the shifter switches (on auto tranny) isollate the black and blue/blk wires and connect them together. (this tells the computer you are in Park or Nuetrall, so the starter will engage)
Also you will need to find the reverse switch on the new gearbox and wire it up to the revers wires, so the reverse lights will work...
Lastly, the One of the oxygen sensors was moved to a different location (befor the CAT) on the trooper, so you may want to swap to Trooper exhaust or have a shop install the sensor ahead of one of the Cats...
Driving the manual trannied VX is AWESOME!!! More controll, power.
Power and shifting seems VERY similar to a 90s era 5.0lt 225HP mustang!!! VERY FUN! 0-60 times has surely dropped.
Everything feels more "DIRECT"...
The TOD functions just as it did with the AUTO...
Fuel Mileage has increased...figure 2-3 mpg better!
Duralbility...The Trooper clutch is HUGE...a 10.4" plate with 1700#s clamping force...(1 Ton style) however, due to the Pull-type design, pedal effort is light! (Pull style clutches are AWESOME, usually used on exotics) And have 30% less pedal effort than older push style systems...
The AR5 is a well build gearbox with 3 sycro rings (not 2) for smooth quick shifts, even with large heavy-duty clutch disks.
Feel free to ask questions or comment...
Reply With Quote