VT_Maverick's 5 Speed Swap

[WormGod]

If I recall correctly, Troopers with autos have TOD & Troopers with manuals get a non-TOD transfer case.

Correct.

I prefer TOD personally but I loves me a manual. Talk about a dilemma....

[Triathlete]

If I recall correctly, Troopers with autos have TOD & Troopers with manuals get a non-TOD transfer case.

I stand corrected...my brain for some reason was not seeing auto vs. manual, it was in the gray area

[Leon R]

You lose TOD with the Manual Trooper as its only a 2wd-4hi-4lo. Also you get a 2-1 low gear () on the transfer case with the Trooper. Keeping the VX transfer case with this swap is key.

Does this transfer case have a "center" differential, so that it could operate on dry roads like an AWD?

[VXorado]

Does this transfer case have a "center" differential, so that it could operate on dry roads like an AWD?

No, the 4wd Hi/Low positions are locked. You'll be rolling around in 2wd for dry pavement.

[blacksambo]

Great work. Did you know Isuzu built at least five VX's with manual shift and TOD??? Yes, that's right, rally competition models. You can verify this plus learn a thing or two by consulting the VX parts book. Sections 2-20 and beyond detail the pedals etc. If you don't have access let me know, I'll have my wife scan and post the manual transmission pages. Good luck.

[Buffy]

Great work. Did you know Isuzu built at least five VX's with manual shift and TOD??? Yes, that's right, rally competition models. You can verify this plus learn a thing or two by consulting the VX parts book. Sections 2-20 and beyond detail the pedals etc. If you don't have access let me know, I'll have my wife scan and post the manual transmission pages. Good luck.

I was not aware that Isuzu made 5 manual VXs. Learn something new every day. If you could scan the documentation I would love to read it!

[vt_maverick]

If you have the time that would be great!!!

[vt_maverick]

Just learned something... the same AR-5 manual that we're swapping into my VX was also used on the Pontiac Solstice GXP. That car featured a dual-turbo 2.0 L I4 Ecotec engine that made 260 hp and 260 lb-ft torque while getting 19/28 MPG. The VX is heavier by almost a thousand pounds, but you'd drop a good chunk of that just by going from a V6 to an I4...

So since we know an AR-5 mates to an Ecotec engine is it conceivable that you could swap that engine instead? Discuss...

[VXorado]

So since we know an AR-5 mates to an Ecotec engine is it conceivable that you could swap that engine instead? Discuss...

You have boggled my mind with this statement.

[vt_maverick]

You have boggled my mind with this statement.

Because it's that dumb of an idea? Or because it's unthinkable to go "down" to a four-banger?

[VXorado]

Because it's that dumb of an idea? Or because it's unthinkable to go "down" to a four-banger?

No its a pretty clever question and after thinking about it for a while, I didn't have a good answer.

Heavy VX= bad canidate for a 4 cylinder

I4 smaller/lighter than 3.5L= good weight shed for VX

I4 turbos= possible annoying turbo lag (maybe not since there's 2)

I4 more HP= that's all good

I4 better MPG= also all good

Sky/Solstice short production run= that engine could cost big $$$

Too many pros/cons to make a stance. I think its a great idea as long as the extra 45HP goes to the wheels. Then again the MPG alone may make the swap worth it.

[89Vette]

No its a pretty clever question and after thinking about it for a while, I didn't have a good answer.

Heavy VX= bad canidate for a 4 cylinder

I4 smaller/lighter than 3.5L= good weight shed for VX

I4 turbos= possible annoying turbo lag (maybe not since there's 2)

I4 more HP= that's all good

I4 better MPG= also all good

Sky/Solstice short production run= that engine could cost big $$$

Too many pros/cons to make a stance. I think its a great idea as long as the extra 45HP goes to the wheels. Then again the MPG alone may make the swap worth it.

Often top HP numbers don't tell the whole story. For a 2-ton vehicle, torque is an important consideration. It doesn't matter how much HP you generate if it takes 20-seconds getting it from 0-25mph. (IOW if that HP doesn't happen until higher rpms)

Responsiveness is usually a product of cubic inches and compression. OTOH, I haven't driven a dual turbo 4-cylinder.

[eternal21]

Just learned something... the same AR-5 manual that we're swapping into my VX was also used on the Pontiac Solstice GXP. That car featured a dual-turbo 2.0 L I4 Ecotec engine that made 260 hp and 260 lb-ft torque while getting 19/28 MPG. The VX is heavier by almost a thousand pounds, but you'd drop a good chunk of that just by going from a V6 to an I4...

So since we know an AR-5 mates to an Ecotec engine is it conceivable that you could swap that engine instead? Discuss...

Very much so, just wiring the instrument cluster would be the biggest concern. Add'l info: there is also a 2.4 non turbo engine, and it would also appear that the aforementioned 2.0 is the same engine in the Cobalt SS and HHR SS, as per ebay auction 130586906920.

I, for one, in order to increase gas mileage would strongly consider a 2.0L w/a 5MT, especially since there are aftermarket parts to boost the power of the 2.0L.

[vt_maverick]

Very much so, just wiring the instrument cluster would be the biggest concern. Add'l info: there is also a 2.4 non turbo engine, and it would also appear that the aforementioned 2.0 is the same engine in the Cobalt SS and HHR SS, as per ebay auction 130586906920.

I, for one, in order to increase gas mileage would strongly consider a 2.0L w/a 5MT, especially since there are aftermarket parts to boost the power of the 2.0L.

+1, my thoughts exactly (mileage AND power without adding the weight of extra cylinders). I wonder if you could just replace the VX instrument cluster with a Solstice / Sky / HHR / Cobalt cluster? You'd lose the TOD lights and odometer, but maybe something could be worked out? I suppose it depends on how integrated the clusters are.

[Buffy]

Feeling better and got a bit more done.

Completed pedals and interior...



I took my dremel and opened up the stock console some to accommodate the shift pattern. I am still trying to find a shift boot for this...



I took the connectors for the auto and taped them to the harness. Here is the harness ready to be installed...



Here is where all the majic happens. I am having a connector sent to me and will make a harness for the clutch switch, backup light switch, and hopefully cruise...



I ran the breather tube for the transfer case up into the engine compartment...



The big challenge is getting the wires run and connected to the correct O2 sensor. Another challenge is keeping wires away from the hot exhaust parts.