VT_Maverick's 5 Speed Swap

[vt_maverick]

Don't worry, you'll still have the only 99 5-speed! 2000 and 2001 are drive by wire per Jerry Lemmond, so the wiring will be somewhat different anyway. But we'd love to have whatever you've got! Can you scan and email them to us? I can shoot your our emails via PM, or you could even post them here if the resolution is high enough to be readable.

***EDIT - Nevermind on the drive-by-wire thing, see post #19 below***

[Buffy]

Ok, I got a little more done today but not as much as I had hoped. I hit several junk yards today looking for a Rodeo console to use but struck out. I did, however, score a nice set of asisn manual hubs.

I did get the dash removed and the clutch pedal installed today. I also removed the hard line from the Trooper and got it installed. The cool part is the mounting tabs for the lines is installed on the VX. I am having to get a different clutch master cylinder sent to me as the one I need has a 10 mm nut and the one I received was a 12 mm, no big deal though. I have plenty to keep me busy. The clutch assembly arrived this afternoon and I was working on getting it installed but for the life of me could not find my clutch alignment tool!

When the project is done and I am satisfied with everything, I will created a word document with pictures and commentary if everyine thinks it will be of use to the community.

So here are some pictures...

Starting to take the dash apart...





If you look at the center of the picture you can see the blockoff plate and the mounting studs for the pedal assembly...



Here I have removed the auto bushing from the rear crank...



Ok, trivia time, this is the tool Jerry lent me to remove the bushing. A very simple too that fits perfectly into the bushing, injects grease and has a surface to tap to force the bushing out. Extra credit to whoever can name this former Isuzu part turned tool....

[Buffy]

Here are a few pictures of the clutch and flywheel....

New pilot bearing...



Installed, just tap it in until it bottoms out...



New flywheel installed, bolts torque to 47 ft pounds...



Factory clutch plate....



Factory pressure plate, man is this thing heavy duty!...

[Buffy]

Don't worry, you'll still have the only 99 5-speed! 2000 and 2001 are drive by wire per Jerry Lemmond, so the wiring will be somewhat different anyway. But we'd love to have whatever you've got! Can you scan and email them to us? I can shoot your our emails via PM, or you could even post them here if the resolution is high enough to be readable.

This must be a Trooper thing because yours still has a throttle cable. This is good in our case because I can just take the computer out of the Trooper and install it, no need to have the one in your VX reflashed.

[vt_maverick]

This must be a Trooper thing because yours still has a throttle cable. This is good in our case because I can just take the computer out of the Trooper and install it, no need to have the one in your VX reflashed.

Sweet!