VT_Maverick's 5 Speed Swap

The 99 Trooper is the best. I think after 99 the Troopers went to drive by wire. But over all any 98 and above will work. 2000 and up will require you to have the computer reprogrammed.

Does it matter what engine it has? Isn't there a 4 cyl, 5 speed?

According to Edmunds the 3.5 V6 was the only option in 98 and 99. I think they discontinued the 4 cylinder on the previous generation maybe?

Were there any issues mounting the new transmission to the VX chassis?

Quote:

---

Originally Posted by SilverBullet75

Were there any issues mounting the new transmission to the VX chassis?

---

It is a direct swap. Meaning the cross member is the same even your original driveshafts are reused. Everything bolts into place. You have to remember the VX is built on the RS Trooper frame that the US did not get. All parts and pieces bolt in place using factory hardware.

Buffy, do you have a write-up on the wiring harness? Seems like the wiring was the most challenging part of this swap.

Another possibility, I would be willing to buy a harness from you if you want to make another one.

Quote:

---

Originally Posted by vt_maverick

Greg and I had this conversation just before he left and we're both in agreement that working from a donor vehicle is much easier. It really is questionable whether you could assemble everything piecemeal for less $$$, and you can't beat the convenience of being able to look at the way the manual was wired from the factory while performing the install in the VX. For me it turned out to be a real steal - my $800 got us the 94K transmission, ECM, wiring harness, exhaust, master cylinder, shift boots and shifter, clutch switch (or was it neutral switch Greg?), and probably a few other things I can't remember right now.

---

Good call, I started looking on craigslist & found a 99 with engine problems for $1000. I'm not buying yet but can imagine it will be much easier to get a troubled Trooper than running back & forth to the parts yard.

Quote:

---

Originally Posted by VXorado

Buffy, do you have a write-up on the wiring harness? Seems like the wiring was the most challenging part of this swap.

Another possibility, I would be willing to buy a harness from you if you want to make another one.



Good call, I started looking on craigslist & found a 99 with engine problems for $1000. I'm not buying yet but can imagine it will be much easier to get a troubled Trooper than running back & forth to the parts yard.

---

The wiring was the biggest unknown for me going in. In the end it was very simple once I had the answers of course. I was thinking about creating a word document and maybe get it posted for reference. I will make sure the wiring portion of the write up is detailed.

Buying a 99 Trooper is the best way to do this conversion. There are alot of small pieces you can rob off it, there will be bolts, etc. be sure to save the manual heat shields as those will be important! The computer is a direct swap in, no reprogramming needed. You can use the hard line for the clutch master cylinder and the actual clutch master. I had to use the clutch switch from the donor. I used the wiring harness from the manual to make the connection for the backup lights and pulled wires from it to make the harness that went to the neautral and clutch switches. You run 4 wires to the switches ansd you are good. You can get the mode switch off the auto tranny and modify it for the swap. I might be able to create a wiring harness that is a pluc and play kind of thing by the time you get ready for it. Just send me tha old harnesses and I will send you what you need to install.

There are some gotchas to look out for like the OEM clutch kit does not include a clutch alignment tool. Advance Auto sells one for $1.50, Auto Zone and O'Riely did not offer one. The OEM slave cylinder does not include the push rod, usually not a big deal, but I was missing mine and had to go out and buy a cheapie slave cylinder to get the rod.

I will detail all of this in the write up.

Great, can't wait for the write-up and we'll talk about the harness when the time is right. I need to buy a house first so I have a nice big garage :bgwo:

VXorado - how many miles on your donor?

The ad didn't say. I'll be looking this summer & will start the swap once I find a low mileage donor.

What kind of mileage do you recommend to stay under on this type of transmission?

Or, should it be rebuilt before installation into the VX (obviously a safer bet..)?

According to Jerry Lemond anything under 150K should be fine. Anything above that you may want to consider having it gone through.

Quote:

---

Originally Posted by vt_maverick

Well Greg and I met a few hours ago and I drove the VX back to my place and promptly parked her in the garage (need to do a few things before I leave her tomorrow afternoon for a business trip :(). I've only driven her those 7-8 miles but I can tell you this much: someone at Isuzu should have been fired for not offering the VX with a manual option. It's a completely different driving experience with the manual, way more fun even with the puny stock 215 HP. The clutch is buttery smooth both in terms of pedal travel and the "feel" of moving between gears. The ratios are interesting in the AR-5, 1st and 2nd are strong enough to pull you forward without even pressing on the gas - and I'm pretty sure you could start out in 2nd if you wanted to. Should be LOADS of fun once I get "launching" down... :D And of course the install was just as clean in person as you'd expect from the pictures Greg's posted here - just a little bit of Dremel work was required to keep the stock VX center console.

I am VERY impressed and EXTREMELY happy with the finished product. Now I'm going to go back out to the garage and think up an excuse to drive her again tomorrow morning before I leave. :) Thanks again Greg! Fantastic job!!! :thumbup:

---

I have to remark here. No Isuzu did not miss the manual shift option, in fact five were built for factory racing efforts. What we must remember is that VX was a concept car that was designed to be seen by more than the auto show attendees. That mean't it had to be inviting to drive by the widest range of potential drivers possible. A lot of people hate manual shift. They think it's too much work, especially for a $30K purchase price vehicle. Isuzu was looking for lots of street exposure of the VX design to trumpet their style capability. Average Joe's climbing rock piles was not the intended purpose. That terrain already belonged to dowdy Jeeps. Isuzu was gunning for the suburban weekend warrior showing off in the supermarket parking lot so somebody would be inspired buy an Ascender or Axiom to please their wife, but still remember fun the VX halo cast on their family everyday vehicle.

If I recall correctly there were also consideration of passing emissions tests with manuals.

I'd be curious to know more about that emissions issue, if you have any info on that?

Quote:

---

Originally Posted by blacksambo

Isuzu was looking for lots of street exposure of the VX design to trumpet their style capability. Average Joe's climbing rock piles was not the intended purpose. That terrain already belonged to dowdy Jeeps.

---

Surprisingly the trend is going toward auto transmissions in the 4 wheeling scene mainly because its much easier to drive an auto in rough terrain. Racing is manual transmission's last stand but with dual clutch autos now being used in supercars, they may be fazed out on the track too.

Personally I love manuals & can't wait to be stalling out on those rock piles soon :thumbup:

Quote:

---

Originally Posted by blacksambo

I'd be curious to know more about that emissions issue, if you have any info on that?

---

Not really it was just something rattling around in my brain.

Quote:

---

Originally Posted by blacksambo

I have to remark here. No Isuzu did not miss the manual shift option, in fact five were built for factory racing efforts. What we must remember is that VX was a concept car that was designed to be seen by more than the auto show attendees. That mean't it had to be inviting to drive by the widest range of potential drivers possible. A lot of people hate manual shift. They think it's too much work, especially for a $30K purchase price vehicle. Isuzu was looking for lots of street exposure of the VX design to trumpet their style capability. Average Joe's climbing rock piles was not the intended purpose. That terrain already belonged to dowdy Jeeps. Isuzu was gunning for the suburban weekend warrior showing off in the supermarket parking lot so somebody would be inspired buy an Ascender or Axiom to please their wife, but still remember fun the VX halo cast on their family everyday vehicle.

---

Yes they did miss the manual shift option - notice I said "not offering the VX with manual option." Saying a race truck counts as an "offering" is like saying that Ford offers a 1000 HP engine in their Taurus because they built a handful of NASCAR cars. I agree that not everyone wants a manual, which is why most manufacturers generally offer only 10-20% of their models as manuals, even in sports cars (the Infiniti G35 is a good example of that tactic). In this case they elected to go all in on one transmission type, which I think is a shame. I believe 10% of original owners might have opted for the manual option, especially given the opportunity to gain a few MPGs.

Also, the purpose of a manual is not exclusively (and certainly not primarily) for rock crawling. If anything a manual makes the on-street driving experience more fun for those that like a manual transmission. I doubt many owners will actually ever do this swap, but I do think those that do will really enjoy the change.

Quote:

---

Originally Posted by rsteinmetz70112

If I recall correctly there were also consideration of passing emissions tests with manuals.

---

Quote:

---

Originally Posted by blacksambo

I'd be curious to know more about that emissions issue, if you have any info on that?

---

The Trooper exhaust that we switched in was only from the headers to the catalytic converter - everything from the cat to the tailpipe stayed the same. I don't see how a transmission change would affect emissions, unless it resulted in lower MPGs?

Quote:

---

Originally Posted by VXorado

Surprisingly the trend is going toward auto transmissions in the 4 wheeling scene mainly because its much easier to drive an auto in rough terrain. Racing is manual transmission's last stand but with dual clutch autos now being used in supercars, they may be fazed out on the track too.

Personally I love manuals & can't wait to be stalling out on those rock piles soon :thumbup:

---

Lol - I think if I did a lot of crawling I would have strongly considered staying with the auto for just that reason. But since I do 90-95% street driving with a few trips in the deep sand each summer it's a much better choice. I also think the extremely low gearing in 1st and 2nd will come in handy when it snows - I can basically use those gears like the "Winter Mode" on the automatic but with more control.

Quote:

---

Originally Posted by vt_maverick

Lol - I think if I did a lot of crawling I would have strongly considered staying with the auto for just that reason. But since I do 90-95% street driving with a few trips in the deep sand each summer it's a much better choice. I also think the extremely low gearing in 1st and 2nd will come in handy when it snows - I can basically use those gears like the "Winter Mode" on the automatic but with more control.

---

I think you might have the winter logic idea a bit off? You don't use lower gears for snow/ice. You use higher gears to start to reduce torque output on slippery surfaces. That's what winter mode does. It starts you automatically in third gear instead of first. You use lower gears for more torque application on grippy surfaces facing steep grade climbs, and for pulling stumps out of the ground. I hope this helps.

You're right, got that backwards. Was thinking the lower ratios were at the bottom and not at the top (duh). Good catch. :thumbup:

I gotta love your enthusiasm, though!

I've got spirit, yes I do, I've got spirit, how about you? ;) :laughy:

Awesome!!!!! So when my 3.5L finally goes out and I have it rebuilt and bored-out to 4.0L I might need to go to the AR-5 as well, hmmmmm.

Also does AR-5 sound like an assault rifle to anyone else?

Quote:

---

Originally Posted by LittleBeast

Also does AR-5 sound like an assault rifle to anyone else?

---

So, if an AR-15 shoots 5.56 and an AR-10 shoots 7.62x51, then what the hell would an AR-5 shoot?:rollb2:

Quote:

---

Originally Posted by RabidPony

So, if an AR-15 shoots 5.56 and an AR-10 shoots 7.62x51, then what the hell would an AR-5 shoot?:rollb2:

---

Fiddy...:yesgray:

Quote:

---

Originally Posted by RabidPony

So, if an AR-15 shoots 5.56 and an AR-10 shoots 7.62x51, then what the hell would an AR-5 shoot?:rollb2:

---

Hmmmmmm .223????? 22-20??? :?:

Quote:

---

Originally Posted by Buffy

The wiring was the biggest unknown for me going in. In the end it was very simple once I had the answers of course. I was thinking about creating a word document and maybe get it posted for reference. I will make sure the wiring portion of the write up is detailed.

Buying a 99 Trooper is the best way to do this conversion. There are alot of small pieces you can rob off it, there will be bolts, etc. be sure to save the manual heat shields as those will be important! The computer is a direct swap in, no reprogramming needed. You can use the hard line for the clutch master cylinder and the actual clutch master. I had to use the clutch switch from the donor. I used the wiring harness from the manual to make the connection for the backup lights and pulled wires from it to make the harness that went to the neautral and clutch switches. You run 4 wires to the switches ansd you are good. You can get the mode switch off the auto tranny and modify it for the swap. I might be able to create a wiring harness that is a pluc and play kind of thing by the time you get ready for it. Just send me tha old harnesses and I will send you what you need to install.

There are some gotchas to look out for like the OEM clutch kit does not include a clutch alignment tool. Advance Auto sells one for $1.50, Auto Zone and O'Riely did not offer one. The OEM slave cylinder does not include the push rod, usually not a big deal, but I was missing mine and had to go out and buy a cheapie slave cylinder to get the rod.

I will detail all of this in the write up.

---

About that write up..... ;)

Thanks for bumping this Eternal, reminded me I had a question for Mav.

What RPM are you running at at 60 and 70 MPH? Curious about some stuff on my rig and you are the only other person with a 5-speed to compare too. Glad you made it out to Moab, it was cool to see your setup in person.

Checked last night and 60 MPH was about 2300-2400 and 70 MPH was roughly 2700-2800. IIRC from the trip 80 MPH was 3100-3200. How does that compare?

:grino: I drove the 5 speed in Moab and the 3.5L-AR5-TOD work really great together. I'm very surprised Isuzu didn't add the option when they put the VX into production.

I'm waiting for my 4l30e to show some signs of failure... then the 5 speed swap will be at the top of my list.

Quote:

---

Originally Posted by vt_maverick

Checked last night and 60 MPH was about 2300-2400 and 70 MPH was roughly 2700-2800. IIRC from the trip 80 MPH was 3100-3200. How does that compare?

---

Awesome, thanks for checking.

I spent most of my drive with the cruise set at 60 on the speedo, but thanks to my 35's, my GPS said I was doing 72 MPH. I was right on 2500 RPM.

Quote:

---

Originally Posted by vt_maverick

Checked last night and 60 MPH was about 2300-2400 and 70 MPH was roughly 2700-2800. IIRC from the trip 80 MPH was 3100-3200. How does that compare?

---

Pretty darn close to stock. IIRC, the 5th gear is the same as 4th in the stock automatic. So, it stands to reason there won't be any difference on the hwy.

Quote:

---

Originally Posted by Etfren

Awesome, thanks for checking.

I spent most of my drive with the cruise set at 60 on the speedo, but thanks to my 35's, my GPS said I was doing 72 MPH. I was right on 2500 RPM.

---

Bigger tires would lower the torque rating at the rear wheels. IOW, making it feel a hair less powerful. Plus, we've yet to see anyone report an improvement in MPG from larger tires. Looks and traction are cool though!

Quote:

---

Originally Posted by 89Vette

Pretty darn close to stock. IIRC, the 5th gear is the same as 4th in the stock automatic. So, it stands to reason there won't be any difference on the hwy.

---

Yeah I've come to realize that there aren't serious MPG gains with the AR-5 in highway driving. But the fun-to-drive factor and (hopefully) better reliability still make it well worth it IMHO.

On 35's with 4:77's...(All values in 4th, TC locked)

55=2k

68ish=2.5k

Pulling trailer, 13.47 mpg best recorded on Moab excursion.

Quote:

---

Originally Posted by 89Vette

Bigger tires would lower the torque rating at the rear wheels. IOW, making it feel a hair less powerful. Plus, we've yet to see anyone report an improvement in MPG from larger tires. Looks and traction are cool though!

---

Oh yeah, it accelerates way slower than it did on stock size tires due to the extra weight and change in the gearing. Mileage wise, I only ran about one full tank through it on stock tires and got 16 MPG. I've been getting the same 16 MPG average with the 35's so far.

On my trip to Moab most of my tanks I got 16 MPG as well. The best I got was one tank of 20 MPG, which was the last tank coming into Moab. I think it was 'cause I was driving a bit slower coming down Hwy 6 and I had the TOD off. I left the TOD off the whole way home and didn't notice any mileage difference.

Quote:

---

Originally Posted by vt_maverick

Yeah I've come to realize that there aren't serious MPG gains with the AR-5 in highway driving. But the fun-to-drive factor and (hopefully) better reliability still make it well worth it IMHO.

---

Doesn't seem to be. I wish we could get a 6-speed with a super low 1st gear for crawling and a nice long 6th gear for highway cruising. The fun to drive factor is certainly a nice feature of the 5-speed though.

Buffy, I'm wondering if you could answer a question for me. I'm in the midst of my swap, and I had a question about the brake pedal assembly.

http://www.supermotors.net/getfile/9...e/100_2047.jpg

http://www.supermotors.net/getfile/9...e/100_2054.jpg

In the top picture, you have them displayed side by side, with the Vehicross pedal on the right, the Trooper pedal on the left. When I pulled the brake pedal bracket assembly there is a noticeable size difference, as well as a the bolt holes along the top not matching up. Obviously you got the Trooper pedal assembly inside. Did you a) disassemble the bracket assembly and just take the pedal arms, or did you b) somehow mate the entire pedal assembly in there by re-drilling the mating holes?

I didn't see where anyone had started a document on this mod so I took a cut at it. It only contains info in this thread & I think that Buffy had a lot of stuff he wanted to add to it. I still need to clean it up IRT layout & stuff but it's worthless to do that until all of the content is in there.

Word file is too large to post here. The attachment is a low res pdf so don't worry about the image quality for now (just the content). Y'all can just email me stuff you want added or I can try to find a FTP to post it to for all to access.

BTW, I'm missing some pix on page 34. If anyone has them, lemme know.