5-Speed Swap Info

[CoastieCosta567]

My trans just blew up yesterday, so I am off to the junkyard this weekend to look for a manual.

man that blows bro, what milage was your tranny in, cuz i'm scared mine will kick a leg soon, well if your doing the 5 speed swap, i wish you good luck and hope it turns out supa sweet. keep us posted.

[Joe_Black]

Pick up a copy of the Trooper shop manual for the UK models and you'll find a different selection of Aisin 5-speed manuals to choose from, IIRC many are available here. I haven't done squat on hardly any projects since getting laid off last July so this is all from memory. My plan for the Ebony was and still is to put a 3.1L Isuzu diesel in with 5-speed and TOD for stage rally, with the specific idea of using as much OEM off-the-shelf components as possible. I'd love to go sequential with the gearbox, but even if I had a job the $$$ would be prohibitive.

But for those looking to do this definitely get the UK Trooper manual, it's available on eBay in CD format from several sellers just be sure to check the feedback out. I got mine for about $12 shipped and it's a great quality indexed PDF of the factory manuals.

[Ascinder]

So, Joe, is there any giant difference between the Aisin and the MUA5 as far as durability, torque ability, ease of install, etc? What benefits would one gain by using this? Right now I have a line on a cheap MUA5 so all I still need is a clutch, clutch pedal, master and slave cylinders, and that appears to be it. I am eventually going to swap the entire powertrain out, but since this is my daily driver, I figured at least I'd take the opportunity to try and see if this swap could be done on a VX.

[Joe_Black]

The Aisin 5-speed (I'll see about getting a model number posted as soon as I can find the CD) was stuck behind the 3.1L and later 3.0L intercooled turbo-diesel Troopers so is a pretty stout unit. AFAIK, the t-case isn't integral and I think I reasoned out how to mate the TOD to it using either an off-the-shelf adapter or one was fairly straightforward to make. Again, I'm operating on memory here and haven't thought in this circle for a while.

It seems almost as if the US Isuzus got the weakest drivetrain components since we got the weakest engines in most cases, so I've been eyeballing Trooper front clips from the UK and Japan. I've heard that stuff like that may be getting either more difficult to import or pricier depending upon which overbearing governmental rumor you like best.

Again, grab the CD shop manual for the JDM/UK Isuzus. I drooled my keyboard after I got mine!

[twistedsymphony]

So, Joe, is there any giant difference between the Aisin and the MUA5 as far as durability, torque ability, ease of install, etc? What benefits would one gain by using this? Right now I have a line on a cheap MUA5 so all I still need is a clutch, clutch pedal, master and slave cylinders, and that appears to be it. I am eventually going to swap the entire powertrain out, but since this is my daily driver, I figured at least I'd take the opportunity to try and see if this swap could be done on a VX.

don't forget electrical... the computer might not like the 5-speed, even though the trans has it's own separate computer the engine computer still gets data from the trans and if it stops getting that data it will throw a CEL that can't easily be removed... the easy solution would be to swap out for a ECM that was originally designed for that motor with a manual trans

also electrical connectors on the trans.. manual transmissions typically have a reverse sensor (for turning on reverse lamps) a speed sensor (for your speedo), and depending on other stuff it might also have a reverse lockout (to prevent you from shifting into reverse while driving) among other things.

Also a Manual ecu might want a clutch pedal switch to determine when you're using the clutch, though a lot of times this is just used to start the car and can be tied to ground to fool the computer into thinking that you've always got the clutch pedal in.

if you're getting the trans from a junk yard it might not be a bad idea to snip off all these connectors and take them with you. I konw on transmissions swaps I've helped with in the past I was able to call a dealership and get "pigtails" for all of the connectors I needed , which are essentially the plug with a few inches of wire that I could use to build the harness myself... these aren't always cheap though. usually $15+ per connector, might be more for something like an Isuzu though.

then there is other stuff like the clutch line, any mounting brackets you might need...

most times the bolts used for the automatic flywheel wont work with the manual trans flywheel...

little crap like that can add up an add up fast, but thinking about it beforehand can save you some coin, especially if you've got a junk yard with a donor vehicle.

[fstopmonk]

So, has anyone actually done this manual transmission swap yet? My tranny has crapped and I never thought it was putting all the engine power to the wheels. Frankly for the $3k a rebuild trans is gonna cost I can probably do the swap, I just want to know if anyone has actually done it, what is cost and what was involved. This is my only car so there is no way I can use it for a guinea pig.

Any help would be much appreciated...

[BigMeatVX]

Yes!!! Someone has FINALLY done it...ME

I have installed a 5 speed in my VX AND I kept the TOD case!!!!!!

It was actually quite easy, as it is a complete "bolt in" set up...

I am using the 5 speed out of a 99 Trooper, (AR5 or MA5)....

I would have done this swap LONG ago, but I listened to the "know it alls" on here that were giving out in-correct info!!!!

[jimmyray]

Yes!!! Someone has FINALLY done it...ME

I have installed a 5 speed in my VX AND I kept the TOD case!!!!!!

It was actually quite easy, as it is a complete "bolt in" set up...

I am using the 5 speed out of a 99 Trooper, (AR5 or MA5)....

I would have done this swap LONG ago, but I listened to the "know it alls" on here that were giving out in-correct info!!!!

If you have completed the swap and it was a successs can you let us all know what parts you actually used ?