manual transfer case swap

[RamAirZ]

I think your front shaft will work but it's the rear that needs modified when going to the manual case, the overall length is shorter on the manual case. The cases before 95' don't have the SOTF motor on them so makes everything a little simpler. The only sensor back there are the VSS and then whatever the TOD uses but since the TOD computer is unplugged you shouldn't see any new issues.

[BigMeatVX]

Be sure to look for a T-case out of a LATE 90s (not early 90s) TROOPER....
Rodeo ones are ALL intergral....meaning you cant just unbolt it and swap it out....

I do have a 99 Trooper T-Case out of a NON-TOD rig...I am not useing any more....(YES I had it mounted on my VX for about one year)
Yes, it bolts right up to the auto 4l30e that we have in the VX...Let me know if you want it....

However keep in mind that this case is ONLY 2:1 in low range....This is the main reason that I removed it and went BACK to the TOD...I know that there are lower gears availble, but didnt choose to go that route....

Lastly, the rear driveline does NOT bolt up....the flanges (and splines) are different... I had to have a new flange made....
And the front output is different as well....
You will need the front driveline off a trooper (I also have this) and it uses traditional u-joints instead of our superior CV style ones....

[RamAirZ]

Not true, early 4L30 t-cases can be swapped out and are EASIER to do because you don't have a SOTF motor on the case, this has also been verified by Jerry Lemond. Jerry believes the flanges on the early case are the same as our VX as well but either way that's not a huge deal, the front length should stay the same the rear should need to be modified. Worst case scenario buy the driveshaft from the donor vehicle just for the flanges in case you need them and if the rear needs lengthened like I think it should it shouldn't be much and any driveline shop should be able to do it fairly reasonable. Only the MUA5 transmissions had integral cases.

[RamAirZ]

Here's a pic of a 92-97 trooper case:

[RamAirZ]

A PM from Jerry:

"YES MANUAL SHIFT T/C WILL BOLT RIGHT ON, AND BEA RELATIVELY EAYS SWAP AS LONG AS YOU USE A 92-95 TROOPER OR 93-95 RODEO, ANYTHING LATER WILL HAVE THE SHIFT ON THE FLY MOTOR ON THE T/C AND THAT WILL HAVE TO BE WIRED UP TO WORK, EASIER TO USE THE MANUAL T/C ,,

DRIVE SHAFTS WILL HAVE TO MODIFIED, SLIGHTLY JUST THE LENGTH, I THINK THE DRIVE FLANGES ARE THE SAME ON THE V/X AS THE EARLY T/C , THE LATER ONES LIKE ON THE 98 AND UP TROOPER ARE MUCH BIGGER, I DONT THINK THE VX HAS THE LARGER YOKE FLANGES , BUT THEY ARE NOT HARD TO SWAP ANYWAY , ANY DRIVE SHAFT SHOP AND SW THEM ,

ANY OF TH E 5SPD 4WD MUAS WILL BOLT RIGHT TO THE ENG AND ANY 3.2 0R 3.5 FLYWHEEL AND CLUTCH SET WILL WORK, , THE PEDAL ASSY UNDER THE DASH IS ALMOST IDENTICAL FROM A TROOPER TO THE RODEO , WHERE IT BOLTS TO THE FIREWALL, BUT THE PEDALS ARE DIFF LENGTH AND DIFF ARCH , AND I AM NOT SURE OF THE ARC ON THE VX , PROB CLOSER TO THE SAME AS THE RODEO, THAN THE TROOPER , WHICH HAS A LONG PEDAL, ARM. ON THE MANUAL 5SPD YOU WILL PROB HAVE TO MODIFY THE CROSS MEMBER AT THE MOUNT , SINCE THEY ARE A DIFF LENGTH THAN THE TOD SET UP FOR THE MUA,"



I thought I had pics of the case I pulled out of a 93' Rodeo when we rebuilt my friends Rodeo but I don't. Here is an ebay link to a case from a 95' passport showing it's removable

http://cgi.ebay.com/ebaymotors/ws/eB...category=33727

[BigMeatVX]

Your right ,

I should have clarified ALL rodeo MANUAL transmissions have an integral T-case...of cousre the autos do not....


No need to change the transmission/crossmember mounts though....they are the same....

And the flanges both input and output ARE different (as are the spline count)
On the TOD case VS the aisan one (in your above pic)

That (in your picture) is the exact T-case I have already used in my VX


Lastly the VX DOES use the Larger (huge) flange and u-joint at the rear of the transfercase....not compatable with any rodeo I know of....

Finally, The 3.2 and 3.5 flywheels are NOT the same....the 3.2 uses a smaller clutch disk and the flywheel in not machined for the larger 3.5 disk....
However, if you were haveing the flywheel turned anyway, it would be feasable to have the shop increase the diameter of the disk area to that of a trooper....as the REST of the flywheel is IDENTICAL.....

You could use the 3.5 flywheel in a 3.2 application but not the other way around (without mods, or running a smaller clutch than the 3.5 came with)

[BigMeatVX]

I always thought that the Front Axle Disconect was on the front axle, NOT on the transfer case?????

[RamAirZ]

I always thought that the Front Axle Disconect was on the front axle, NOT on the transfer case?????

The front axle disconnect IS on the front axle, the SOTF motor is, from my understanding, basically for shifting into 4HI, the lever is used for mainly 2WD and LO functions and when you move it into HI the motor engages the gear to make going to 4HI at 55mph easy. Also the front axle disconnect is just on the long drivers side axle. When you put it in 4HI the motor engages the 4WD and sends signal to the vacuum switch on the front axle to engage.

[BigMeatVX]

The front axle disconnect IS on the front axle, the SOTF motor is, from my understanding, basically for shifting into 4HI, the lever is used for mainly 2WD and LO functions and when you move it into HI the motor engages the gear to make going to 4HI at 55mph easy. Also the front axle disconnect is just on the long drivers side axle. When you put it in 4HI the motor engages the 4WD and sends signal to the vacuum switch on the front axle to engage.

Right, thats what I thought...and thats also how our Axiom is as well....

Dont know what model number it was, but my 91-92 parts trooper DOES have a 5-speed that IS integral to the transfer case....and I know its not a AR-5....but then again it wasn't the 3.5....just as you mentioned, lol...

[RamAirZ]

Ya the 3.5 used a 10 7/8" clutch disc and the 3.2 used a 10 1/4", on the flywheel I have had both off before and they looked identical and all the part #'s I have seen are identical for 3.2 to 3.5, and even replacement flywheels use the same part number. Maybe the aftermarket ones are drilled for either pattern? Also no 3.5 Trooper ever used an MUA5 so that is probably part of it too, they used the AR5. Maybe what jerry meant was either flywheel can be used with matching clutch, either way they would work, both trannies are 1" 24 spline shafts. On the crossmember mounts, a few guys with troopers with TOD that swapped to early model MUA5's (not AR5 like you have) had to modify the mount. The flanges aren't really a big deal either way, just take your D/S in with the new flanges have them swapped.

[BigMeatVX]

Ya the 3.5 used a 10 7/8" clutch disc and the 3.2 used a 10 1/4", on the flywheel I have had both off before and they looked identical and all the part #'s I have seen are identical for 3.2 to 3.5, and even replacement flywheels use the same part number. Maybe the aftermarket ones are drilled for either pattern? Also no 3.5 Trooper ever used an MUA5 so that is probably part of it too, they used the AR5. Maybe what jerry meant was either flywheel can be used with matching clutch, either way they would work, both trannies are 1" 24 spline shafts. On the crossmember mounts, a few guys with troopers with TOD that swapped to early model MUA5's (not AR5 like you have) had to modify the mount. The flanges aren't really a big deal either way, just take your D/S in with the new flanges have them swapped.

Both of the aftermarket ones I bought have the same pattern, however I believe MOST of aftermarket is only makeing the smaller disk (3.2) and selling it as the both 3.2/3.5 ones anyway????

[RamAirZ]

Your 91-92 should be an MUA5. Borg Warner also had a transmission offered in some of the early 90's trucks but I believe it's case was removable and it wasn't as common. Ya I'm not sure what's up with the aftermarket flywheels just saw the part numbers were the same awhile back. Either way it's not a catastrophic issue. I'm still debati8ng if I wanna go 5-spd swap with an MUA5 or just swap the TOD case for an earlier manual case. If I keep it auto the wife can drive it if need be, if I swap it, well then I need to teach her how to drive a 5spd lol. At least the MUA5 would be basically bulletproof behind our motors.

[BigMeatVX]

I chose the AR-5 because of the tripple cone syncros (like the world class T-5) and the options of different transfer cases....

At Moab, I watched Corbin break a MUA-5 transfer case in his tricked out Dana 60ed AMIGO on 37s....but he also has twin cases, and that had something to do with it no doubt....he broke the low range in the primary case!

[RamAirZ]

wow, I'm sure those 37's and dual cases did have something to do with it lol. Was he running stock gear sets or Revo gears? I know a guy running a turbocharged pup with an MUA5 pushing over 300rwhp (not a whole lot honestly but more than we throw at it) and it holds up just fine. Either way ya go they are stronger than the stock 4L30E lol. The world class T5 wasn't all that strong honestly. Start throwing down some real power at em' and you'd blow em' up just like any other T5 in the Camaro's and Mustangs. TKO's all the way on that front! But sticky tires and lots of power will do that. The AR5 is also used in the solstice and the Mallet conversion folks keep it behind there stock LS2 conversions, but they don't recommend drag radials or slicks using it. The AR5 is very similar to the toyota R154

[BigSwede]

My MUA5 has held up nicely so far with 35s...3+ years and 4 trips to Moab.