manual transfer case swap

[BigMeatVX]

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

[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.

[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...

[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.

[BigMeatVX]

The AR-5 is also used in the H3 and Canyon/Colorado trucks and has a larger input shaft and different rear transfer-case bolt pattern as well...FYI

[RamAirZ]

Yup, just used the solstice as an example for the power output part I've done my research on that AR5 when I was going to use it in a Firebird build up in our shop. The truck versions also use a different gear ratio in 3rd than the Sky and Solstice versions. The truck versions also have a different shifter position and the "GM" AR5's use a 26 spline input, where as the Isuzu one is 24. The diameter is 1 1/8 instead of 1" but they use a smaller clutch disc than the Trooper AR5 setup. Also their bellhousing bolt pattern is different on an Ecotec engine, similar to like a 60 degree V6 but not quite, it's special. And BigSwede, what kinda clutch are you running in yours? I know my MUA5 held up nice on just 33's in the Rodeo and my random trips for over a year but nothing like what you put yours through

[RamAirZ]

How do you like your Axiom Allan? My wife has been thinking about getting rid of her newer Camry for an SUV and I'm thinking of convincing her to get an Axiom lol

[BigSwede]

And BigSwede, what kinda clutch are you running in yours? I know my MUA5 held up nice on just 33's in the Rodeo and my random trips for over a year but nothing like what you put yours through

My clutch is, um, whatever it came with when I bought it with 108K miles...

I will say the Teralow (aka Revolution) gears probably save the clutch some grief off road...

[RamAirZ]

Ya I know when I was going through the rock garden in Gorman that Tommy smelt a little clutch lol. Stock gears, stock clutch (or whatever was in it when I bought it) on 33x12.50's lol. I'm hoping to do some revo gears soon when I swap either tranny's or t-cases

[BigSwede]

Attention to anyone contemplating a manual tranny swap - there is a guy on the planet parting out a manual tranny 99 Trooper.

http://forum.planetisuzoo.com/viewto...=321049#321049