Isuzu Trooper Manual Swap

I originally posted this on Planet Isuzoo, but I thought you all might have answers, too, as you seem to know everything about anything.

I've got a 1991 Trooper with the 2.8 V6 and a 4l30e at the moment, and I'm about to swap in a manual transmission. Here's a list of what I've ordered so far:

MUA5 transmission with the correct 2.8 bell housing and married transfer case. Sachs Flywheel
Exedy Clutch kit
Floor Shifter
Shift knob (It's an 8 ball, just a running joke my friends and I have with our trucks)
Clutch/Brake pedal assembly
Clutch master and slave cylinder
Shift boots
DORMAN H380173 rubber clutch hose (the only part RockAuto lists as a Trooper clutch line)

And here's what I still have to track down

Clutch hard line- I read about some kind of clutch dampener, which I would delete anyway. I think I'll end up just making my own line.

Fywheel bolts- Where can I find 2.8 flywheel bolts? Better yet, what size are they? I can just go to the local faster shop and get the correct bolts if I knew what size they were. I found some cheap S10 bolts on parts geek.com, but I'm unsure of their quality. I'd like ARP if they make them in the correct size.

Pressure plate bolts- Same as above, anyone know the size?

Also, I'm wondering if I'll need to cut the tunnel any for the standard shifter. I think the hole is already big enough, but I haven't removed the automatic yet. I'm also curious about the skid plates. Are they the same between automatic and manual transmission Troopers?

I have a full shop at my disposal and I'm a skilled mechanic/fabricator, so I'm not too worried about the swap. I'd like to use as many factory parts as possible, so I can source replacements anywhere in the country (and cut down on fabrication time). Money is also not a major consideration, I don't want to skimp on something this difficult to remove and replace. I'm trying to buy new/rebuilt wherever possible, because I hate pulling transmissions.

Oh, and is there anything besides a rear main seal that I should do "while I'm in there?" I'm planning on rebuilding the transmission before it goes in, too.

Last question- has anyone here done this swap before? It doesn't seem that hard to me, but then again I grew up with turbo BMWs and rotary-powered Triumph Spitfires.

Sorry for any spelling/grammar mistakes, I typed this in a hurry.

I've never even been in a Trooper, but I am glad someone else here likes to buy new parts!

Wifey had an older 5 speed Trooper. What I'm getting at is there should be plenty of old parts in the salvage yards.

As for the clutch line, just get a flexible line or fabricate one. I've got one in the RB20 240sx. Ill have to check to see what brand it is.

MG Bryan wrote: I've never even been in a Trooper, but I am glad someone else here likes to buy new parts!

He does--especially with his parents' money. The parts for his auto-to-manual swap are Tommy's h.s. graduation gift. Yeah, we're a weird family.

Margie

Marjorie Suddard wrote:

MG Bryan wrote: I've never even been in a Trooper, but I am glad someone else here likes to buy new parts!

He does--especially with his parents' money. The parts for his auto-to-manual swap are Tommy's h.s. graduation gift. Yeah, we're a weird family. Margie

That's actually an awesome graduation gift!

Oh, I forgot to mention that it is a GM 60* V6, which is a fairly common engine. Anyone know where to find fasteners for it?

Long ago, I had one of the early 2 door Troopers with a manual. I had a trusted local shop replace the clutch. They warned me in advance that they were charging extra due to the weight and difficulty of dealing with the tranny/transfer case combo. Later they told me that even with the upcharge, the job ate their lunch. Good luck - sounds like a worthwhile swap.

Looks like I no longer have a clutch pedal on the way. Does anyone know if a Rodeo clutch pedal assembly is the same part?

The "one-who-knows Jensens" is the "one-who-knows Isuzus"
Seems that Curmudgeon hasn't been around here lately.

Yeah, been running around in circles.

This is AIMI's online parts catalog. Plug in your year etc and you can find the OE part #'s, then compare that with what you want to snag parts from. http://www.myisuzuparts.com/

Great way to search for boneyard parts from the comfort of your couch: http://www.car-part.com/index.htm Even if you can't find the exact part it tells you which boneyard nearby has a car.

The Rodeo and Trooper pedal boxes are completely different, unfortunately. The pickups use the same pedals as the Rodeo, in fact the Rodeo was really a lwb pickup chassis with a different body.

I want to say the Trooper pedal boxes are all the same, you just have to swap the pedals. That should save a lot of disassembly! But it would mean getting both pedals from a M/T version so your feet don't snag the brakes when you try to shift. That makes the people behind you scream and then cuss real loud.

It's not that the transmission is really all that heavy but with the transfer case hanging off it's lopsided, weight wise. It can be a real PITA to lift for that reason.

I'd just bend a new hard line, that's easier than trying to snake one out of another car. That dampener thing is supposed to change how the pedal feels, I know of one which was removed with no ill effects.

I found myisuzuparts.com a few minutes ago, I have a list 3 pages long of parts I want now, that was a bad influence.

Thanks for the other information, I think I can get this figured out.

Marjorie Suddard wrote:

MG Bryan wrote: I've never even been in a Trooper, but I am glad someone else here likes to buy new parts!

He does--especially with his parents' money. The parts for his auto-to-manual swap are Tommy's h.s. graduation gift. Yeah, we're a weird family. Margie

Man, I got a book and some cards. Want to adopt me?

I made my own line w/ss braided hose & fittings. been running without the dampener for years and could not tell the difference, never had any issues.

you could probably just buy a whole 2.8/5spd truck for less or equal to what all those parts will cost.

The V6/5 speed trucks were rare up (down?) here. I saw exactly one; all the rest were 2.3 or 2.6/5 speed with the occasional automatic.

Woohoo! I found a pedal assembly! The only things I have left to find are a few miscellaneous bolts/ clips, which will either come from the boneyard or st. Charles Isuzu.

You all changed my mind about factory clutch line, I'll make my own without the dampened.

search salvage yards

Let your mouse do the walking.

tuna55 wrote:

Marjorie Suddard wrote: The parts for his auto-to-manual swap are Tommy's h.s. graduation gift. Yeah, we're a weird family. Margie

Man, I got a book and some cards. Want to adopt me?

I thought I already had adopted you guys!

Margie

Marjorie Suddard wrote:

tuna55 wrote:

Marjorie Suddard wrote: The parts for his auto-to-manual swap are Tommy's h.s. graduation gift. Yeah, we're a weird family. Margie

Man, I got a book and some cards. Want to adopt me?

I thought I already had adopted you guys! Margie

Well, in some ways, I guess, but not in the 'awesome graduation gift' kinda way. I'm going to be 30 in a week or two, it might be too late for that.