Well after a couple of years of owning the Trooper the auto transmission has started to go. So instead of having it replaced at a cost of $4,000, (local shop), I decided to swap it to the AR5 attached to the TOD transfer case instead.
I want to make this thread a detailed guide of sorts with links to other threads, videos, and lots of photos so that anyone else that wants to do this swap can reference this and have some of the guesswork taken out or at least get some ideas. Hopefully, it will help someone with their swap. I will keep updating this thread until I'm completely done.
Here is a list of all the parts needed for the swap:
AR5 transmission
OEM clutch kit
OEM Flywheel bolts
OEM Pressure plate bolts
OEM Rear main seal
Clutch pedal assembly (99 Trooper)
OEM flywheel (used/resurfaced)
OEM brake/clutch pedal pads
OEM clutch hard line and softline
Center console
OEM master cylinder
OEM slave cylinder
2002 trooper Manual ECU
New rubber h/p fuel lines (rear lines are too short if using the Manual hard fuel lines)
Various Nuts & Bolts you may need to buy:
Transmission:.....one - 80mm (m12x1.25)
Transmission:.....three - 45mm (m12x1.75)
Dust Shields:......two - 45mm (6mm x 1.0) and one 6mm nut.
Slave Cylinder:...two - 30mm (10mm x 1.5)
Clutch Pedal Bracket:...two - 8mm x 1.25 nuts w/ washers
I also bought a few tools for the job as well. I picked up a clutch alignment tool, 17mm 0* offset wrench, clutch bleeder, and a floor jack because I was always having to borrow one from someone.
I was trying to shoot for around $1,500 dollars but I exceeded that a little bit...closer to $2,000. I can put my costs up later if anyone wants them.
I started working on it last week and have been taking pictures, so hopefully, I can get those posted if Photobucket wants to cooperate with me.
Helpful Links:
VX 5 Speed Swap
https://forum.planetisuzoo.com/viewtopi ... speed+swap
Has anyone put an AR5 in a 3.2 Trooper?
https://forum.planetisuzoo.com/viewtopi ... 22&t=72724
John's Auto to Manual MUA5 Transmission Swap
https://forum.planetisuzoo.com/viewtopi ... 22&t=49934
Hatfield's 2000 Trooper Build
https://forum.planetisuzoo.com/viewtopi ... 1&start=50
Christmas in July! Zaphod's VX Manual Swap Thread
https://www.planetisuzoo.com/viewtopic. ... 7#p5449247
Cruise Contol after Swap
Cruise Control after swap
Car-Part.com
Car-Part.com--Used Auto Parts Market
Videos:
Servicing Quick Connect / Quick Disconnect Pull Type Clutches
Bleeding a clutch by blocking the slave cylinder
I want to make this thread a detailed guide of sorts with links to other threads, videos, and lots of photos so that anyone else that wants to do this swap can reference this and have some of the guesswork taken out or at least get some ideas. Hopefully, it will help someone with their swap. I will keep updating this thread until I'm completely done.
Here is a list of all the parts needed for the swap:
AR5 transmission
OEM clutch kit
OEM Flywheel bolts
OEM Pressure plate bolts
OEM Rear main seal
Clutch pedal assembly (99 Trooper)
OEM flywheel (used/resurfaced)
OEM brake/clutch pedal pads
OEM clutch hard line and softline
Center console
OEM master cylinder
OEM slave cylinder
2002 trooper Manual ECU
New rubber h/p fuel lines (rear lines are too short if using the Manual hard fuel lines)
Various Nuts & Bolts you may need to buy:
Transmission:.....one - 80mm (m12x1.25)
Transmission:.....three - 45mm (m12x1.75)
Dust Shields:......two - 45mm (6mm x 1.0) and one 6mm nut.
Slave Cylinder:...two - 30mm (10mm x 1.5)
Clutch Pedal Bracket:...two - 8mm x 1.25 nuts w/ washers
I also bought a few tools for the job as well. I picked up a clutch alignment tool, 17mm 0* offset wrench, clutch bleeder, and a floor jack because I was always having to borrow one from someone.
I was trying to shoot for around $1,500 dollars but I exceeded that a little bit...closer to $2,000. I can put my costs up later if anyone wants them.
I started working on it last week and have been taking pictures, so hopefully, I can get those posted if Photobucket wants to cooperate with me.
Helpful Links:
VX 5 Speed Swap
https://forum.planetisuzoo.com/viewtopi ... speed+swap
Has anyone put an AR5 in a 3.2 Trooper?
https://forum.planetisuzoo.com/viewtopi ... 22&t=72724
John's Auto to Manual MUA5 Transmission Swap
https://forum.planetisuzoo.com/viewtopi ... 22&t=49934
Hatfield's 2000 Trooper Build
https://forum.planetisuzoo.com/viewtopi ... 1&start=50
Christmas in July! Zaphod's VX Manual Swap Thread
https://www.planetisuzoo.com/viewtopic. ... 7#p5449247
Cruise Contol after Swap
Cruise Control after swap
Car-Part.com
Car-Part.com--Used Auto Parts Market
Videos:
Servicing Quick Connect / Quick Disconnect Pull Type Clutches
Bleeding a clutch by blocking the slave cylinder