BtW's 1991 Isuzu Trooper Restoration

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Re: BtW's 1991 Isuzu Trooper Restoration

Postby Jem Andes » Fri Jun 19, 2015 7:41 pm

btw1549 wrote:Picked up something special from a member this past week :D
20150617_1828202.jpg


Very nice!
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby wmorrisiii » Fri Jun 19, 2015 9:38 pm

That is great bt! Now I can stop feeling guilty for grabbing that last one in NC. I do have an extra set of JDM markers for you if you want them. I knew it was only a matter of time before you found the grill...so I ordered an extra set from Andy :D
Willie's 1990 Trooper LS, 2.8L
The Duck Marsh Debutante

Willie's 1987 Trooper LS, 2.3L
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby btw1549 » Sat Jun 20, 2015 3:04 pm

wmorrisiii wrote:That is great bt! Now I can stop feeling guilty for grabbing that last one in NC. I do have an extra set of JDM markers for you if you want them. I knew it was only a matter of time before you found the grill...so I ordered an extra set from Andy :D


I think I'm actually going to order some of the clear side markers and rear housings from him for my build. The amber led bulbs will look good behind the clear lens! I may also take you up on those JDM markers though. Looks like I may be heading south in the near future here so I'll let you know :)
BtW - 1991 LS Trooper In Progress, Complete Restoration with 3.4L Swap! (The Tank)
viewtopic.php?f=15&t=72642

2002 Isuzu Axiom In Progress, Complete Drivetrain Rebuild with Suspension Refresh/Lift
viewtopic.php?f=15&t=74409
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby wmorrisiii » Sat Jun 20, 2015 4:53 pm

I'm around, just let me know.
Willie's 1990 Trooper LS, 2.8L
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby Naththig5327 » Sun Dec 13, 2015 9:31 pm

You better feel bad lol jk I'm in nc and I really want a round headlight bad lol
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby Naththig5327 » Sun May 15, 2016 6:46 pm

Hey wmorrisiii do you still have those jdm markers
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby btw1549 » Mon Aug 01, 2016 3:18 pm

I think I may have destroyed the front locker.

I ordered some parts and wanted to change the trans fluid and some other odds and ends to get it road worthy to get it to my new home in NC. When I pulled it in the garage and opened the hood there was a snake sleeping in the corner of the engine compartment. Not wanting a snake in the garage I pushed the truck outside slowly and while doing this I heard a clicking noise coming from the front end. Looked down and found the front axles spinning along with the wheels. Looked at the hub and the hubs were both on free so after I got the snake removed and put it in the air I spun the left front wheel to find that the hub was still engaged internally even though it was on free. So I locked the right front wheel and spun it and the locker breaks free pretty easily. I was going to drain the fluid to see if there was any debree in the diff but I didn't have any replacement fluid so it will have to wait until I come home in 2 weeks to finish everything up and drive it back to NC.

As of right now I am pretty disappointed though....
BtW - 1991 LS Trooper In Progress, Complete Restoration with 3.4L Swap! (The Tank)
viewtopic.php?f=15&t=72642

2002 Isuzu Axiom In Progress, Complete Drivetrain Rebuild with Suspension Refresh/Lift
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby wmorrisiii » Mon Aug 01, 2016 9:34 pm

Black snake? I've run three out of the shop so far this year. The last one I saw at eye level from under the truck. That was a surprise! Haven't seen any bad ones yet this year though, which is a very good thing.

I'm wondering what you are going to find when you drain the fluid too. What brand of locker? Aussie? Wonder what happened. Any way you cut it that sucks.
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby btw1549 » Wed Aug 03, 2016 9:37 pm

Think it was a gardener actually but he was about 2 feet long. Scared the crap out of me as I stuck my hand right next to him to grab the trans dipstick.

It's an Aussie. We'll see what we find. Hopefully no metal. It's just breaking free really easy...
BtW - 1991 LS Trooper In Progress, Complete Restoration with 3.4L Swap! (The Tank)
viewtopic.php?f=15&t=72642

2002 Isuzu Axiom In Progress, Complete Drivetrain Rebuild with Suspension Refresh/Lift
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby btw1549 » Sun Aug 14, 2016 9:51 am

Got a transplant going on!

2016-08-13 14.58.242.jpg

2016-08-13 15.32.172.jpg


I know I can look this up but to save time if someone reading knows the answer will I need to change out the ecm harness for the manual or will the automatic trans ecm harness have the connector for the manual trans harness in it somewhere?

Also any input on a clutch kit, Exedy, Sachs, Luk?
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BtW - 1991 LS Trooper In Progress, Complete Restoration with 3.4L Swap! (The Tank)
viewtopic.php?f=15&t=72642

2002 Isuzu Axiom In Progress, Complete Drivetrain Rebuild with Suspension Refresh/Lift
viewtopic.php?f=15&t=74409
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby wmorrisiii » Sun Aug 14, 2016 12:05 pm

I just ordered a TD clutch (Exedy) for the 87. More holding power and direct fit to the MSG. I expect Jerry has or knows which one bolts up to the 2.6. On the wiring harness it would make sense that one wiring harness would have connections for either tranny. Based on that I'm guessing the Trooper doesn't.
Willie's 1990 Trooper LS, 2.8L
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby hessmess » Sun Aug 14, 2016 12:34 pm

The actual answer is no. But it will work. I ended up cutting out some of the wires that are not needed and then I had to jumper something but I forgot now. I think it was the wire for the park switch so it would start. The backup lights had to use the auto backup lite switch as it is wired different and I never worked out the clutch switch. Once I sat down and thought about it, it all worked out just fine. There was a sticky on this and while it was for a different model, it did help me get this done. I am not a mechanic like you and I got it done by myself. It made a big difference on my old 91. I figure you already have the trans crossmember figured out also. On mine I used the stock mount locations and bolt holes and made my own crossmember. It is still around here somewhere. I ended up junking out that Trooper for donations to my current ones.
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby btw1549 » Sat Nov 26, 2016 10:17 pm

Update on the transplant. The manual is all in and working now including all of the wiring.

It's been written up enough about the swap but I'll add some of my points.

The first of which is a huge one in my opinion, the transmission mount cross member. Wasn't 100% sure what I was going to do with this. I had thought of just using the automatic cross member and welding on a plate to extend it out to the correct distance for the manual transmission mount. Well test fitting everything in place the transfer case came in contact with the cross member so that option was out. Then I thought of still using the cross member but notching it out around the transfer case in addition to the extension. Just as I began to work all this out in my head I remembered I had a trailer hitch (yes another one) laying around outside the garage off of a Cadillac Eldorado. The reason I had thought about it was because I was trying to find a plate of 1/2 steel for the gusset I was going to make. Well when I went outside and brought the trailer hitch in it appeared that I could just use the trailer hitch for my cross member! It literally had the perfect shape to it already so without haste took the cutoff discs to it to remove the hitch portion and two mounting plates and then began to drill some holes and make my cross member. Below is the final result! This thing saved me so much time in the process. I did weld a piece of flat steel to the front of it as kind of an extra bash guard. It does not hang any lower than the original auto cross member did either. I just need to get time to clean it up and paint it now.

2016-11-26 15.12.01.2jpg.jpg

2016-11-26 15.12.09.2jpg.jpg

2016-11-26 15.12.14.2.jpg

2016-11-26 15.12.48.2.jpg

2016-11-26 15.13.37.2.jpg
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BtW - 1991 LS Trooper In Progress, Complete Restoration with 3.4L Swap! (The Tank)
viewtopic.php?f=15&t=72642

2002 Isuzu Axiom In Progress, Complete Drivetrain Rebuild with Suspension Refresh/Lift
viewtopic.php?f=15&t=74409
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Manual Swap Wiring 2.8l

Postby btw1549 » Sat Nov 26, 2016 10:37 pm

The next issue was the wiring. Three items need to be accounted for in this scenario. 1st is the neutral safety switch / clutch switch. 2nd is the reverse lights. 3rd is the 4wd indicator in the dash.

Starting with the neutral safety / clutch switch. With the V6 auto there are two harnesses. One is for the range mode selector and the other is for the torque converter, valve body and transfer case. The harness for the range mode sensor contains the neutral safety switch wires. Inside this harness are two large wires, larger than the rest in the connector. One wire is black and the other is blue with a black strip. This is a ground circuit and the black wire is the ground and the blue wire with the black strip goes to a diode and then to the ecm. If you jump these two wires you will eliminate the neutral safety switch and the truck will start.

I wanted things to be right though so I pulled out the wiring diagram and began to do some searching. What I found was under the dash board on the left hand side is a green diode box (pictured below). When you remove the cap there are three diodes inside. The middle diode is for this circuit. There is a red with black strip wire and a blue with black strip wire going into the middle of the diode box. The red with black strip wire is the one you want. Remove this wire from the diode box and connect it to the red with black strip wire that is part of the clutch switch (also pictured below). Then take the black wire from the clutch switch and run it to ground. Now the circuit is complete. The clutch switch now functions as it should!

2016-11-26 15.15.32.2.jpg

2016-11-26 15.15.38.2.jpg


Onto the 2nd and 3rd wiring issues. Both of these can be completed under the hood with just 4 wires. The two wires in the black range mode connector will get you reverse lights. The two wires in the black connector that you will need are blue and green. You simply take these two wires and connect them to the two green wires in the manual trans harness. I happened to have another manual truck that is bound to the scrap yard so I took the plug on the body harness side to make a small connector. On the other end I used the connector from the range mode sensor that I got from Jerry. This way I don't damage the harness and can still disconnect everything.

For the 4wd indicator you need to move to the blue connector. Inside the blue connector there is a green wire and a black wire. Unfortunately there are two black wires in the connector so you will need to do a test in the old connector to determine which one it is. The red wires in the manual harness are the ones you will be connecting to. I did not have an extra blue harness so I did remove these wires from the connector and temporarily attached them to the manual harness until I can get an extra blue connector to complete the splice.

And with that I have reverse lights, the 4wd indicator on the dash and a clutch switch that works, in addition to having a manual trans finally! I cannot believe how much more pick-up this thing has with the manual in it!

2016-11-26 15.14.36.2.jpg

2016-11-26 15.14.43.2.jpg
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BtW - 1991 LS Trooper In Progress, Complete Restoration with 3.4L Swap! (The Tank)
viewtopic.php?f=15&t=72642

2002 Isuzu Axiom In Progress, Complete Drivetrain Rebuild with Suspension Refresh/Lift
viewtopic.php?f=15&t=74409
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby MarkB.NV » Sun Nov 27, 2016 5:11 pm

btw1549 wrote:Update on the transplant.
...
Just as I began to work all this out in my head I remembered I had a trailer hitch (yes another one) laying around outside the garage off of a Cadillac Eldorado.



You sir, represent the best in cheap and clever bahstards. I salute your genius. 8)
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby wmorrisiii » Tue Nov 29, 2016 10:34 pm

Keep it up with all the welding and heavy steel everywhere BT, and yours is going to weigh more than mine :lol:

Seriously, the tank is looking great, glad to see the progress. Nothing like having old metal laying around just waiting to be repurposed. Especially heavy stuff that lets you overbuild to your hearts content :D
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The Duck Marsh Debutante

Willie's 1987 Trooper LS, 2.3L
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby bradzuzu » Wed Nov 30, 2016 3:52 pm

Nice job !! I remember running into issues when I changed body's on my amigo (new one was a auto and my chassis was a manual) many years ago so I don't remember :)
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby btw1549 » Mon Feb 27, 2017 2:32 pm

Picked up some accessories Saturday night! Can't wait to get everything on the truck!

20170226_155114_resized_2.jpg

20170226_155641_resized_2.jpg

20170226_155806_resized_2.jpg

20170226_155758_resized_2.jpg

20170226_153243_resized_2.jpg
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BtW - 1991 LS Trooper In Progress, Complete Restoration with 3.4L Swap! (The Tank)
viewtopic.php?f=15&t=72642

2002 Isuzu Axiom In Progress, Complete Drivetrain Rebuild with Suspension Refresh/Lift
viewtopic.php?f=15&t=74409
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby btw1549 » Mon Feb 27, 2017 2:33 pm

and last but not least...

20170226_155300_resized_2.jpg
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BtW - 1991 LS Trooper In Progress, Complete Restoration with 3.4L Swap! (The Tank)
viewtopic.php?f=15&t=72642

2002 Isuzu Axiom In Progress, Complete Drivetrain Rebuild with Suspension Refresh/Lift
viewtopic.php?f=15&t=74409
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby btw1549 » Mon Apr 03, 2017 12:43 pm

It's nice to have The Tank back here in NC with me. I can actually work on it now. Last weekend I fixed and exhaust leak and my trailer wiring. This weekend I started the swap out of the Intake manifold and throttle body for my bored out intake manifold and the 4.3l throttle body. For those of you that are new to the thread I built this 3.4l prior to joining the forum and was unaware of this upgrade. I never swapped it out, A) because it is a PITA and B) I have a full fuel injection set up awaiting to be installed. The fuel injection set-up means taking the truck out of commission for a lengthy period of time though and I am waiting until school is finished to take on that project.

So I have been running the truck with the 2.8l throttle body for several years. There were no real drive ability issues other than I could tell the engine was starving for air at the top end. I mean I drove this truck across the entire country several years ago and it pulled just fine; however, when I drove it down to NC loaded up with a trailer on the back I could really notice the power loss at highway speeds (75-80) around 3000-3500 RPM. Therefore before Uwahrrie I figured it would be a good idea to let the engine breath a little bit.

2017-04-012 16.57.31.jpg


Before I swapped this to a manual recently I felt as though there was a slight leak in the radiator between the trans cooler and the coolant section. The fluid was always really dark like it had been burnt. But I wasn't 100% sure because there was no coolant in the trans fluid and the fluid wasn't very low. The truck did run hot several times during the cross country trip which I figured may have just deteriorated the coolant. Well when I drained the coolant it came out mostly green; however at the bottom input to the radiator the fluid came out brown and large chunks of debris fell out of the hose. So I ended up flushing out the whole systems this weekend in both directions and got some more debris out but not a lot and the fluid flowed out the hoses without any sort of noticeable restriction. Also the heat works fine so I don't believe I have any blockages.

2017-03-312 11.03.47.jpg

2017-03-312 11.03.40.jpg


Since it overheated during my cross country trip I wanted to find a better radiator option. I spent several hours on the interwebs looking at dimensions for radiators just about every vehicle ever built to see if anything else out there had semi close dimensions. I ended up finding one that I believe will work, but it has yet to arrive so I will keep my fingers crossed until it gets here and update once it arrives and I test fit it. If it works though it will be a reasonably priced all aluminum 3 row option for the trooper.

Trooper Possible Radiator.JPG
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BtW - 1991 LS Trooper In Progress, Complete Restoration with 3.4L Swap! (The Tank)
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2002 Isuzu Axiom In Progress, Complete Drivetrain Rebuild with Suspension Refresh/Lift
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby hessmess » Mon Apr 03, 2017 8:30 pm

I have followed this thread for years. I am glad you are at a point where you can spend some time on this gem!
86 Trooper (sold to brother) wrecked and recycled
88 Trooper (recycled)
91 Trooper, 3.1, bored .40, Cam, 4.3 TBI, roller rockers, Fiero valve covers, remote oil filter, LSD, 2.25 Cat back exhaust, BJ flip, 5 speed conversion, Round eye conversion-retired and parts donated to the new 91
91 LS Trooper, 5 speed, 3.4, bored intake, LSD, rebuilt using parts donated from the first 91
viewtopic.php?f=15&t=81567
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby btw1549 » Mon Apr 03, 2017 8:54 pm

hessmess wrote:I am glad you are at a point where you can spend some time on this gem!


So am I! I've got 40 odd days left in this MBA program and then I will have my weekends free once again for a change. Over the years though I have been able to identify where I went wrong and what I did right in this build. That being said, I've been buying the necessary components to correct my "mistakes". I haven't revealed anything yet but I have some big plans for this rig in the near future!
BtW - 1991 LS Trooper In Progress, Complete Restoration with 3.4L Swap! (The Tank)
viewtopic.php?f=15&t=72642

2002 Isuzu Axiom In Progress, Complete Drivetrain Rebuild with Suspension Refresh/Lift
viewtopic.php?f=15&t=74409
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby btw1549 » Wed Apr 12, 2017 8:47 pm

Here is the progress from last weekend.

To start I got a coat of paint on the intake manifold:
2017-04-07 14.59.07 Resize.jpg


Then I moved on to test fitting the new radiator. It fits in place of the old radiator very well but I will not be able to just mount it to the old bolt holes as I had hoped. It also has plenty of clearance for the fan. I started working on the new mounts on Monday and will make a new fan shroud but will just modify this one enough to get me to Uwahrrie and back.
2017-04-07 17.44.02 Resize.jpg

2017-04-07 17.49.29 Resize.jpg

2017-04-07 14.53.39 Resize.jpg


And then I finished of the weekend by bolting down the intake manifold, bolting on the EGR valve, thermostat housing, and other fittings, and testing out the new Fiero valve covers (still need to paint). You can also see here the top off the radiator. It sits slightly higher than the old radiator however the hood closes without any contact.
2017-04-07 17.44.17 Resize.jpg


Oh and I also resealed and painted my power steering reservoir as it was leaking really bad. Throwing fluid everywhere and it would empty out the reservoir just sitting there. No pictures of this though.
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BtW - 1991 LS Trooper In Progress, Complete Restoration with 3.4L Swap! (The Tank)
viewtopic.php?f=15&t=72642

2002 Isuzu Axiom In Progress, Complete Drivetrain Rebuild with Suspension Refresh/Lift
viewtopic.php?f=15&t=74409
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby btw1549 » Wed Apr 12, 2017 8:51 pm

I knew I had a better image of the radiator height:
2017-04-07 14.53.31 Resize.jpg
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viewtopic.php?f=15&t=72642

2002 Isuzu Axiom In Progress, Complete Drivetrain Rebuild with Suspension Refresh/Lift
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Re: BtW's 1991 Isuzu Trooper Restoration

Postby wmorrisiii » Thu Apr 13, 2017 7:34 am

Looking great! When are you getting to URE, BT? I'm there Thursday until Saturday and I want to see this truck.

Willie
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