95 Trooper 5Spd build from plain to ???

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95 Trooper 5Spd build from plain to ???

Postby 800XL » Sat Jan 10, 2015 10:07 am

It all started with a Craigslist ad, a 95 Trooper with a 5spd and a shifting problem for $800. I was also looking at another ad for a 96 with what sounded like timing tensioner rattle. The guy with the 96 never got back to me. I got a ride up to look at this truck about 50 miles from home, and found it to be in fairly good running shape, but with a pushed in bumper, stuck in 2nd gear and leaking power steering fluid from the pressure hose. No amount of working the shifter back and forth would get it even into neutral. I figured the shifter was just worn and slipped between gears and I'd be able to fix it fairly quick. I offered the seller $600, he said he'd take $625. That bought me this.

IMG_87381789712583.jpeg


I hopped in and took off in 2nd, headed for home with darkness closing in. After going a few miles I decided to take a stab at getting the shifter out and fixed in a grocery store parking lot. The bolts were being stubborn, hard to reach, and about that time a drunk driver crashed into a pole just outside the lot. With expired out of state plates I decided to just run it and got back on the road.

Most of the trip went smooth other than having to wrap out the RPMs in 2nd then coast just to come close to highway speeds. It made the trip tho, without any other problems.

The next couple days I read and researched and tried to figure out what might be wrong inside the tranny to cause it to be stuck in one gear. I had visions of bent or broken shift forks, seized bearings, basically nightmare tranny killers, but my gut said it has just gotten the shifter out of place. Finally I got out the 4 bolts holding the remote shifter on and found the right shift rail slid into 2nd. I popped that back into the neutral position, and started it up. Sure enough it was in neutral. I put the shifter back in, and the gears seemed to shift fine. I buttoned it back up and drove around then down to the DMV for title transfer. It has been my daily driver ever since.

I had bought a spare tire cover about 6 years earlier thinking I'd repaint it to match my brown 86. I never got it done, but it turned out to be a color match.

IMG_87414962240747.jpeg
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-Tim

1995 Trooper SOHC 5 Spd, daily driver.
97 camshaft swap
Multec 2/Delphi 98-02 Isuzu injector swap
drilled out exhaust restrictors
285/75-16 Kenda Klever M/T on Snowflakes

95 Trooper Build Thread

1986 Trooper LWB 2 Door - Impulse 2.3L high compression motor, 31x10.5 tires

1977 and 1979 Chevy LUVs - a 2WD and a 4WD matched set, projects in the works
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Re: 95 Trooper 5Spd build from plain to ???

Postby BigSwede » Sat Jan 10, 2015 1:35 pm

Nice! Check with Jerry for a shifter bushing, they wear out, the slop might have got yours bound up. Oh, and if your PS hard line is leaking, it is tricky to find the right one, all the parts stores show an incorrect line. Might be worth asking Jerry about that too.
95 Trooper LS - 4" lift, 35" tires, 5.38 gears, ARB lockers
Indy4x Revolution 3.07:1 low range gears, Indy4x HD tie rods, homemade sway bar disconnects, Calmini HD sway bars, Darlington diff drop, OME 929 coil springs + 1" poly spacers and 1" body lift, Indy4x HD torsion bars, Indy4x HD rear axle links, Indy4x Kevlar brake lines, ARB bullbar, custom rear bumper with swing-out dual jerry can carrier, rock sliders, Sears Platinum Group 31 battery, ARB mini-compressor, Indy4x kevlar air lines, Warn M8000 winch, Blue Sea 6006 winch cutoff switch, Yaesu FT-1900R 2-meter ham radio, Larsen MHW-150C 1/2 wave antenna, Cobra 18WXST CB radio, Firestik II CB antenna, IPF driving lights, generic fog lights, two (2) Blue Sea auxiliary fuse panels, sleeping platform, and outofrshell Dave's custom 1" shifter extension. (I actually typed this list as a joke but people seem to like it.)
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Re: 95 Trooper 5Spd build from plain to ???

Postby 800XL » Thu Jan 15, 2015 9:47 am

I started with the beginning of the story, which was actually more than a year ago. Both of those issues are long gone and fixed. I got the bushing for the end of the shifter from Jerry and the power steering pressure line from a parts store. I didn't have much trouble finding the right one, but then I usually tell the store a part number after doing my own research instead of relying on their idea of what fits.

The shifter issue has come back once, sticking into 3rd gear this time. I'm thinking of swapping the remote shifter pod, but it's a fluke thing so not a big priority yet.

For the first year I mostly just drove it. Replaced the shoved in bumper, broke the bug guard slamming the hood too hard once, and generally just collected parts.

It now has a factory rubber rear mat, cargo cover, and more recently a Dakar badge, compass, map lights, lighted sun visor, and driver side grab handles.

Besides the "show" parts, I've also got Aisin manual hubs ready to put on. I have some rough idle and slow start issues so I've some multech2 injectors ready to go on when I finish collecting up the parts to pull the intake. The plan is to replace the timing belt, water pump, tensioner, valve cover gaskets, one cracked valve cover, cam plugs, water pipe o rings, and maybe swap to aluminum timing covers.
Also in the queue is a pair of grand Cherokee springs to lift the rear. Thanks to DutchBro for that Christmas present.

The radiator had developed small leak from a crack near the upper hose connection last month. I put a band aid on that with some very rough sand paper and JB weld. So far that has held great but the new rad is about to get ordered.

Coming soon will hopefully be a LSD rear, and of course actually turning bolts and putting some of these parts on.
-Tim

1995 Trooper SOHC 5 Spd, daily driver.
97 camshaft swap
Multec 2/Delphi 98-02 Isuzu injector swap
drilled out exhaust restrictors
285/75-16 Kenda Klever M/T on Snowflakes

95 Trooper Build Thread

1986 Trooper LWB 2 Door - Impulse 2.3L high compression motor, 31x10.5 tires

1977 and 1979 Chevy LUVs - a 2WD and a 4WD matched set, projects in the works
800XL
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Re: 95 Trooper 5Spd build from plain to ???

Postby 800XL » Wed Jan 28, 2015 5:23 pm

I found a cargo cover and the large factory floor mat for the rear on trips to the junk yard.
2015-01-28 04.21.32.jpg


I caught a deal on the sway bar end links through rockauto, you can see the difference between stock and the new greasable replacements from MOOG. I also replaced the sway bar bushings with greasable poly from energy suspension. The rubber originals were spongy from getting soaked with power steering fluid and just age. The end links went on at the same time as a pair of KYB gas-a-just shocks. The factory originals had long ago ceased to absorb any shock. Overall the on road handling was vastly improved, and the ride is smoother too.
2015-01-28 04.19.53.jpg


When I got it, the bumper had been hit and shoved up and back. I got a replacement from the junk yard and mostly for the grill, body pieces, and headlights pulled back into place. The Dakar badge was another junkyard find.
2014-11-10 16.11.18.jpg
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-Tim

1995 Trooper SOHC 5 Spd, daily driver.
97 camshaft swap
Multec 2/Delphi 98-02 Isuzu injector swap
drilled out exhaust restrictors
285/75-16 Kenda Klever M/T on Snowflakes

95 Trooper Build Thread

1986 Trooper LWB 2 Door - Impulse 2.3L high compression motor, 31x10.5 tires

1977 and 1979 Chevy LUVs - a 2WD and a 4WD matched set, projects in the works
800XL
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Re: 95 Trooper 5Spd build from plain to ???

Postby 800XL » Wed Jan 28, 2015 5:40 pm

I found an Acura SLX at the junk yard and pulled the compass/altimeter, the map lights and sunroof control, and the metal bracket that holds both in place. Here is the bracket installed and the cuts into the head liner done.
2015-01-28 04.13.21.jpg


And here are both installed. For the cut out, on the map lights just cut to match the hole in the metal bracket where the lights clip in. Doesn't have to be perfect, just don't go too far out or the map light won't cover over it.

2015-01-28 04.14.27.jpg


I wired power to the lights from the dome light, the white wire is hot. I also installed the drivers side lighted mirror visor, wired to the same for power.

With all these things, always get the connector and cut as much of the wiring leading to it that you can get. It just works better if you have as much factory harness and connectors as you can get.

During this process I also installed the grab handles above the driver door and on the windshield pillar. You have to cut a square hole in the trim but it's fairly easy to see where. I used a dremel with a rotary cutter bit, just take care not to go too big or it will show.
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Last edited by 800XL on Sun Feb 28, 2016 10:40 am, edited 1 time in total.
-Tim

1995 Trooper SOHC 5 Spd, daily driver.
97 camshaft swap
Multec 2/Delphi 98-02 Isuzu injector swap
drilled out exhaust restrictors
285/75-16 Kenda Klever M/T on Snowflakes

95 Trooper Build Thread

1986 Trooper LWB 2 Door - Impulse 2.3L high compression motor, 31x10.5 tires

1977 and 1979 Chevy LUVs - a 2WD and a 4WD matched set, projects in the works
800XL
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Re: 95 Trooper 5Spd build from plain to ???

Postby 800XL » Wed Jan 28, 2015 6:05 pm

I haven't locked myself in the back yet, but I wanted to avoid that problem so I picked up the parts to add back in the rear door inside handle. 92-93 Troopers have the handle, but by 94 they decided it was too dangerous for people hauling kids in the back and removed it. You need the inside handle, the latch mechanism, and the rod that connects the two. There are clips that hold the rod in place but zip ties looped though worked better than reusing the clips.
2015-01-28 04.10.15.jpg

In the first pic you can just see the white square where the inner door handle will screw to. I didn't grab the screw retainer from the donor, but these for license plates fit, just barely and with much force.
2015-01-28 04.09.05.jpg

This is the cut out needed on the door panel for the handle, notice the outline in the plastic showing about where to cut. Don't go to the line, cut out roughly a rectangle leaving a little less than half an inch before the line.
2015-01-28 04.08.06.jpg

Finished install and put on the cargo racks too. I got these from a truck with brown interior and painted to almost match Can't say I'd recommend going that route. Try to find a match if possible. They are attached by drilling holes in the door panel and using push lock fasteners from the hardware store.
2015-01-28 04.09.48.jpg
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-Tim

1995 Trooper SOHC 5 Spd, daily driver.
97 camshaft swap
Multec 2/Delphi 98-02 Isuzu injector swap
drilled out exhaust restrictors
285/75-16 Kenda Klever M/T on Snowflakes

95 Trooper Build Thread

1986 Trooper LWB 2 Door - Impulse 2.3L high compression motor, 31x10.5 tires

1977 and 1979 Chevy LUVs - a 2WD and a 4WD matched set, projects in the works
800XL
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Re: 95 Trooper 5Spd build from plain to ???

Postby BigSwede » Thu Jan 29, 2015 1:09 am

Thanks for reminding me - I need to keep an eye out for a 92-93 for rear door handle setup. My old 93 RS had one.
95 Trooper LS - 4" lift, 35" tires, 5.38 gears, ARB lockers
Indy4x Revolution 3.07:1 low range gears, Indy4x HD tie rods, homemade sway bar disconnects, Calmini HD sway bars, Darlington diff drop, OME 929 coil springs + 1" poly spacers and 1" body lift, Indy4x HD torsion bars, Indy4x HD rear axle links, Indy4x Kevlar brake lines, ARB bullbar, custom rear bumper with swing-out dual jerry can carrier, rock sliders, Sears Platinum Group 31 battery, ARB mini-compressor, Indy4x kevlar air lines, Warn M8000 winch, Blue Sea 6006 winch cutoff switch, Yaesu FT-1900R 2-meter ham radio, Larsen MHW-150C 1/2 wave antenna, Cobra 18WXST CB radio, Firestik II CB antenna, IPF driving lights, generic fog lights, two (2) Blue Sea auxiliary fuse panels, sleeping platform, and outofrshell Dave's custom 1" shifter extension. (I actually typed this list as a joke but people seem to like it.)
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Re: 95 Trooper 5Spd build from plain to ???

Postby 800XL » Thu Jan 29, 2015 2:11 am

I actually picked up an extra handle, rod, and latch. Not sure what it would cost to ship, that rod is kind of long so it would need a bigger box than the other parts
-Tim

1995 Trooper SOHC 5 Spd, daily driver.
97 camshaft swap
Multec 2/Delphi 98-02 Isuzu injector swap
drilled out exhaust restrictors
285/75-16 Kenda Klever M/T on Snowflakes

95 Trooper Build Thread

1986 Trooper LWB 2 Door - Impulse 2.3L high compression motor, 31x10.5 tires

1977 and 1979 Chevy LUVs - a 2WD and a 4WD matched set, projects in the works
800XL
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Re: 95 Trooper 5Spd build from plain to ???

Postby 800XL » Fri Jan 30, 2015 3:02 am

I still have some adjustments to the sheet metal around the grill and headlights but I got the chrome 94 grill installed that I picked up from the last junkyard trip. The parts around it are just slightly off from where the bumper pushed up into them and it made fitting the grill a bit of a challenge. Looks better though.

20150127_101058-1.jpg


I also got the CB antenna mount installed and stuck the CB in the blank under the radio. I was hoping to fit a Uniden President Grant radio in there, but that thing is huge. So I gave up the extra tweaked power and side band for a Cobra 18WX ST II. It fits perfectly and the metal brackets from the storage box that was in that space can be used to secure it. The hole on the brackets furthest in is about 1/2 inch too far back tho, so drill a new hole further out to line it up perfectly with the dash trim. Picture of that installed to come, or I'll figure out where to mount the Uniden.

I also have a pic of the coming attraction:
2015-01-28 04.11.36.jpg


Needs cleaned and paint, then a free couple hours to install.
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-Tim

1995 Trooper SOHC 5 Spd, daily driver.
97 camshaft swap
Multec 2/Delphi 98-02 Isuzu injector swap
drilled out exhaust restrictors
285/75-16 Kenda Klever M/T on Snowflakes

95 Trooper Build Thread

1986 Trooper LWB 2 Door - Impulse 2.3L high compression motor, 31x10.5 tires

1977 and 1979 Chevy LUVs - a 2WD and a 4WD matched set, projects in the works
800XL
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Re: 95 Trooper 5Spd build from plain to ???

Postby comerz » Fri Jan 30, 2015 1:14 pm

Very Nice. When you get a chance post a picture up of your cb!
--Link to my progress page http://forum.planetisuzoo.com/viewtopic.php?f=15&t=80525
--94 isuzu rodeoport 3.2L. lifted in front 3 inch 4 in back (2 in leaf, 2 in shackle)
--"the person who says it cannot be done should not stand in the way of the person doing it"
--Link to easiest way to bleed clutch http://forum.planetisuzoo.com/viewtopic.php?f=1&t=80414
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Re: 95 Trooper 5Spd build from plain to ???

Postby 800XL » Tue Feb 03, 2015 3:24 am

I still haven't pulled the CB back out to drill the holes further out to get it sitting out just right in the dash.
20150202_184854-1.jpg
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-Tim

1995 Trooper SOHC 5 Spd, daily driver.
97 camshaft swap
Multec 2/Delphi 98-02 Isuzu injector swap
drilled out exhaust restrictors
285/75-16 Kenda Klever M/T on Snowflakes

95 Trooper Build Thread

1986 Trooper LWB 2 Door - Impulse 2.3L high compression motor, 31x10.5 tires

1977 and 1979 Chevy LUVs - a 2WD and a 4WD matched set, projects in the works
800XL
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Posts: 785
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Re: 95 Trooper 5Spd build from plain to ???

Postby BigSwede » Tue Feb 03, 2015 10:02 am

Yep, that's what I did.
95 Trooper LS - 4" lift, 35" tires, 5.38 gears, ARB lockers
Indy4x Revolution 3.07:1 low range gears, Indy4x HD tie rods, homemade sway bar disconnects, Calmini HD sway bars, Darlington diff drop, OME 929 coil springs + 1" poly spacers and 1" body lift, Indy4x HD torsion bars, Indy4x HD rear axle links, Indy4x Kevlar brake lines, ARB bullbar, custom rear bumper with swing-out dual jerry can carrier, rock sliders, Sears Platinum Group 31 battery, ARB mini-compressor, Indy4x kevlar air lines, Warn M8000 winch, Blue Sea 6006 winch cutoff switch, Yaesu FT-1900R 2-meter ham radio, Larsen MHW-150C 1/2 wave antenna, Cobra 18WXST CB radio, Firestik II CB antenna, IPF driving lights, generic fog lights, two (2) Blue Sea auxiliary fuse panels, sleeping platform, and outofrshell Dave's custom 1" shifter extension. (I actually typed this list as a joke but people seem to like it.)
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Re: 95 Trooper 5Spd build from plain to ???

Postby comerz » Tue Feb 03, 2015 12:51 pm

Nice! I like the flush mount though!
--Link to my progress page http://forum.planetisuzoo.com/viewtopic.php?f=15&t=80525
--94 isuzu rodeoport 3.2L. lifted in front 3 inch 4 in back (2 in leaf, 2 in shackle)
--"the person who says it cannot be done should not stand in the way of the person doing it"
--Link to easiest way to bleed clutch http://forum.planetisuzoo.com/viewtopic.php?f=1&t=80414
comerz
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Re: 95 Trooper 5Spd build from plain to ???

Postby 800XL » Tue Feb 03, 2015 1:13 pm

Right now there is a gap in front of it. It also sits too far back and I can't see the channel or the meter while driving.
-Tim

1995 Trooper SOHC 5 Spd, daily driver.
97 camshaft swap
Multec 2/Delphi 98-02 Isuzu injector swap
drilled out exhaust restrictors
285/75-16 Kenda Klever M/T on Snowflakes

95 Trooper Build Thread

1986 Trooper LWB 2 Door - Impulse 2.3L high compression motor, 31x10.5 tires

1977 and 1979 Chevy LUVs - a 2WD and a 4WD matched set, projects in the works
800XL
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Re: 95 Trooper 5Spd build from plain to ???

Postby comerz » Tue Feb 03, 2015 3:03 pm

Ah I see what youre saying. Surely youll figure it out lol. I have a cobra 25ltx classic mounted on the passenger side of my radio bin
--Link to my progress page http://forum.planetisuzoo.com/viewtopic.php?f=15&t=80525
--94 isuzu rodeoport 3.2L. lifted in front 3 inch 4 in back (2 in leaf, 2 in shackle)
--"the person who says it cannot be done should not stand in the way of the person doing it"
--Link to easiest way to bleed clutch http://forum.planetisuzoo.com/viewtopic.php?f=1&t=80414
comerz
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Re: 95 Trooper 5Spd build from plain to ???

Postby 800XL » Tue May 19, 2015 7:17 pm

I swapped the map light bulbs for LED. I found these on amazon that are flat instead of multisided:
41HjKtPvsSL._SY400_.jpg

Cutequeen 4PCS LED Car Lights Bulb White T10 3528 8-SMD 194 168 (pack of 4) https://www.amazon.com/dp/B00BGJBMC4/re ... wvb12HDWBX

I haven't tested at night yet, but I bet you can tell which bulb is which.

2015-05-19 16.06.09.jpg
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-Tim

1995 Trooper SOHC 5 Spd, daily driver.
97 camshaft swap
Multec 2/Delphi 98-02 Isuzu injector swap
drilled out exhaust restrictors
285/75-16 Kenda Klever M/T on Snowflakes

95 Trooper Build Thread

1986 Trooper LWB 2 Door - Impulse 2.3L high compression motor, 31x10.5 tires

1977 and 1979 Chevy LUVs - a 2WD and a 4WD matched set, projects in the works
800XL
Trail Master
 
Posts: 785
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Re: 95 Trooper 5Spd build from plain to ???

Postby 800XL » Mon Jun 15, 2015 1:22 pm

Finally managed to get the limited slip third member cleaned up and installed.
First the new part got the rust cleared off and a coat of paint.
2015-06-15 09.30.19.jpg


Then I got the truck up on jack stands and drained the diff, finding this on the magnetic drain plug:
20150611_211111-1.jpg


Unbolted everything and dropped the diff (on to a cardboard box to break the fall, heavy sucker) and I found this inside:
2015-06-15 02.19.18.jpg


I cleaned several more chunks out of the axle housing. I'm still not quite sure what failed to let the spider gears start to chip like that but I was already planning to pull the open diff anyway for the replacement so not too worried about it. To finish up I ran a small magnet around inside the housing and extended it as far down the tubes as I could reach. Then I cleaned up the surfaces of the parts to reassemble and coated the mating surfaces with non hardening permatex. Took two of us to lift the third member into place and slide it in.
2015-06-15 02.20.25.jpg


The final step was a test drive, which had to wait until the next day since it was late.
2015-06-15 12.22.57.jpg
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Last edited by 800XL on Sun Feb 28, 2016 10:36 am, edited 1 time in total.
-Tim

1995 Trooper SOHC 5 Spd, daily driver.
97 camshaft swap
Multec 2/Delphi 98-02 Isuzu injector swap
drilled out exhaust restrictors
285/75-16 Kenda Klever M/T on Snowflakes

95 Trooper Build Thread

1986 Trooper LWB 2 Door - Impulse 2.3L high compression motor, 31x10.5 tires

1977 and 1979 Chevy LUVs - a 2WD and a 4WD matched set, projects in the works
800XL
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Posts: 785
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Re: 95 Trooper 5Spd build from plain to ???

Postby 800XL » Mon Nov 16, 2015 6:40 pm

A few months back I started a project to do all the things I could think of to my engine all at once. It has gotten stalled along the way but I'm getting closer and ready to make a final push to finish it. Here is the modest list of replacements, swaps, upgrades, and maintenance tasks:

Swap cams from a 97 engine
Swap intake rockers and shafts to cut the rattle
Replace a cracked valve cover
New valve cover gaskets
New intake/plenum gaskets
Clean intake and throttle body
Swap upper timing covers to aluminum from a 96-97
New timing belt
New tensioner
New water pump
New coolant pipe O rings
Clean the sludge out from under the intake in the "valley of doom"
Swap injectors and harness connectors to Multec2 (98-02 Isuzu V6)
Clean and service the "new" injectors

I've got a lot of this done, but a lot of reassembly left. I'm starting on the injectors I got from a donor now. I've glued a red tube from a can of injector cleaner into a plastic valve stem cap. A rubber tire valve stem squeezes just over the top of the injector, then the modified cap screws on. I've wired one injector connector to a small 9v power supply to use to pulse the injector open while spraying cleaner through it. I found I needed 4 hands to hold the contraption, spray, and power the injector. I needed a foot switch...
2015-11-16 14.19.06.jpg
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Last edited by 800XL on Wed Mar 15, 2017 2:59 pm, edited 1 time in total.
-Tim

1995 Trooper SOHC 5 Spd, daily driver.
97 camshaft swap
Multec 2/Delphi 98-02 Isuzu injector swap
drilled out exhaust restrictors
285/75-16 Kenda Klever M/T on Snowflakes

95 Trooper Build Thread

1986 Trooper LWB 2 Door - Impulse 2.3L high compression motor, 31x10.5 tires

1977 and 1979 Chevy LUVs - a 2WD and a 4WD matched set, projects in the works
800XL
Trail Master
 
Posts: 785
Joined: Fri Feb 13, 2004 2:39 pm
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Re: 95 Trooper 5Spd build from plain to ???

Postby 800XL » Tue May 03, 2016 2:48 pm

There is a lot to update on this post. Swapped cams, swapped to 98+ multec 2/Delphi style injectors. I'll update more soon.

Only took a year but I finally got the CB mounted further out. I drilled a hole in the metal mount for the storage bin a half inch out from the original hole i had been using. You could get out dead on flush if you wanted but I wanted to be sure I could see the channel readout without leaning down. I'm still going to take this CB out though and replace the bin. I'll put my President Grant hanging off the side of the console.

2016-05-03 11.34.07.jpg


I also replaced the instrument panel surround. I found one that had the factory anti theft light in it, but was from a manual trans truck so it did not have the auto trans display. Not too common from what I've seen to have factory anti theft with a manual trans. The bit I'm holding in the pic is the cheesy looking alarm LED that was installed with the aftermarket alarm. Just hooked up the wires to the factory LED and it works great.

2016-05-03 11.37.35.jpg
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-Tim

1995 Trooper SOHC 5 Spd, daily driver.
97 camshaft swap
Multec 2/Delphi 98-02 Isuzu injector swap
drilled out exhaust restrictors
285/75-16 Kenda Klever M/T on Snowflakes

95 Trooper Build Thread

1986 Trooper LWB 2 Door - Impulse 2.3L high compression motor, 31x10.5 tires

1977 and 1979 Chevy LUVs - a 2WD and a 4WD matched set, projects in the works
800XL
Trail Master
 
Posts: 785
Joined: Fri Feb 13, 2004 2:39 pm
Location: Yamhill County Oregon
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Re: 95 Trooper 5Spd build from plain to ???

Postby matthew996 » Sat Mar 11, 2017 4:14 pm

Nice project! I've done the rear door handle as well for my kids.

I have the compass that I've been waiting to install since I figure I'll have to take the dash out and wire it to the stereo, etc. From what it looks like, you wired it to the lights, correct? Did you have much wiring to do past the rear view mirror? I would like to see more of how to installed the compass.

Thanks!

Matt
1994 Isuzu Trooper LS: Pretty much stock except for 3rd row seats
1995 Isuzu Trooper Limited: Diesel Conversion with 4JG2-TD engine (rebuilt prior to swap) from the U.K., stock otherwise (for now)
1992 Isuzu Rodeo (sold)
2004 Isuzu Ascender (sold)
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Re: 95 Trooper 5Spd build from plain to ???

Postby 800XL » Sat Mar 11, 2017 6:01 pm

I ran compass power from the stereo key on power wire then run up behind the trim next to the windshield and power to the map lights and lighted sun visor mirrors from the dome light. You can ground right at the compass. You also need two wires out to the temp sensor for the compass that goes on the core support just in front of the radiator. I would mount that away from the stock location tho, like behind the headlight or bumper. It gets hot from the engine on the core support.
-Tim

1995 Trooper SOHC 5 Spd, daily driver.
97 camshaft swap
Multec 2/Delphi 98-02 Isuzu injector swap
drilled out exhaust restrictors
285/75-16 Kenda Klever M/T on Snowflakes

95 Trooper Build Thread

1986 Trooper LWB 2 Door - Impulse 2.3L high compression motor, 31x10.5 tires

1977 and 1979 Chevy LUVs - a 2WD and a 4WD matched set, projects in the works
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Re: 95 Trooper 5Spd build from plain to ???

Postby 800XL » Thu Mar 16, 2017 2:35 am

Adding some details about the work that I've done over the last year or so.

I got the idea for the 96-97 cam upgrade from a post by mtman. He described the power increase as comparable to the DOHC head swap he did later. What I noticed most was more acceleration further up towards red line, but also a bit more power all around. It appears that the difference is th later cams have a bit more intake duration.
I pulled cams from a 97 Trooper. It's a chore to pull them from a junk yard truck, but they are fairly cheap that way. The 96-97 Rodeo, Passport, and Trooper SOHC cams should all be the same upgrade.
-Tim

1995 Trooper SOHC 5 Spd, daily driver.
97 camshaft swap
Multec 2/Delphi 98-02 Isuzu injector swap
drilled out exhaust restrictors
285/75-16 Kenda Klever M/T on Snowflakes

95 Trooper Build Thread

1986 Trooper LWB 2 Door - Impulse 2.3L high compression motor, 31x10.5 tires

1977 and 1979 Chevy LUVs - a 2WD and a 4WD matched set, projects in the works
800XL
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Re: 95 Trooper 5Spd build from plain to ???

Postby 800XL » Thu Mar 16, 2017 8:56 pm

The injector upgrade was another mtman inspired project. Here is his detailed thread on the subject:

viewtopic.php?f=22&t=77480

The stock multec 1 injectors are a wet coil design and have been known to degrade when exposed to ethanol fuels. Nearly all gas these days has some ethanol in it so i figured an upgrade would help to future proof things. Plus I had symptoms of leaking injectors already like hard starting and occasional backfire into the intake. Once bad enough to scorch the air filter.

The upgrade is delphi style multec 2 injectors, conveniently used in Izuzu 3.5L Troopers and Rodeo 3 2 and 3.5L.

20160101_230315_crop_793x442.jpg


I pulled these from a junkyard truck. I actually pulled several extras. You could buy new or rebuilt and tested ones, but I rebuilt my own. I bought rebuild parts from mrinjector for about $35, with enough parts for 7 injectors. For cleaning to start I dunked them in a can of Chemdip for a few days. I then pulled the screens and sprayed them out with chemtool cleaner, making sure to let any debris run out the top of the injector not further in. With the new parts installed I put each injector into a jig i made for pressure cleaning. One rubber tire valve stem with valve core removed, valve cap with a small hole drilled in the top, glue one cleaning tube from the carb cleaner can into that hole, then slip the valve stem onto the top of the injector. I used a connector and some harness to connect power to the injector, and wired it through a guitar amp foot switch to keep my hands free. Use the bare minimum voltage needed to get a click out of the injector. I ended getting two AA batteries to work after starting with a 9v power adapter.
Hook the tube to a can of carb cleaner, spray some, then pulse the power to the injector to spray it through.

20160101_220043_crop_887x741.jpg


The spray should come out evenly and a very fine mist. Keep in mind atomized carb cleaner spray can be seriously flammable if not explosive. Outdoors would be the best place for this. All 7 injectors i rebuilt had good clean spray patterns. I can't say if they all had the same flow rate, but for the price they have worked very good. It might be better to just get a set cleaned if you don't want to mess with this clean and rebuild process.

They fit right in place of the stock injectors and the safety clips even match up.

20160102_134625-2656x1494.jpg


The whole package looks like they belong there.

20160109_170339-2656x1494.jpg


The wiring i just cut connectors from the donor and soldered but there are adapters available that are plug and play for the factory harness to the new injectors.

Overall these injectors seem to have improved throttle response and cured all of my hard starting and backfire issues. But I had very likely bad injectors to begin with so any performance comparison is going to be hard.
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Last edited by 800XL on Fri Apr 14, 2017 2:43 pm, edited 1 time in total.
-Tim

1995 Trooper SOHC 5 Spd, daily driver.
97 camshaft swap
Multec 2/Delphi 98-02 Isuzu injector swap
drilled out exhaust restrictors
285/75-16 Kenda Klever M/T on Snowflakes

95 Trooper Build Thread

1986 Trooper LWB 2 Door - Impulse 2.3L high compression motor, 31x10.5 tires

1977 and 1979 Chevy LUVs - a 2WD and a 4WD matched set, projects in the works
800XL
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Re: 95 Trooper 5Spd build from plain to ???

Postby 800XL » Thu Mar 16, 2017 9:05 pm

In the middle of all the cam and injector upgrades i picked up a spare set of valve covers and a set of aluminium timing covers. They got sanded and polished before install. It's been about a year now and they are still fairly shiny. Next time they're off i may try to polish and paint with clear.

The timing covers come from 96-97 troopers, rodeos, or passports. They used a metal cover to allow installation of a cam sensor. I left the sensor plugging the hole, and aviator swapped on the newer cam pulley with the magnet in it in case I ever add aftermarket engine management for a turbo or supercharger and want cam position.

Turned out looking good. I cleaned the intake inside and out as well. It had chunks of yellowed clear coat on it.
20160118_142028-2656x1494.jpg
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-Tim

1995 Trooper SOHC 5 Spd, daily driver.
97 camshaft swap
Multec 2/Delphi 98-02 Isuzu injector swap
drilled out exhaust restrictors
285/75-16 Kenda Klever M/T on Snowflakes

95 Trooper Build Thread

1986 Trooper LWB 2 Door - Impulse 2.3L high compression motor, 31x10.5 tires

1977 and 1979 Chevy LUVs - a 2WD and a 4WD matched set, projects in the works
800XL
Trail Master
 
Posts: 785
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Re: 95 Trooper 5Spd build from plain to ???

Postby 800XL » Fri Apr 14, 2017 2:56 pm

I got a great birthday present from DutchBro. All the way from Iceland and hand made. Needs powder coat or paint before it is permanently installed, but it highlights the Jerry sticker nicely.

20170325_171842_crop_740x818.jpg
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-Tim

1995 Trooper SOHC 5 Spd, daily driver.
97 camshaft swap
Multec 2/Delphi 98-02 Isuzu injector swap
drilled out exhaust restrictors
285/75-16 Kenda Klever M/T on Snowflakes

95 Trooper Build Thread

1986 Trooper LWB 2 Door - Impulse 2.3L high compression motor, 31x10.5 tires

1977 and 1979 Chevy LUVs - a 2WD and a 4WD matched set, projects in the works
800XL
Trail Master
 
Posts: 785
Joined: Fri Feb 13, 2004 2:39 pm
Location: Yamhill County Oregon
Has thanked: 52 times
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