'97 Honda Passport SAS

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Re: '97 Honda Passport SAS

Postby paulevans76 » Sun Sep 11, 2016 1:49 pm

Wrong size for the hole? Were the steering arm holes each the same size/taper and were the TRE's the same as well?
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Re: '97 Honda Passport SAS

Postby TheMadHatter » Mon Sep 12, 2016 2:32 pm

paulevans76 wrote:Wrong size for the hole? Were the steering arm holes each the same size/taper and were the TRE's the same as well?



Ya that was the problem.. they sent me 2 3/4 ton instead of 1 ton.
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Re: '97 Honda Passport SAS

Postby TheMadHatter » Sun Sep 25, 2016 1:53 am

So I was working on my np205 today and discovered that the shift pin retainer is cracked rendering my case useless :angryfire: So now i am exploring other options and have a couple questions.

With my 2wd auto trans (4l30e?) am i able to simply swap the nose of the houseing with a 4x4 nose then install a transfer case?

If i end up just swaping the whole tranny out are there any non isuzu options that bolt up fairly nice people recommend?
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Re: '97 Honda Passport SAS

Postby totten » Sun Sep 25, 2016 9:28 pm

Nice work and thanks for pics. Will be super when done.
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Re: '97 Honda Passport SAS

Postby Dingbat » Mon Sep 26, 2016 9:00 am

TheMadHatter wrote:So I was working on my np205 today and discovered that the shift pin retainer is cracked rendering my case useless :angryfire: So now i am exploring other options and have a couple questions.

With my 2wd auto trans (4l30e?) am i able to simply swap the nose of the houseing with a 4x4 nose then install a transfer case?

If i end up just swaping the whole tranny out are there any non isuzu options that bolt up fairly nice people recommend?

If I recall correctly, the 2wd output shaft is also different between 2wd and 4wd.
To confirm PM our local 4L30e guru Buster28.
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Re: '97 Honda Passport SAS

Postby TheMadHatter » Mon Sep 26, 2016 11:16 am

Dingbat wrote:If I recall correctly, the 2wd output shaft is also different between 2wd and 4wd.
To confirm PM our local 4L30e guru Buster28.

Thanks Dingbat pm sent. Ya i didnt consider that, ill post up what Buster28 pms me.
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Re: '97 Honda Passport SAS

Postby TheMadHatter » Mon Sep 26, 2016 4:41 pm

TheMadHatter wrote:
Dingbat wrote:If I recall correctly, the 2wd output shaft is also different between 2wd and 4wd.
To confirm PM our local 4L30e guru Buster28.

Thanks Dingbat pm sent. Ya i didnt consider that, ill post up what Buster28 pms me.

Ok so Buster messaged me a picture showing that the output shaft are entirely different and incompatible. So now i am searching craigslist and ebay for a tranny, maybe a 5spd.
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Re: '97 Honda Passport SAS

Postby lorenzo816 » Mon Sep 26, 2016 5:38 pm

there are only so many combinations that will work behind the 3.2
its been documented here and on 4x4wire.

Sucks about your 205 but was looking forward to seeing a 4wd isuzu SAS attacked in a different method.

Why don't you go to Utah and pick up Chad's isuzu?
One of the original dual case jobs and works.
I'd go pick it up but want pics first and a good way to get it home.

If you get his rig, you won't have to go through all the headache we all had to go through trying to get the front output far enough back to get a decent usable driveshaft angle.


viewtopic.php?f=2&t=88562


Mua5 with dual cases, auto with single case to a limiting strap on the passenger side or a modified Yota trans with single or dual cases behind the Ar5 bellhousing are you only options now my friend unless you ditch the 3.2 motor/trans combo and start fresh with a whole new drivetrain, weld up new motor mounts and trans mount.
Good luck.
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Re: '97 Honda Passport SAS

Postby TheMadHatter » Mon Sep 26, 2016 10:34 pm

lorenzo816 wrote:there are only so many combinations that will work behind the 3.2
its been documented here and on 4x4wire.

Sucks about your 205 but was looking forward to seeing a 4wd isuzu SAS attacked in a different method.

Why don't you go to Utah and pick up Chad's isuzu?
One of the original dual case jobs and works.
I'd go pick it up but want pics first and a good way to get it home.

If you get his rig, you won't have to go through all the headache we all had to go through trying to get the front output far enough back to get a decent usable driveshaft angle.


viewtopic.php?f=2&t=88562


Mua5 with dual cases, auto with single case to a limiting strap on the passenger side or a modified Yota trans with single or dual cases behind the Ar5 bellhousing are you only options now my friend unless you ditch the 3.2 motor/trans combo and start fresh with a whole new drivetrain, weld up new motor mounts and trans mount.
Good luck.


I wish i could but being a poor college student i dont have the time or resources to go to utah right now haha. I took another good look at the case and i am starting to wonder if it fixable. At first i was thinkin that it wouldnt be doable but i read somewhere about using nickel electrodes on the cast caseing.. this isnt my picture but this is the part of the case that is cracked. Also i only have half of the broken piece dunno where the hell the other half went.. ill probably have to head over to pirate 4x4 with the pic bein its a 205 but if anyone has any suggestions fire away.
2016-09-26 19.29.23.jpg
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Re: '97 Honda Passport SAS

Postby nasty610 » Sat Oct 01, 2016 8:07 am

I wouldn't say those are the only options Lorenzo. Technically you could use a Camaro T5 bell housing to bolt a sm420/465 or a NV4500 to an Isuzu engine. The transmission input would need to be turned down to fit the smaller Isuzu input bushing. It's been done quite a few times on the 60 degree engines. Or just use a T5wc from a S10.
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Re: '97 Honda Passport SAS

Postby TheMadHatter » Fri Oct 07, 2016 1:13 am

So i drove her out of the back yard the other day and it moves :mrgreen: heres how its sitting at the moment
2016-10-06 22.06.05.jpg


It actually stayed alot lower than I had envisioned but I'm happy with it. These ome yj springs already feel pretty flexy too

Not likeing this shackle angle so i picked up some longer ones.. autozone actually has some pretty sturdy cut to length ones for $20 a set gonna try to get them on this weekend..
2016-10-06 22.07.07.jpg
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Re: '97 Honda Passport SAS

Postby TheMadHatter » Fri Oct 07, 2016 1:17 am

Also just a side note, the stocker rims won't clear the tie rods on a d44, i had to throw my old wheel spacers back on.. Anyone know what backspaceing i need?
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Re: '97 Honda Passport SAS

Postby TheMadHatter » Sat Oct 08, 2016 11:58 pm

New shackles are on at a length of 10" :mrgreen:

2016-10-08 20.53.27.jpg


Im likeing this angle what do you guys think?

2016-10-08 20.54.40.jpg
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Re: '97 Honda Passport SAS

Postby TheMadHatter » Tue Oct 11, 2016 11:31 pm

So I picked up this divorced tcase today for $60 in a

parts lot (came with a cylinder head and 5spd for a

nissan 720 :tongue2: ). The tcase is a T100L, seems to

be in good shape.

2016-10-11 20.03.04.jpg


2016-10-11 20.04.49.jpg


2016-10-11 20.03.55.jpg


It's a little thing but is pretty sturdy and reliable. A couple

people on pirate4x4 have reported running them pretty

hard. One guy with 38s and a 305. :evil2:
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Re: '97 Honda Passport SAS

Postby lorenzo816 » Sun Apr 16, 2017 8:36 am

curious how this is going.
any updates?
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