Regearing to 4.56 on 2002 Trooper - What's it gonna take?

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Regearing to 4.56 on 2002 Trooper - What's it gonna take?

Postby McMoneyPit_2 » Wed May 10, 2017 5:08 pm

Hey guys I'm new to Isuzu/Troopers but am hungry to get the most out of my family adventure rig. I've recently upgraded to manual hubs and 33" tires (among other things) and feel like the auto trans makes the rig a little gutless on the road. I've haven't been off road much yet because all my shocks were blown/clearance issues. Also, worried that without gears my auto trans will die prematurely. I've scoped out some salvage Gen 1 Trooper 4.56 gears/parts (4.77 seems too hard to find) but have some questions on the process.

Will Trooper Gen 1 carriers fit in Gen 2 axles? Or will I have to pull the gears and put them in my Gen 2 carriers?
How difficult will changing gears be on these Isuzu carriers? I assume the pinion will have to be re-shimmed?
Will 4.56 gears from a Gen 1 have any fitup issues with my rear G80 limited slip differential? get
Where is the best place to buy the bearings/seals that I will need?

Any help would be great. I don't have an build posts yet but i'll work on that.
2002 Trooper TOD, - ARB bumper, LED spotlights, AISIN manual hubs, 2" OME suspension lift, 33x10.5x15 BFG KM2 mud terrains, Pro Comp steelies, blacked out, more to come
2005 Jeep Rubicon - lots of lift and 35s (SOLD)
2002 Ford Ranger 4x4 - 3" body lift, 2" suspension lift, 33x12.5x15 Cooper STT, Riddler diff armor, custom rear bumper
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Re: Regearing to 4.56 on 2002 Trooper - What's it gonna take

Postby egagnon086 » Wed May 10, 2017 8:31 pm

I think your troop has the modified 12 bolt, so you would have to swap the entire axle.
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Re: Regearing to 4.56 on 2002 Trooper - What's it gonna take

Postby sassee » Thu May 11, 2017 9:12 am

you'll need a complete rear end, 95-97 works best. also have to front carrier with 4:56's
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Re: Regearing to 4.56 on 2002 Trooper - What's it gonna take

Postby egagnon086 » Thu May 11, 2017 9:41 am

So does the 02 have TOD, would the system end up going crazy if he swapped both diffs for an earlier version. I know my 02 rodeo sport when nuts after I swapped the front axle to an earlier one with out the SOTF.
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Re: Regearing to 4.56 on 2002 Trooper - What's it gonna take

Postby McMoneyPit_2 » Thu May 11, 2017 10:30 am

jeez a whole rear end? This is becoming a more time consuming/expensive ordeal than i thought. Is the 95-97 rear end at least a bolt in swap? Or would i have to make modifications to make it work?

Sigh.. yes it has TOD right now.
2002 Trooper TOD, - ARB bumper, LED spotlights, AISIN manual hubs, 2" OME suspension lift, 33x10.5x15 BFG KM2 mud terrains, Pro Comp steelies, blacked out, more to come
2005 Jeep Rubicon - lots of lift and 35s (SOLD)
2002 Ford Ranger 4x4 - 3" body lift, 2" suspension lift, 33x12.5x15 Cooper STT, Riddler diff armor, custom rear bumper
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Re: Regearing to 4.56 on 2002 Trooper - What's it gonna take

Postby egagnon086 » Thu May 11, 2017 11:57 am

I think they are bolt in but different lengths, Trac widths. So maybe wheels spacers would be needed.
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Re: Regearing to 4.56 on 2002 Trooper - What's it gonna take

Postby JLEMOND » Fri May 12, 2017 8:28 pm

egagnon086 wrote:I think they are bolt in but different lengths, Trac widths. So maybe wheels spacers would be needed.


95-97 WILL BOLT RIGHT IN , HOWEVER THE DRIVE SHAFT /COMPANION FLANGE IS COMPLETELY DIFF, MEANING A NEW DRIVE SHAFT , ALL SO THE TRANS END OF THE SHAFT IS LARGER . YOU WILL NEED THE FRT DIFF ASSY ALL SO.

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Re: Regearing to 4.56 on 2002 Trooper - What's it gonna take

Postby McMoneyPit_2 » Mon May 15, 2017 12:13 pm

So after a fully loaded trip to Flagstaff from Tucson for Overland Expo West I realized how much the trooper struggles with elevation change. So I would like to pursue this mod as long as i can keep it under 1000ish.

Is is possible to find a 95-97 trooper axle with both the G80 and HC6 codes? If so I would have to do very little to swap.
What would be the issue with TOD? Could I just override TOD to be full 50/50 split to avoid any issues?
As far as the front carrier goes I assume any isuzu 10 bolt with the 4.56 gears will work?
As far as driveshaft issue.. Will I need a 95-97 driveshaft? Could the flange be modified to work?

Lastly, has anyone on this forum done something like this before? First hand experience would be golden.
2002 Trooper TOD, - ARB bumper, LED spotlights, AISIN manual hubs, 2" OME suspension lift, 33x10.5x15 BFG KM2 mud terrains, Pro Comp steelies, blacked out, more to come
2005 Jeep Rubicon - lots of lift and 35s (SOLD)
2002 Ford Ranger 4x4 - 3" body lift, 2" suspension lift, 33x12.5x15 Cooper STT, Riddler diff armor, custom rear bumper
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Re: Regearing to 4.56 on 2002 Trooper - What's it gonna take

Postby oldestisuzuist » Mon May 15, 2017 1:02 pm

A suggestion:
The swap from 4.30 to 4.56 gears is only about 6% reduction, or very close to what a 2" smaller tire diameter would provide. Before jumping into the gear swap see if you can borrow two 31" tires/wheels for the rear, take the truck for a test drive under all conditions you feel it's underperforming, see if the gear change will be all that you expect or not. It could be it's not worth the money.
Last edited by oldestisuzuist on Mon May 15, 2017 1:03 pm, edited 1 time in total.
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Re: Regearing to 4.56 on 2002 Trooper - What's it gonna take

Postby egagnon086 » Mon May 15, 2017 1:03 pm

Read through this, it has some pointers on doing the swap.

viewtopic.php?f=15&t=60191&hilit=clutch+hose#p516554
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Re: Regearing to 4.56 on 2002 Trooper - What's it gonna take

Postby McMoneyPit_2 » Tue May 16, 2017 1:59 pm

I'm beginning to agree with the oldestisuzuist. If i go to all of the trouble of doing this I may as well shoot for the 4.77 gears which are still available from independent4x albeit very pricey.

Thanks for that post egagnon086. I read through most of it and need to message the guy about some questions. Like why he switched away from the SOTF front axle.

I'm still looking for answers to whether or not i'll need different/modified driveshafts. I see that indpendent4x has TOD and non-TOD third members so there must be a difference in the front at least.
2002 Trooper TOD, - ARB bumper, LED spotlights, AISIN manual hubs, 2" OME suspension lift, 33x10.5x15 BFG KM2 mud terrains, Pro Comp steelies, blacked out, more to come
2005 Jeep Rubicon - lots of lift and 35s (SOLD)
2002 Ford Ranger 4x4 - 3" body lift, 2" suspension lift, 33x12.5x15 Cooper STT, Riddler diff armor, custom rear bumper
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