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1990 isuzu trooper ls
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Discussion Starter · #1 ·
Hi All,

recently purchased a trooper with a bad transmission and decided to manual swap it. Through the help of this forum I found a very comprehensive manual swap, which has been great.

I would say that I am 90% done with the swap, but am hung up on a few critical steps.

1. The transmission crossmember:
It seems that the two crossmembers are virtually identical except for two mounting holes for the transfer case skid place on the manuals crossmember. I have a different transmission mount. Despite that the crossmember will not line up with the transmission mount and the mounts on the frame. Do I need to remove and shift the frame perches? Do I have the wrong crossmember?

2. Wiring:
The wires coming from the manuals harness do not have matching connectors in the body harness. I assume I will have to do some splicing?

Thanks in advance,
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I would use the auto trans harness, cut the wires you need (backup lights, 4wd indicator) and wire those into the switches on the trans. Also, I made an adapter out of 1/2" steel to allow the cross member to catch the transmission mount on my manual swap.
 

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I've got a different Trooper and different trans so I was able to modify my cross-member to make it work. In your case, it looks like you'll just have to make your own cross-member from scratch. A 1st gen Trooper with the auto has a different frame than a 1st gen Trooper with the manual which is causing the issue.

If you wanna read about my project to get ideas:
 

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1990 isuzu trooper ls
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Discussion Starter · #6 ·
I've got a different Trooper and different trans so I was able to modify my cross-member to make it work. In your case, it looks like you'll just have to make your own cross-member from scratch. A 1st gen Trooper with the auto has a different frame than a 1st gen Trooper with the manual which is causing the issue.

If you wanna read about my project to get ideas:
Yep, has to weld some extended flanges to the old xmember and added some additional mounting points along the frame to keep it from flexing. Seems pretty solid!
Thanks for the help. Now on to wiring!
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A couple of diagrams, maybe that'll help with wire colors, routing & such.

Font Rectangle Parallel Schematic Slope
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Rectangle Handwriting Font Parallel Diagram
 

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The automatic Troopers and the manual Troopers use a DIFFERENT frame. The automatic tranny is LONGER that a manual tranny, so the crossmember mounts on the frame are too far back. You either have to cut them off and reweld them in the correct place, or (like I did) make straps from 2" x 1/4" stock, drill a hole and bolt them to the frame forward and to one or more of the original crossmember mount holes, then fit and drill holes in the straps to mount the crossmember. THIS WORKS. I put thousands of miles on mine after doing the swap this way. I pulled all kinds of trailers and vehicles and some stumps (broke the carrier bearing doing that). The crossover pipes (3 out of 4) are different too, as well as driveshafts. Dennis
 
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