I've spent most of this week detailing the 4JG2 diesel engine.
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I boxed up the brackets, valve cover, etc and delivered them to my local powder coater. I should see some pretty parts back in 3 weeks or so. After I assemble the motor I’ll post another picture.
I spent the rest of today getting an idea of the needed modifications for the drivelines. The 1994 Bighorn 4JG2 w/ Aisin Warner automatic transmission uses the same driveline flange on the output of the transfer case (rear driveline) as the 1992 gas Trooper 5-speed. I slid off the 1992 driveline front yoke assembly and low and behold it slides right on to the 1999 Trooper rear driveline spline. I’m using the 1999 frame, frontend and rear end differential. Preliminary measurements indicate I won’t need to change the rear driveline length; we’ll see…
The Aisin Warner tranny is about 48.5” long. I crawled under my US 3.5L gas Trooper and measured the overall length of the GM automatic transmission. Believe it or not the overall length is the same. The Aisin Warner (AW30-80LE) automatic transmission is longer than the GM tranny but the GM bell housing is shorter. I think this is why the overall length is the same.
I won’t have the total answer until I get the 4JG2 diesel mounted on the 1999 Trooper frame. It looks like the transmission mount will be about 2.5” farther back from the current tranny mounts.