Super Trooper Restoration

This is the place to discuss NON-diesel engine and driveline modifications.
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iPupGary
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Location: Vancouver, WA

Super Trooper Restoration

Postby iPupGary » Sun May 13, 2012 1:07 pm

Yesterday was the official start date for my Trooper restoration and diesel swap. I purchased a 1999 Trooper with a blown motor and also a 1992 Trooper. I’ll be using the cab off the 1992 and the frame, doors, fenders, hood and interior out of the 1999. I purchased a 4JG2 3.1L Turbo diesel w/ inner cooler from JDM Montreal, Canada for the power plant. Of course I’ll be converting the truck to veggie as well. I’m taking on the extra challenge of installing an Aisin-Warner AW30-80LE automatic transmission. So if you are interested in a diesel Trooper conversion, you are welcome to follow along with me as I take on my new challenge for the next year or two.


4JG2 3.1L Turbo diesel

DSCN1051.JPG



The first to do item Saturday was to pressure wash the frame, wire wheel a small amount of rust in preparation to give the frame a coat of hammered black paint.

I used a engine crane to lift the frame for cleaning and prep work.

DSCN1050.JPG


1992 donor Trooper

DSCN1056.JPG



Parts out of the 1999 Trooper

DSCN1055.JPG


DSCN1057.JPG


DSCN1061.JPG



-Gary
1982 Chevy Luv 2wd short bed diesel w/ veggie conversion (under construction)
1999 Isuzu Trooper 3.5L Gas

soot fart
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Location: Puyallup, WA

Re: Super Trooper Restoration

Postby soot fart » Sun May 13, 2012 1:32 pm

Way cool project Gary. That scrawny brother of yours is going to be so jealous! If you need any help locating anything up north let me know. Pm me your #s and address as I get to Vancouver occasionally. Jerry

jasonw86
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Re: Super Trooper Restoration

Postby jasonw86 » Sun May 13, 2012 10:30 pm

Is there a reason you chose that brand of paint? I painted my 84 ls frame with "Hammerite" brand paint with a brush around '97. Did that in an enclosed garage and sacrificed a brain cell or two. Killed many more removing the ls rubber moldings with goof-off and laquer thinner in the same manner. Looking forward to this build playing out. Good luck.
1984 diesel LS long bed 4x4
1983 diesel 4x2 long bed
1984 diesel 4x2 short bed MPG Plus
1984 diesel 4x2 automatic longbed
1982 diesel 4x4 LUV mikado shortbed
1986 gas LS 4x4 Trooper II 2 door
1984 turbodiesel 4x2 automatic longbed

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Halden
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Isuzu vehicle(s): 1983 Diesel LS Long Bed 4x4, 2 '84 Diesel I-Marks (Sold)

Re: Super Trooper Restoration

Postby Halden » Sun May 13, 2012 11:11 pm

This looks pretty dang epic. I'd love to see the finished results!
“Music is not a language. Any musical piece is akin to a boulder with complex forms, with striations and engraved designs atop and within, which men can decipher in a thousand different ways without ever finding the right answer or the best one” -Xenakis

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iPupGary
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Re: Super Trooper Restoration

Postby iPupGary » Tue May 15, 2012 1:26 am

I couldn’t find the Hammerite brand in a 1 quart size locally, only in a rattle can. Rustoleum version “Hammered” was available locally from Home Depot in a 1 quart size. I’ve used them both and they are good products. Hammerite color Black is more true black than Rustoleum’s Hammered.

-Gary
1982 Chevy Luv 2wd short bed diesel w/ veggie conversion (under construction)
1999 Isuzu Trooper 3.5L Gas

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iPupGary
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Re: Super Trooper Restoration

Postby iPupGary » Tue May 15, 2012 1:38 am

Today I finished painting the frame with 2 coats of Rustoleum’s Hammered. As you can see the color is more of a Charcoal grey than black.

DSCN1070.JPG


I also clean up the 4JG2 Diesel engine with some engine degreaser and some Simple Green.

DSCN1092.JPG


DSCN1094.JPG


-Gary
1982 Chevy Luv 2wd short bed diesel w/ veggie conversion (under construction)
1999 Isuzu Trooper 3.5L Gas

jasonw86
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Re: Super Trooper Restoration

Postby jasonw86 » Tue May 15, 2012 2:45 am

iPupGary wrote:I couldn’t find the Hammerite brand in a 1 quart size locally, only in a rattle can. Rustoleum version “Hammered” was available locally from Home Depot in a 1 quart size.


Ace Hardware and affiliates carry it here. Lowes and Home Depot don't have it, at least in my area. Did you stretch the pic of that tranny? It looks almost as long as my shortbed pup.

Going to venture a guess that it is about 38" long.
1984 diesel LS long bed 4x4
1983 diesel 4x2 long bed
1984 diesel 4x2 short bed MPG Plus
1984 diesel 4x2 automatic longbed
1982 diesel 4x4 LUV mikado shortbed
1986 gas LS 4x4 Trooper II 2 door
1984 turbodiesel 4x2 automatic longbed

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iPupGary
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Re: Super Trooper Restoration

Postby iPupGary » Tue May 15, 2012 12:28 pm

Jason,

The Aisin-Warner AW30-80LE Automatic is 42.5" to be exact from the bell housing to the output coupler of the transfer case. Jerry Lemond says this is a great automatic transmission but it is indeed very long. I’m sure I’ll have to shorten the drive line.


-Gary
1982 Chevy Luv 2wd short bed diesel w/ veggie conversion (under construction)
1999 Isuzu Trooper 3.5L Gas

jasonw86
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Re: Super Trooper Restoration

Postby jasonw86 » Tue May 15, 2012 12:45 pm

Wow, that is longer than most of Jerry's tall tales :lol:
1984 diesel LS long bed 4x4
1983 diesel 4x2 long bed
1984 diesel 4x2 short bed MPG Plus
1984 diesel 4x2 automatic longbed
1982 diesel 4x4 LUV mikado shortbed
1986 gas LS 4x4 Trooper II 2 door
1984 turbodiesel 4x2 automatic longbed

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iPupGary
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Re: Super Trooper Restoration

Postby iPupGary » Fri May 25, 2012 10:46 pm

I've spent most of this week detailing the 4JG2 diesel engine.

DSCN4648.JPG

DSCN4647.JPG


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.

-Gary
1982 Chevy Luv 2wd short bed diesel w/ veggie conversion (under construction)
1999 Isuzu Trooper 3.5L Gas

luvcamas
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Location: camas WASHINGTON

Re: Super Trooper Restoration

Postby luvcamas » Sun May 27, 2012 2:34 am

man oh man willy wonka is at it again :P . Hey jerry you never offered to drop by my place, are we not friends :? :( . It must be all those white t shirt jokes or maybe the mt bar thing. I know, its the fact that i let the secret out that you live at the old isuzu plant . Well if you do show up down here I will some mt. bars and a clean t shirt for you :lol:
1986 turbo/d 4x4 SB
2-1981 2wd diesel LB
1981 4wd diesel SB
1982 diesel 4x4 SB
1985 S-10 diesel extra cab 1981 2wd diesel SB /and several parts trucks

jasonw86
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Re: Super Trooper Restoration

Postby jasonw86 » Sun May 27, 2012 2:40 am

luvcamas wrote:...a clean t shirt for you :lol:

I'd start with the coveralls...they cover more surface area :lol:
1984 diesel LS long bed 4x4
1983 diesel 4x2 long bed
1984 diesel 4x2 short bed MPG Plus
1984 diesel 4x2 automatic longbed
1982 diesel 4x4 LUV mikado shortbed
1986 gas LS 4x4 Trooper II 2 door
1984 turbodiesel 4x2 automatic longbed

fallguy
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Location: athens ga

Re: Super Trooper Restoration

Postby fallguy » Fri Jul 13, 2012 3:40 am

Any updates????
91 isuzu pickup dropped 8" all around,weber carb,header,96 tacoma front bumper. i drive it like i stole it cuz thats the way she likes it!...no bags,no switches,just hammered!!!

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iPupGary
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Re: Super Trooper Restoration

Postby iPupGary » Sun Jul 15, 2012 3:55 pm

Before I left for the National meet I dropped off a box full of parts to have powder coated. I need the motor mounts in order to mount the motor on the frame and to size up the drive lines, which is the next step in the process. The powder coater is dragging his feet. It’s been 5 weeks and he only has half of the job done. I’m going to give him another call next week.

I was thinking that the drivelines were going to be one of the major headaches in the diesel conversion. I think I may get lucky.

If you have been keeping up with the postings, I’m using a 1999 frame, frontend, and rear end. The frontend uses a non-standard driveline (see photo 1). The 4JG2’s transfer case uses a front driveline mounting flange with a 50mm X 70mm bolt pattern. The 1999 gasser is totally different as you can see in Photo 1. So it turns out that the 4JG2’s mounting flange is the same as a 1992 US Trooper gasser (50mm X 70mm). So I removed the front end driveline mounting flange off my 1992 Gas Trooper’s frontend and low and behold it mounts perfectly to my 1999 frontend. I took a few measurements with my caliper to ensure it is the same design as the inside of the 1999 flange (see photo 2).

So I contacted Jerry Lemond to help me find a standard driveline with the 50mm X 70mm mounting flange on both ends. I took a few measurements to determine the length requirement for my front driveline. Jerry was able to find a front driveline off a US trooper that used an automatic transmission with the proper mounting flange and the correct length based on my measurements. I won’t know for sure if the driveline will be the proper length until I get the engine mounted.

As far as the rear driveline is concerned, I think I’ll get lucky with that driveline as well. The rear driveline slip yoke off the 1992 gas Trooper mounts directly onto the 1999 driveline. So I’ll use the rear portion of the 1999 driveline and the front slip yoke off the 1992 with the 4JG2 compatible 50mm X 70mm driveline flange. The 1999 and 1992 slip yokes are the same length as well. After making a few rough measurements for the rear driveline, I shouldn’t have to change the length of the rear driveline either. Again, I won’t know for sure until I have the motor mounted.

After I get the motor mounted on the 1999 frame, I’ll probably wire up the 4JG2 and the Aisin-Warner automatic transmission. I want to get he engine started and verify the automatic transmission is working properly before I take the project any further. The only control module I’ll need for this project is the Transmission Control module or TCM for short. The 3.1L 4JG2 that I purchased uses a mechanical IP so I won’t need the ECM for the motor.

Thank you for you interest. The fact that you guys are interested in this project helps keep me motivated to finish it.

-Gary
Attachments
DSCN4678.JPG
1999 gas Trooper (w/ auto tranny) front DL
DSCN4681.JPG
1992 Gas Trooper DL 50X70mm flange mounted on a 1999 Trooper frontend
DSCN4680.JPG
Early Model Trooper DL with 50X70mm mounting flange
DSCN4679.JPG
4JG2 transfer case DL mounting flange (50X70mm)
1982 Chevy Luv 2wd short bed diesel w/ veggie conversion (under construction)
1999 Isuzu Trooper 3.5L Gas

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heathw
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Location: Mcminnville, TN

Re: Super Trooper Restoration

Postby heathw » Fri Jul 20, 2012 10:16 am

I am jealous :). I would like to do this one day. Why did you use the 92 body instead of the 99?
91 Isuzu p/u Converted to diesel
86 4X4 Pup diesel


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