4spd-->5spd ea trans 'clutch parts options'

[TajMan]

Apparently this wasn't completely documented properly before, even though many people have completed the 5spd swap into an old 4spd manual car.

 

So you have a ea81 engine in a car that used to be 4-speed, and now you want to use the 5-speed trans out of a former ea82 car.

 

from what I've learned, here are your 'clutch parts options'

 

option1:

-use a large ea81 4-speed flywheel(recessed), but have a machine shop surface down the outside lip 'to a .815" step. That means machining down the outside edge by about .1" or so.'

ea81 modified flywheel gets used with an ea82 pressure plate and TOB which were used on the 5-speed car from factory. And the 5-speed clutch disc will fit with its correct pressure plate no problem.

 

option2:

-use an ea82 flywheel AND pressure plate AND TOB all from the 5spd car. The bolt holes to the crankshaft are different than ea81, use ea81 bolts and probably rock the flywheel clockwise with all bolts slightly loose before you torque them to 55ft-lbs, should be fine this way, thanks GeneralDisorder. I believe ea81 engine bell-housing needs to be ground/clearance'd a little to keep ea82 flywheel from coming into contact, and timing marks for the ea81 engine need to be transfered/scratched onto the new flywheel.

 

option3:

-custom Isuzu Trooper TOB option like I'm finishing up, stock ea81 large flywheel and pressure plate are used with custom TOB solution, and starter motor needs to be spaced out with washers 2.6mm-4mm to accommodate for the deeper ea81 flywheel (5-speed trans starter is spaced differently, you don't want teeth grinding). 5-speed clutch disc for this option can be tricky to source, clutch center hub has to be small enough to fit inside recess of ea81 pressure plate (stock piece had 6 small hub springs). Local clutch shop finally got me the kind of custom disc solution I needed.

 

Custom TOB solution comes from an 85 Isuzu Trooper 4cyl manual car,

YOU ACTUALLY MAKE AN ENTIRELY 1-OFF T.O.B. USING PARTS FROM THE NEW ISUZU BEARING AND BRACKET FROM THE OLD 5-SPEED T.O.B.

 

Here are my pics, you can see where I'm at. I believe if I can get some type of steel washer ring for support, this TOB should work and not risk cracking the plastic of the insert..

 

 

I will post with what I work out for my setup and how it goes.

[Gloyale]

In the trooper that bearing goes with a carrier piece, that should mate up to the EA82 clucth fork. when I suggested the bearing, i thought a new one would include the carrier.

 

could source one from a wrecker?

[TajMan]

THAT MAKES A LOT MORE SENSE!

lol

 

It appears if I want one of those, I'd need to drop a Trooper transmission myself in the junk yard!

jeez no thanks, before that I think I'm trying to get my 1.5"-2.5" ring to work..

Edited January 24, 2012 by TajMan