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1996 Isuzu Wizard manual conversion

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1996 Isuzu Wizard manual conversion

Postby WIZ96 » Tue Mar 28, 2017 7:54 pm

Hi, I have a gearbox out of a bighorn Irmscher 4jg2t, AS-5 transmission, and want to convert my 96 wizard 4jg2t auto..
I see that the transfer case on other manual boxes are bigger would it be better to get another box with bigger case or is the AS-5 ok to bolt up?

Thanks
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Re: 1996 Isuzu Wizard manual conversion

Postby geeves » Wed Mar 29, 2017 5:16 am

You should be ok with the box. Only catch with the box itself is the gear stick. If you can find a Mu or Rodeo box it has a remote unit to place the gear stick further back.
You need a front driveshaft out of a manual Mu and you need to have your rear driveshaft modified. Also the gearbox crossmember needs modification. Remember a gearbox change is not a certificate required mod but welding the chassis is so look for a non cut or weld solution
Sanding your knuckles before starting work can help. That way you cant skin them
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Re: 1996 Isuzu Wizard manual conversion

Postby WIZ96 » Wed Mar 29, 2017 10:06 am

Ok, Thanks for that. Would you know if another manual box would be easier to use the Mua?
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Re: 1996 Isuzu Wizard manual conversion

Postby geeves » Wed Mar 29, 2017 3:23 pm

only box that will bolt to the 4jg2 without an adapter plate
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Re: 1996 Isuzu Wizard manual conversion

Postby WIZ96 » Wed Mar 29, 2017 6:13 pm

Thanks so ill have to start thinking about cross member mod.. Thinking of using a plate from existing CM to suit?
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Re: 1996 Isuzu Wizard manual conversion

Postby isuzurob » Wed Mar 29, 2017 7:00 pm

Any modifications to any mounts will need certing, also 3.1 wizard never come out factory manual so legally it also needs cert along with modified drive shafts
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Re: 1996 Isuzu Wizard manual conversion

Postby geeves » Thu Mar 30, 2017 4:48 am

My understanding was that if you use unmodified mounts you are ok meaning making an adapter to go from the gearbox mount to the existing crossmember you are ok. However the new rear driveshaft would still trigger certification so welding mounts no longer such a bad idea
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Re: 1996 Isuzu Wizard manual c onversion

Postby WIZ96 » Thu Mar 30, 2017 5:33 pm

Oh ok thanks. I Bolted box up the gearbox this morning and both driveshafts bolt up, although the shaft that slides on DS is nearly at its
full travel on both driveshafts.. Is that oK?
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Re: 1996 Isuzu Wizard manual conversion

Postby geeves » Fri Mar 31, 2017 7:39 am

I dont know a lot about driveshaft splines but I would of expected at least a third travel left. Also no sideways movement.
Sanding your knuckles before starting work can help. That way you cant skin them
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Re: 1996 Isuzu Wizard manual conversion

Postby WIZ96 » Fri Mar 31, 2017 8:13 pm

Great, I am going with the adapter plate, looks straight forward. I think the shafts will be fine.. Just not to sure about the drive shaft angle
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Re: 1996 Isuzu Wizard manual conversion

Postby WIZ96 » Tue Apr 11, 2017 7:08 pm

Would I have to swap my diff for a manual one or is the auto ok to use?
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Re: 1996 Isuzu Wizard manual conversion

Postby geeves » Wed Apr 12, 2017 7:43 am

they are the same
Sanding your knuckles before starting work can help. That way you cant skin them
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Re: 1996 Isuzu Wizard manual conversion

Postby Chewie1990 » Mon Jul 13, 2020 3:47 pm

Manual conversion from mu to wizard do I need to olter drive shaft
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