Day 2 Feed the clutch line across the firewall, it goes behind the AC hoses. Gearbox in. We had it sitting on a 3 ton jack and a small one under the transfer case. Went in easy. Do front drive shaft before putting in the cross member. Rear drive shaft in. Remove the box in the pedal box area. Clutch master in followed by the pedal box.
Still working out the ABS wrinkle. Wiring changes to follow.
Wondering if the conversion was a good idea.
PS Unplugged PCM altogether speedo still works. Test drove fine. Just need to sort pedal height/stroke out. Still playing with ABS.
Manual gearbox conversion
Re: Manual gearbox conversion
what was the issue with the abs? I cant see how the trans affects the abs
Re: Manual gearbox conversion
geeves wrote:what was the issue with the abs? I cant see how the trans affects the abs
Apparently there is a switch which I think screws into the transfer case which disables the ABS in 4L.
Also apparently there is a plug which can be removed from non ABS boxes and the switch screwed in.
Only got told this from a guy that replaced a manual box in a MU that had ABS with a manual box from a Jackaroo that didn't.
Interestingly he also said that engine RPM at 100 kph in 5th was 200rpm higher with the Jack box? doesn't make sense unless it was a MSG box.
Apparently there is a switch which I think screws into the transfer case which disables the ABS in 4L.
Also apparently there is a plug which can be removed from non ABS boxes and the switch screwed in.
Only got told this from a guy that replaced a manual box in a MU that had ABS with a manual box from a Jackaroo that didn't.
Interestingly he also said that engine RPM at 100 kph in 5th was 200rpm higher with the Jack box? doesn't make sense unless it was a MSG box.
Re: Manual gearbox conversion
My understanding regarding ABS and manual gearboxes is this.
There is a switch on the gearbox that knows when you are in 1st of 2nd gear (regardless transfer box ratio selection). Between the switch and the selector rods there is also a ball bearing and a small pin (about 20mm long) that is moved by detents on the selector rods. The switch gives a yes or no signal to the ABS and this somehow changes the parameters of the ABS ECU. If this small rod, and/or the ball bearing, is missing (as mine is) or the switch is faulty the ABS ECU will give an error message. I unplugged my switch and the error went away (I will fix it one day). It seemed to be triggered by the ABS ECU getting a signal from the speed sensor of say 80kph+ but the ECU thinking that the gearbox was only in 1st or 2nd gear.
FYI the Isuzu code JE5 = ABS
There is a switch on the gearbox that knows when you are in 1st of 2nd gear (regardless transfer box ratio selection). Between the switch and the selector rods there is also a ball bearing and a small pin (about 20mm long) that is moved by detents on the selector rods. The switch gives a yes or no signal to the ABS and this somehow changes the parameters of the ABS ECU. If this small rod, and/or the ball bearing, is missing (as mine is) or the switch is faulty the ABS ECU will give an error message. I unplugged my switch and the error went away (I will fix it one day). It seemed to be triggered by the ABS ECU getting a signal from the speed sensor of say 80kph+ but the ECU thinking that the gearbox was only in 1st or 2nd gear.
FYI the Isuzu code JE5 = ABS
Re: Manual gearbox conversion
ABS was simply the plug to the front left sensor was removed with the rest of the gearbox stuff (explained why i had a brown plug with no apparent home). I pulled the two wires out of the plastic tubing all the way back to the main plug then enclosed it in is own plastic tube and ran it back down. The ABS port was on a small bracket almost directly under the fuse box and near the bonnet catch lever.