NV 4500 conversion?

[Cschafer]

Well I finally got around to pulling everything out of my 96 parts truck and I had a couple questions on replacing the getreg. What has to be done with the clutch hydrolics,Anything? Will the 205 bolt right up to the back of the nv and are the output shafts the same size in both trannys? I am going to build a new crossmember anyways so that really doesent matter. Is there any thing else to look out for while doing the swap?

TIA
Cade

[Fnschlaud4620]

My cousin did this same thing, he used the 205 that was in behind the getreg he had to turn the front housing on the 205 in the lathe to make it fit the rear seal on the nv4500. Other than that it went right in. He had an oil leak because he didn't turn it small enough the first time, and the seal burnt up. but the second time he did it right

[BobS]

Pop the rear seal out of the NV4500 and let the coupler get lubed by running it in the transmission oil. The NV4500 rear mounting is a direct bolt on replacement for the Getrag G360. You also will need to fabricate a transfer case shifter mount or just buy the one from Advanced Adapters.

[Cschafer]

shifter mount wont be a problem. So I am assumining that the 205 has a front seal in it and you just use the bolt flange to seal the trans? What about the clutch hydrolics, are they a bolt in or do I have to mix and match some parts from the 96?

[KTA]

If you use the 2nd gen bellhousing you will have to use the hydraulics and clutch fork for it, if you use the 1gen hsg and fork use the original hydraulics.

[BobS]

Adapter fittings may also be needed if you choose to lengthen the clutch hydraulic hose or make up a new one. They are available from Russell Performance:
http://www.russellperformance.com/auto/ ... pt-2.shtml

[Cschafer]

I wasn't aware that you could use the first gen bell housing. What is a better setup? Obviously the original stuff would be easier but I am putting in a Mitchel twin disk and I'm pretty sure the 96 parts truck has upgraded hydrolics to push it. I'm also assuming that the clutch master cylinders are different and I cant swap the whole system. Will the first gen stuff push the twin disk or should I just go for everything now. Thanks guys for all the help!

[KTA]

Because of the twin disk you should use everything from the donor including the flywheel housing.

[CanadianCummins]

hey every one im new to the posting thing so bear with be. im also doing a nv4500 swap(getrags on her last legs) and was wondering how the bellhoushing from advanced adapters is? i heard from dan at quad 4x4 that they were garbage. but high impact says there good. lol who to believe??? will the stock getrag hydralic stuff work good in case down the road i went to a twin disc like cschafer. for now the trucks stock... but upgrades are pending after tranny swap and i was planning on a southbend mu0090 from piers for now till things get crazy lol or should i hunt down stuff from a 94 up truck. .... i may never need a twin disk but i just want the best option now so its done if i need to do something crazy later.
Thanks James

[dpuckett]

Canadian Cummins- I'd just rebuild the Getrag and stick it back in there. Chances are, it only needs bearings and synchros, maybe an input shaft or 1-2 synchro ring, and PROPER preload set up. I think KTA still has a Getrag in his old beast, holding well over 1000ft-lbs. I havent had any problems after properly setting up a Getrag. Just overfill and dont lug- keep RPMs at 1500+ at all times. They also are not the fastest shifting tranny out there. If you do the work yourself, you can rebuild the Getrag 3-4x by the time you pay for the NV4500 conversion. But, if you do the conversion, be sure to send the old Getrag to Terre Haute of Cape Girardeau

Daniel

[Cschafer]

Well now that I have a little more experience I maybe able to help a little. I don't know about the advanced adapters belhousing but here is the deal. The transmissions are very close in length, they have the same input
shaft and input length. The bareing retainers are differnt size though. The bolt pattern on the bellhousings are differnt were the trans bolts up. The clutch master and slave cylinders are the same but the line is differnt. The line is also of hard plastic and doesnt come off the master cylinder. But the master cylinder is the same so just find a second gen complete setup and switch it out. The problem I ran into is one last check before I put the bellhousings in I measured and the housings are about 5/8 differnt in length. The difference is in the engine adapter. So to do a complete swap you will need the following.

Complete hydrolic setup for 2nd gen
Engine adapter out of 2nd gen
Bellhousing out of 2nd gen
Not sure on the starter but sombody told me they were differnt.
Cut about 5in out of tunnel for new shifter location
build or buy 4x4 shifter bracket
adapt trans crossmember to differnt mount(have seen it done with a simple square tube)

If I were you I'd rebuild the getreg
good luck