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465 to NV3500 Swap Q's

You're going to have to mix and match transmission and transfer cases, because they never put an NV3500 in our body style of trucks. They put them in the IFS trucks, and their transfer case has the front output on the wrong side. An NP208 or and NP241 are your choices.

Martin
 
Thanks for the quick response Russell. I was planning on swapping out the transfer case as well. Which transfer case would you go with? Does it matter? Is one easier to install than the other? Any ideas for a one stop shop donor vehicle? The truck does have manual lockers installed if it makes a difference. Thanks for the help.

You can use a 32 spline NP241, NP208 or a 6 bolt pattern NP205.

The NP241 and NP208 are almost identical, use the same driveshafts, shifter etc. The NP241 has a better low range and a bigger chain than the NP208 though. NP241 also allows for a slip yolk eliminator kit if you so desire.

I wouldn't put a 205 on the back of an NV3500 myself. Aluminum housing + big heavy case on the end + offroad use = busted. Plus, the low range sucks.
 
I think I'll be looking for a 96+ NV 3500 from a K1500. I'll check to see if I can use the transfer case from the same truck. Do I need anything else from this donor truck?
 
88-up 4x4 has driver side drop tcase. if putting in solid axle chevy stuff need pass side drop . unless your running a driver side pumkin axle.
 
I think I'll be looking for a 96+ NV 3500 from a K1500. I'll check to see if I can use the transfer case from the same truck. Do I need anything else from this donor truck?
 
Ok after a little more research. I'll be looking for a 96+ NV 3500 from a K1500 and a NP 241 transfer case from a 88+ K5. Transfer case will be a passenger side mount. Am I on the right track here? Anything else I should be looking for?
 
Ok after a little more research. I'll be looking for a 96+ NV 3500 from a K1500 and a NP 241 transfer case from a 88+ K5. Transfer case will be a passenger side mount. Am I on the right track here? Anything else I should be looking for?

You will need an NP241 from a 89 K5, Suburban or crewcab pickup to get a passenger side drop transfer case with a mechanical speedometer cable drive. The 90 / 91 NP241s are still passenger side drop but have an electronic speedometer sending unit. The newer NP241s beyond that are driver's side drop and will not work for you.

NP208 will work no problems. Just make sure whatever t-case you get has the correct spline count.

Also note that you can get a NV3500 from the 99 - 06 4.8L or 4.3L powered truck as well, they are the same as the 96+ NV3500s in the old body style trucks with a 350, 305, 4.3L etc.
 
Ok. So, the NP208 was available on the K5 after 1980, right? And they are passenger side mount? As long as the spline counts match between the tranny and the transfer case, I should be good to go?
 
If you can't find a passenger drop 241 with a 32 spline input, the input is a direct swap with the later 241. 32 spline inputs seem to be a lot easier to find in the driver drop cases. I'm doing this to put an NV4500 in my truck and will be doing it again for the NV3500 swap into my girl's K5. If you're going to play mix 'n' match in the junkyard, make sure you bring a pair of snap ring pliers. These things have like a dozen of them and they are not fun to remove without the right pliers.
 
Ok. Thx for all the help. Now to get parts. I'll keep you posted on the progress.
 
Im using a chevy axle instead. I got an entire frame with axles, 6" all leaf lift for $400 and a 208 out of a 86 to use. It ended up being cheaper to switch to pass. drop and buy the tcase instead of paying a fortune for the ford axle. The frame gives me all the leaf perches for my 4wd conversion and the 6" rear springs to put in the front for 10" of lift. Now no worries of the driveshaft/slave cylinder interfiering.
 
The S-10 NV3500 will not work for your application. While they will bolt onto your engine, they use a 5 bolt round bolt pattern for the transfercase instead of 6, and the shifter is right at the very tail end of the transmission, putting it up through your floor right about where your center console sits.

You need an NV3500 from behind a 4.3L V6 or 5.0L V8 (and rarely, the 5.7L) from a 96+ K1500. Absolutely avoid any NV3500 with an external slave cylinder on them. Not only does the slave interfere with your front driveshaft unless you've got a bunch of lift, but they are also extremely weak, and break very frequently even with just light and normal use. They also use a very crappy shifter assembly which frequently falls out of gear.

In about 96 they switched to an internal slave transmission, which is what you want to find. I am not sure exactly when they switched it, but there are two versions of shift rails. One is a single rail, and the other has several rails. You want the version with a single rail on it. They are the strongest version of the NV3500 from 88-98. GM continued using the NV3500 until at least 05, possibly up until 07.5. These transmissions are the ultimate in strength, and came behind 4.8L V8 engines which make more horsepower and torque than a Vortec 5.7L. I have one from an 04 in my K5, and have had no mercy with it power shifting and dumping the clutch over and over on it while mud bogging at full throttle with my 6.2L turbocharged diesel engine offroad, with poor gearing and 37" boggers with lockers. No signs of failure at all, no unusual noises etc.

Swapping them in is not a difficult task. They bolt straight in place of your SM465, using the same transmission crossmember in the same position, using the same mount even. They all have a 32 spline 6 bolt round pattern so you can use an NP241 or NP208. NP205 would not be a good choice, as there is no place for the shifter bolt. The clutch is the same as your SM465, no need to change the flywheel, disc or pressure plate. You need to use the hydraulic throwout bearing, of course. The shifter on these trucks sits a few inches back of the SM465, requiring you to cut the floor back a bit, and patch it up at the top. If you want to use the stock shifter boot, you will need to move the NP208/241 shifter back a few inches and shorten the shift linkage under the truck to match. To match the hydro clutch, I personally retrofitted a 93 K3500 bolt on type master cylinder onto my truck. I drilled a hole through the clutch pedal and used a 1/2" bolt with the head cut off / hole drilled through for a hitch pin to attach the linkage to the pedal. I have heard rumours, but have not tested just yet (give me two weeks...) that you can simply splice an 85-91 stock master cylinder to the clutch hose for the internal slave and use it without any trouble. Try at your own risk, you have to buy the master and the slave to get a new hose from GM. The reverse light wiring is a plug in kind of a deal, same connector as your SM465.

Let me know if you have any other questions or run into trouble!
Hi there, great information regarding the swap. My question for is how bad are the pre 96 nv3500s? How much lift is needed to clear the external slave cylinder? I can't find a good used nv3500 that has an internal slave. Have you got anything? Thanks, Dan.
 

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