Hey Dave!
I've got good news for you! That NV4500 will work very nicely behind your diesel.
You should be able to remove your stock transmission, and bolt the NV4500 into place using the mount from the 04 and the transmission crossmember stock to your truck. The mounts should be the same style, and should be in the same positions. Only reason I recommend the 04 mount is because it is newer than your original, which helps keep vibrations down. In addition to being able to simply bolt it straight in, the NV4500 is very close to the same length of your stock transmission, and will accept any 32 spline NP241 or NP208. That means you can re-use your stock speedometer equipment, and driveshafts. Being that the 04 has an internal slave cylinder, you won't have to worry about front driveshaft clearance.
For the clutch, you should be able to bolt that transmission directly up to your 6.2L diesel without any problems. Use a proper 6.2L flywheel and the same clutch disc, pressure plate and pilot bushing / bearing as you'd use if installing an SM465 transmission (or re-use your old stuff if your truck already has an SM465). I'd personally reccomend that you run the factory hydraulic clutch stuff from a 96 3/4 ton with an NV4500. The older slave cylinder will work with the 6.2L pressure plate, and allows you to use a master cylinder that can be retrofitted to the factory clutch pedals for our trucks.
If you do go for this transmission, I would very highly reccomend that you cut off the reverse switch wiring with as long as a pig tail as you can to splice them into your stock reverse wiring (if you have a manual now, don't bother as it plugs right in), and make sure that you get the shifter stick, shifter boot, and the foam block that goes between the top of the transmission and the floor pan.
As far as problems that I ran into goes, the biggest one is that the shifter on the NV4500 sits a fair bit closer to the seat than an SM465 goes. That means that your stock transfercase shifter will be in the way of the NV4500's shifter boot. You'll either need to move the t-case shifter somewhere else out of the way, or you'll need to find and install a very small shifter boot on the NV4500's stick.
I personally have an NV4500 from a 93 in my 80, and an NV3500 from a 04 in my 86, and both had the clearance issue, and both I retrofitted the hydraulic clutch system up. The internal slave stuff I used from a 96 on the NV3500 made for way less headache than the external slave stuff on the 93. Even with 6" of lift up front, I only have about 3" of clearance between the slave cylinder and my front driveshaft.
. Thanks for the help fellas....Dave
