Mudslutk51984
Registered Member
Anyone done this yet? Difficulty level parts prices and time frame??
CK5
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Auto to manual trans swap
- Thread starter Mudslutk51984
- Start date
85-Up it’s easy especially with a hydro clutch, think it took me an afternoon and I used resources on here to do it. Not being an ass but pretty much any question you could have, has surely been answered. Granted this isn’t pirate4x4 where you’ll get flamed, but reading and research can take you a long way on this forum before asking questions.
So, searching this isn't that easy. Lots of terms used for manual swap, manual conversion, etc.
Anyone run across a good thread discussion trans options?
Which swap are you contemplating? Find a good build thread that covers the swap you're looking to imitate. SM465 swaps are very well documented on here and elsewhere.
I did TH400-->NV4500:
https://ck5.com/forums/threads/nv4500-rebuild-questions.316823/
https://ck5.com/forums/threads/the-green-grendel.322496/unread
And 700R4-->NV3500:
https://ck5.com/forums/threads/school-me-on-nv3500-transmissions.322192/
https://ck5.com/forums/threads/the-great-smaug.313869/unread
Good plan.
Possibly 4l80e-->NV4500.
Thanks!
Possibly 4l80e-->NV4500.
Thanks!
In what chassis?
91 Suburban 2500 4x4. So square body.
4l80 is slightly longer so in my nv4500 205 swap measuring I would have to do driveshafts. The th400 to nv4500 goes right in.
Ok. The GM NV4500 will bolt up to the block & NP241, but it will be shorter than the 4L80e. Driveshafts will be wrong and the crossmember will need to slide forward. I do not know 100% whether the 4L80 cross member has the same height offset as the other cross members (though it seems likely).
Read up on the differences between 92-94, 95, and 96+ NV4500 transmission variants. The early bell housing puts an external clutch slave down in line with your front driveshaft (not a great location). The later bell housing has an internal slave with hydraulic lines exiting on the driver side. You can also use a square-body bell SM465 housing by drilling 4 new holes into the NV4500 case (or buy a custom bell from AA).
I used stock hydraulic clutch pedals in both swaps. Mechanical linkage can be used, with the proper bell housing. Novak-adapt offers a hydro conversion kit for mechanical clutch bell housings.
The length, bolting patterns, and mount are identical to the (late-model) SM465 your 1991 truck would have come with. So mixing and matching parts is quite easy.
Hardest part may be finding stock pedals and/or adapting mismatched hydraulic lines (if you keep the NV4500 slave cylinder).
Hm. Too bad there isn't an easy way to space these out.
Maybe a spacer would do it on the front shaft, and then just shorten the rear.
That's a great start, thank you. Not 100% sold on this yet, but definitely leaning that way. Don't really want to pay for another full 4l80e rebuild. Will start doing more research.
Hardest part may be finding stock pedals and/or adapting mismatched hydraulic lines (if you keep the NV4500 slave cylinder).
You can read through my M1009 thread for pictures and details. And ask up when you have specific questions.
https://ck5.com/forums/threads/price-drop-hydraulic-clutch-pedal-assembly.337747/
I used a Swagelok adapter fitting { I have the part # in my build journal }. The quality was great and it adapted the plastic hyd master line to the steel slave line. I think it was about $14.00. With a 6" lift there is all kinds of clearance for the external slave. I realize I have a "horse in this race" but the NV4500 swap was one of the best modifications I have ever done to a vehicle and I have been around a while.
Counter-point...on my NB3500 I had a stock 2004 slave cylinder, with braided plastic hydraulic hose. I wasn't happy with my ability to cleanly cut the braiding without nicking the plastic, and the 6mm line didn't...quite...lock into the 1/4" swagelok adapter. It might have just been user error, but I wound up buying a slave with a normal bubble flare fitting and using the stock square-body hose. There are a lot of ways to skin this cat.
On the 4500 I just used the SM465 bell, clutch linkage, and hydraulics. 100% stock squarebody stuff, paired with a non-squarebody transmission.
My one and only TH350 to SM465 swap in a '72 K5 like 30 years ago I swore would be my last--installing the clutch pedal was the worst part of the job for me,had to take out the steering colum and lie under the dash for two nights after work...installing the flywheel,bell housing,transmission was not so bad with a good jack,but I would just buy a truck with a manual if I wanted another one..(or pay someone else to do the swap)..
I swapped my auto for sm465 in my k5. Mechanical clutch so no hydraulics to screw with. Rebuilt the 465 myself, rock solid tranny. If you get a ranger overdrive for the 465 which is what I have, im pretty sure that combo is the same length as your 4l80e.
