Got my NV4500 installed!

[GMC Truck]

I recently installed a 93 NV4500 into my 1983 Chevy truck. This swap is a really easy although an expensive one. Starting with a used 1993 NV4500 from a GM 4x4 truck does make the swap easier. The 208 transfer case is a direct fit if you have a SM465 or a 400 turbo. You will need an Advance Adaptor's bellhousing to fit the new trans and don't forget thier linkage kit for the mechanical clutch linkage! Thier bellhousing don't have the mount for the crossbar piviot ball. The original clutch with the 465 trans will work just fine with the NV4500 so no extra cost there. NO driveshafts had to be altered cause the overall length is only 3/8 of an inch longer and the slip yokes can take care of that. If you have a straight cross member (long foot) then you need to fab a spacer for the rear trans mount, if your crossmember has the double humps (short foot)then you just have to drill a new hole for the mount. The biggest hassle is the shifter for the 208. You cannot use the plastic box that covers this shifter, it occupies some of the space of the new trans shifter boot location. The solution I came up with is to get another 208 shifter and cut the "ears" off that mount the plastic box. With the ears gone you can use a boot from a 203 shifter and the 2 boots (trans and transfer case) are close but will fit. The only thing you lose is the lighted indicator in the plastic box, but you should know the pattern by now. Unless you don't care you will need new carpet as well to make it look professional.
If you have any other transfer case than the 208 or the newer 241 this swap will be a lot harder and more costly. (driveshafts and adaptors) Pictures comming soon...

 

[GMC Truck]

Heres some of the pictures of the trans after rebuilding it and the mount spacer needed for the "long foot" crossmember. The 208 shifter detail before and after the boots installed. Heres some food for thought for those of you thinking of this swap... the trans I got was an early unit with the ultra low 1st gear. After driving the truck for a few days I have determined that this trans needs hiway gears for for normal driving (2.73 or 3.08) For offroading you should have 3.73 or higher, with about 4.10 being ideal. My truck has the factory 3.42 and I wish I had the newer model trans with the higher ratio. But the 5th gear is awesome 60mph cruise is now at 1400rpm!

 

[cdoggwsu]

Nice! Man, I'd love to do this someday.

Actually, looking at your install I think the 203 boot looks better than the 208 box anyway. I like the 4X4 indicator in the gauge cluster but really have no need to see it on the floor, too.

Install looks great!

 

[GMC Truck]

Yeh the more I drive it the more I like it! That trans is incredable, super smooth shifting and sooooo quiet. I had to heat and bend the shifter post that goes in the trans because when you pull the lever over for low and 1st gear it was hitting my leg, but other than that I really love this trans! Overall cost of this swap $1800.00 and change. Money well spent!

 

[1BEATK5]

1800 is pretty cheap for a nv4500 swap. i was looking to do this in my crew, and total was getting over $2500. looks like a clean install in your truck.

 

[GMC Truck]

1800 is pretty cheap for a nv4500 swap. i was looking to do this in my crew, and total was getting over $2500. looks like a clean install in your truck.

The swap dedends on your transfercase. if its a 208 or a newer 241 then the swap is almost a direct fit. If you have a hydraulic clutch it will be a little cheaper than my total. The key is finding a trans at a reasonable cost. Ideal is $400 to $600 (most are WAY overpriced) and try to find a GM version. Dodge had way more of them on the road than Chevy but you have to buy internal parts to swap them in.

 

[1BEATK5]

my 205 will bolt up to it with a cheap spacer. both my driveshafts will need modified. i already have a hydro clutch.
finding a trans thats in good shape at a reasonable price is the problem.
i was just going to find a cheap core, then buy a reman.

 

[Chevy305]

Hey great write up on the NV4500 swap!
Question for you though, I have a manual clutch (Z bar) SM465, will that bellhousing work with the NV4500?
And is the NV4500 only 3/8" longer than the SM465? I thought it was way longer than that? Or is the tcase adapter where the length comes in?

 

[Larry]

Nice swap GMC Truck. I like your solution for the 4wd shifter to replace the plastic bezel. I have a 1989 V2500 Suburban with an original SM465 that I plan to swap in a NV4500 sometime later this year. Plan to use the 241 that is in it now behind the NV4500. I did a NV4500 in my K10 last year with a NP205 tcase and I love it. After driving it for a year now I can’t stand driving this Suburban with a dump truck shifting 465. It looks like the hardest part of doing the NV4500 swap in the Suburban is the fact the turtle shell on the floor doesn’t bolt off like the K10 did. That will be a hassle to deal with. Here are pictures from my NV4500 swap into the K10.

Chevy 305,

No, your 465 bellhousing will not work with a NV4500. You will need to either use Advance Adapters bellhousing or get one from a 1992-1995 GMT400 C/K truck. The only problem using one of 92-95 housings is the fact the slave cylinder is on the passenger’s side, which isn’t usually a problem for most of us as we all run lift kits where the slave won’t interfere with the front drive shaft. There is one more option of using a 1996-2006 bellhousing with the integrated slave/release bearing. The only problem with that is the trans and bellhousing have to be stabbed onto the engine in one complete assembly which can be an issue on square body trucks that do not have removable turtle shells, as there isn’t enough room to poke everything up there in one assembly.

 

[GMC Truck]

Hey great write up on the NV4500 swap!
Question for you though, I have a manual clutch (Z bar) SM465, will that bellhousing work with the NV4500?
And is the NV4500 only 3/8" longer than the SM465? I thought it was way longer than that? Or is the tcase adapter where the length comes in?

As stated above your 465 bellhousing will not work cause GM changed the bolt pattern. Get the bellhousing from Advance Adaptors cause thier kit comes with everything to work with your "Z"bar linkage. Your clutch and throwout bearing will work just fine. The length is not a problem cause the driveshafts will take up that little difference with the 208 transfer case the 205 may be another issue because of the required adaptor? As of this writing I have several thousand miles on this setup now and its awesome.

 

[Chevy305]

Thanks for the replies guys!

 

[COCHEV]

What size tires are you running with your 3.42s?

Sent from one a dem der smart phones

 

[hillbilly deluxe]

Awesome looking swap. I know if I jumped into your truck that t-case lever would make me do a double take!

 

[GMCbigblock]

Job well done and I vote 5-stars for your project.

I like the NVG4500 and can't think going back to the old 4-speed, altough it remains the famous "rock-crusher". For info, I never had any problem with the NVG's in either of the swaps that I made to my two trucks ('93 behind 454 on my 1987 and '06 behind 496 on my 1981 truck). Good luck.

 

[yakmastermax]

Great info and pics. Nice to know how easy this swap will be.

 

[Upstate]

I have a '84 and '87. I have not made my mind up on which one will have the 4500 go in it. Both are currently autos. One being a Turbo 350 and the other being a 700R4. I have two NP 208s and one NP 205. I will likely install the NP 205 in there.

Correct me if I am wrong, I will need; Adv adapters bell and linkage, Flywheel, Sm465 throwout bearing, clutch disc and pressure plate, pedals and what else?