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NV4500 swap experts

80' 427

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So I just bought a 94 NV4500 and my plan is to swap it into my 82 dually. Right now it has a 6.2 465 and a syncro 205. What is the cheapest and easiest way to get it swapped into this truck? Has any used a 94 external hydro bell housing? It the current syncro 205 would bolt up I would keep it but I am 90% sure this is not the case. ANY suggestions are great. This truck is becoming a service truck on the farm and I just thought is wouldn't hurt the mpgs to let it run a bit slower at speed.
 
The NP205 will bolt right up if it is a 32 spline 6 bolt round pattern case. You will, however, need to figure out how to hook the transfer case shifter up as the NV4500's tailhousing does not have the tapped hole for the big shifter bolt like the SM465 has. One option here would be to make the switch to a twin stick shifter setup which uses shifter cables instead of bolting up to the big bolt shift assembly.

I'd personally opt out from the 205 and switch to an NP208 or NP241 myself, but that would involve a new driveshafts whereas keeping the 205 would mean that stuff would stay the same. You may need a new transmission crossmember from a newer automatic truck if it uses the old puck style transmission mounts vs the single mount.

The NV4500 will use the same clutch as the SM465. Make sure you use the correct clutch fork however, the SM465 part is not the same. The external slave bellhousing will not work very well on a stock height truck. The slave sits on the passenger side and the driveshaft will hit it. Internal slave is a bolt on swap with a new input shaft retainer. You can use a stock 85-87(91) master cylinder with both the internal and external NV4500 slave cylinders and just make an -AN braided clutch hose to connect them together. There are adapters for both the master and slave cylinders to convert them to -AN fittings.

Your floor shifter hole will need to be modified. The shifter on the NV4500 sits a couple inches further back closer to the seat than the SM465 does. The SM465 wiring will plug directly into the NV4500.

All in all a fairly simple swap. You'll need to source the internal slave bellhousing and input shaft bearing retainer along with a set of hydro pedals with a master cylinder, a few clutch hose adapters and braided tubing.
 
If you don't want to mess with the hydro clutch you can get an advance adapters bell housing. I did that so I could retain my mechanical clutch linkage.
 
With the 93-94 someone said I can drill and tap the front of the nv4500 to the sm465 pattern. The current 205 should be a 10 spline race track. Thinking 208 or 241.
 
So it appears the 93-94 has a different bell housing. I see people talk about drilling them. Notice this advance adapters bell seems to only has the upper 2 bolts different.
http://www.advanceadapters.com/prod...95-gm-nv4500-5-speed-adapter-bellhousing-kit/

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