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Nv4500 swap in m1008 HELP

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Slickm1008

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Howdy y'all

So, I got my meat hooks ahold of an nv4500 for a mere $550.

BUT I've got a th400 now. So, who offers a kit for all the BS involved in this swap? I know all the clutch crud is going to be a bit of an issue, then there is finding a bellhousing to mate it to my 6.2 diesel ...and maybe if there's anybody who dose a trans x member for the swap etc etc???

Those who have done this swap PLEASE let me know what issues you ran into etc!!!!!

Thank you thank you!!!

Take care fella's!!!
 
sick price on that trans, and welcome to the forums.

try using the search function to get the dirty details.

Im planning this swap myself in an m1009, from what ive read thus far youll need the cutch pedal assembly, and the proper diesel flywheel and clutch. (sorry no part numbers off the top of my head), the bellhousing from advance adaptors, the proper adapter to mate the nv4500 to whatever t-case youre running, and depending on how everything works, a new or modified set of driveshafts.

youd be perfectly fine running the np208, its a great transfer case with a nice low 2.6:1 low, and in your truck already has the stronger 32 spline input.

not sure about modding or replacing the crossmember, but im sure others here can chime in. trustyk5 has done this swap, as have several others that escape me at present.
 
Advance Adaptors is the place for NV4500 swap info. I'm doing this same swap in my 83 Chevy 4x4 gas and got the bellhousing from them. The diesel is another issue?? As far as the rear crossmember goes its a direct swap if its the style that humps up in the middle. The tricky part i'm running into is the shifter for the 208, it has that boxy plastic housing around it and that wont work with the location of the NV4500 shifter location thru the floor (its 4.5 inches farther back than the older 4 spd). Do you have a hydraulic clutch or linkage?? This trans is only 3/4 of an inch longer than the SM465 so the driveshafts will work fine the slipjoints can cover the 3/4 inch.
 
no sir, no parts so far at all... just the biggest part the truck
 
Advance Adapters will have the bellhousing you need to run a mechanical clutch.

If you want to run hydro (highly recommended!) you "should" be able to splice either the internal or external slave to a factory 85-87(91) hydraulic master cylinder that came stock in our trucks and use the bellhousing that is already on the transmission. I didn't know that at the time and installed a matching 92 new body style master cylinder on my truck, which was a fair bit of work. The NV4500 uses the same clutch as a SM465, so just order a 6.2L flywheel and clutch kit and go to town. Alternatively, you can spend the extra money and buy a 6.5L flywheel and clutch kit (make absolutely sure you get the single mass flywheel, avoid dual mass at all costs) like I did. It requires less effort to actuate due to the clutch pressure plate design (multi finger vs 3 finger).

You'll need to get a pedal assembly to match whichever way you go with the clutch, mechanical pedals for a mechanical clutch or hydro for hydro. Either way, make sure that you get a brake pedal that works with your hydraulic brake booster.

If you have a 32 spline 6 bolt round pattern transfer case in your truck, you can simply bolt it up directly to the back of the NV4500 and run it. I would not waste my time and money on doing an NP205 swap (shifter is a problem, concerns about too much weight on the aluminum tail housing of the NV4500, poor low range, no real added strength etc). You will be able to re-use your stock transmission crossmember and drive shafts as GM more or less standardized the lengths of all the transmission / transfer case combinations by around 82.

You will need to install a high hump transmission cover in your truck if not so equipped, and will need to cut out your own opening for the shifter to come through as the shifter is in a different spot than with the SM465. You will also have to move the transfer case shifter aft a few inches to make room for the NV4500's massive shifter boot.

You will need to find a reverse light wiring harness from an SM465 equipped truck to convert from the switch at the base of the column (no cutting involved, unplug from the column switch and plug into the manual trans harness) and you should also remove the park / neutral switch wiring and splice it into your clutch starter interlock switch on the new pedals to prevent the truck from starting without the clutch pedal down.

I've done this swap two times now, and actually just recently "downgraded" to an NV3500 for the better gear spacing to help my diesel engine out a bit offroad.
 
Ok, SO

What are the Exact donor vehicles I need to ask for the goods from?

Specifically I'm look'n for the bellhousing and pedal assy/master cyl etc for the hydraulic clutch???
 
ped assembly 85-91 square body = hydro clutch.

and if using 96-up int hydro clutch need the hose from the master.

then custom make your own hose from 85 -91 style to 96-up quick conect.

if me tho go the advanced adaptor mech bell route then this much better setup as its all outside and easy to repair. http://www.novak-adapt.com/catalog/kit_hcr3.htm edit : read non usable bell housings at the bottom of the gm section. wont work dam it.
 
As SweetK30 said, you need a pedal assembly from an 85-87 pickup or 85-91 Burb, Crewcab, or K5 equipped with a 6.2L diesel / SM465 combo. You'll need the master cylinder for the same year range of truck.

For the NV4500, it depends on what year your transmission is. If it is a 92-94 you need to get that year range of external slave bellhousing, if it is a 95 - 06 you need to get an internal slave bellhousing.

In either situation, you need to get all of the clutch related parts within the bellhousing (external slave, hose, lever arm, throwout bearing etc for external, hydro throwout bearing and hose for internal).

There are aftermarket fittings available for the hydraulic master cylinder to allow you to convert to the same fitting as the NV4500's hose. Check with Novak for that particular piece. Plug it in, bleed it and go.
 
sweet!

thx

the trans is said to be a 1993.

ok then EXCELENT!

you guys rock!!!

I guess I never knew the sm465 had a hydro clutch...

anyhow u guys r a HUGE help!!!!
 
Russell said:
As SweetK30 said, you need a pedal assembly from an 85-87 pickup or 85-91 Burb, Crewcab, or K5 equipped with a 6.2L diesel / SM465 combo. You'll need the master cylinder for the same year range of truck.

For the NV4500, it depends on what year your transmission is. If it is a 92-94 you need to get that year range of external slave bellhousing, if it is a 95 - 06 you need to get an internal slave bellhousing.

In either situation, you need to get all of the clutch related parts within the bellhousing (external slave, hose, lever arm, throwout bearing etc for external, hydro throwout bearing and hose for internal).

There are aftermarket fittings available for the hydraulic master cylinder to allow you to convert to the same fitting as the NV4500's hose. Check with Novak for that particular piece. Plug it in, bleed it and go.
Click to expand...


ummm... stupid question prolly, BUT for a stock bellhousing, I assume I need to get 1 from a 1993 with a 6.5l?? or are bolt patterns the same?

k thx once more
 
sbc/bbc/diesel all use the same bell pattern.

and its easy to install the hydro clutch in a 80's cab as the dimples are in the firewall were the extra holes need to be. just drop the steering colum out. drop the booster off the firewall. and unbolt and swap in.

fyi if you got vac brakes or hydroboost try and get the pedals/bracket from that. if not you need to swap around the studs for the boosters. in the firewall its easy. and the brake rod pin is in a diffrent location. bu the hydro pedal setup i had had both holes. so i just removed the pin from the auto brake pedal and welded it in the extra hole and perfect.
 
You can get a bellhousing and internal linkage from a 92-94 chevy truck with an NV4500 - Gas or diesel, it doesn't matter. There are cast iron and aluminum bellhousings, either will work fine for you.
 
ya but the ifs trucks run low mount slave on pass side. and if no lift or low lift can hit the front shaft.
 
Get a bell from Advance Adaptors, they also have a adaptor bracket so the 85-91 SM465 slave will bolt up and work. That was the route I took, the upside being easy off the shelf parts and no driveshaft clearance issues.

Rene
 
I forgot about the clearance issue -- My truck has around 4" of lift and it was still pretty close. If I had any real articulation up front, I definitely would have hit the slave with my driveshaft.

I didn't realize they had an adapter bracket to run the stock slave too -- Last I heard they used a mickey mouse landcruiser slave. Sweet deal, probably cost less than a stock bellhousing too!
 
Yeah, it was ~$400 for the bell, and another $40(?) for the bracket. i understood that the bell was machined for a Jeep slave, but it could have been a TLC slave...either way the adaptor bracket worked just fine. I could get some pic's of it this weekend.

Rene
 
Well, I paid $350 shipped for a factory bell, so I don't think that is entirely a bad deal for an early NV4500 at all. Saves a lot of trouble with the clutch stuff and makes the thing a bolt in swap less the trans tunnel modifications
 
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