What's new
CK5
Register an account today to become a member! Once signed in, you'll be able to participate on this site by adding your own topics and posts, as well as connect with other members.

NV4500 Swap

longbedder

longbedder

3/4 ton status
Staff member
Moderator
Joined
Oct 26, 2005
Posts
6,704
Reaction score
10,304
Location
Ridgecrest, CA
I did a cursory search and came up with some piecemeal info...but I didn't find a definitive thread for the info I'm looking for. At any rate, this gets me outta the Lounge :haha:

Current setup:
  • 6.2L diesel w/Banks turbo (mention the turbo because there is a downpipe which may or may not matter)
  • 700R4 (27-spline output)
  • 1983 chassis (tall Trans -> TCase adapter)
  • NP208
  • HAD driveshaft with slip front yoke
I'd like to go manual. What am I going to need besides:
  • Manual center hump for cab (SM465 donor vehicle or just cut a hole in my current setup?)
  • Pedal set w/ master cylinder (donor vehicle specs?)
  • Flywheel (recommendations?)
  • Clutch (recommendations?)
  • NV4500 itself (what year/features should I look for?)
  • T-Case adapter?
  • Switch to NP241 with 32-spline input?
From what I gather, the trans length won't change between these two so the crossmember and driveshaft shouldn't need to change...correct?
 
longbedder said:
I did a cursory search and came up with some piecemeal info...but I didn't find a definitive thread for the info I'm looking for. At any rate, this gets me outta the Lounge :haha:

Current setup:
  • 6.2L diesel w/Banks turbo (mention the turbo because there is a downpipe which may or may not matter)
  • 700R4 (27-spline output)
  • 1983 chassis (tall Trans -> TCase adapter)
  • NP208
  • HAD driveshaft with slip front yoke
I'd like to go manual. What am I going to need besides:
  • Manual center hump for cab (SM465 donor vehicle or just cut a hole in my current setup?)
  • Pedal set w/ master cylinder (donor vehicle specs?)
  • Flywheel (recommendations?)
  • Clutch (recommendations?)
  • NV4500 itself (what year/features should I look for?)
  • T-Case adapter?
  • Switch to NP241 with 32-spline input?
From what I gather, the trans length won't change between these two so the crossmember and driveshaft shouldn't need to change...correct?
Click to expand...

where’d you hear the trans length won’t change? I’d be surprised if a 700r4 and nv4500 were the same length, but I guess it’s possible.

I’d recommend the 12” clutch as I am able to slip my 12” a little bit every once and a while. I can’t imagine an 11” would be good unless it was a light underpowered truck. Clutch activation can be either internal slave or external slave depending on what’s in the way. The internal slave is on the passenger side above the front drive shaft so you need to watch that for clearance. Switching requires a different bellhousing which doesn’t necessarily come with the trans. (Advance adapters makes one)

definitely will need a 32 spline input transfer case.
 
bp71k5 said:
where’d you hear the trans length won’t change? I’d be surprised if a 700r4 and nv4500 were the same length, but I guess it’s possible.
Click to expand...
I found it in a few places when I searched NV4500 swap.

Actually...it seems like (based on said search results) I oughta just drag @ZooMad75 into this conversation...
 
85-87-91 hydro clutch master / pedal combo will work a external slave nv4500 just fine . i know one i did for a build thats been working great for years now . just need part of the hard line from the nv4500 slave up and over to the flex line from the pedal master . then cut / flare a nut on and use a union to connect and bleed out . FYI : its metric bubble flare for the stock stuff . so try and get a nut and union for this to save from custom hose rework later if you need to swap in a hose .

4x4 nv4500 is the adapter on the back for the round 6 pattern t-cases . so no real adapter needed . unless doing a 205 . then there is a few options . but sounds like you want 208 or 241 case.

we used a std old school flywheel and generic 12" clutch kit for his built 400 sbc with the swap . he turns 4.56 gears and 37" tires no problems .
 
bp71k5 said:
where’d you hear the trans length won’t change? I’d be surprised if a 700r4 and nv4500 were the same length, but I guess it’s possible.
Click to expand...

They are within a 1/4" between an 700 and a 4500. That's measuring from the face of the bell housing to the face of the t-case mounting surface. So on the 700 that includes the t-case adapter. But since the 4wd version of the 4500 has the same 6bolt round mounting flange built into the 5th gear housing it has no extra adapter in-between it and the t-case.

But to add to that, the 4500 bolted into my truck, replacing a factory 700r4 with zero modification. The cross member is in the stock location and both driveshafts we took out during the swap bolted right back in.

As far as a clutch goes, you need to get one that fits the application of what 4500 you end up with. Yes, there is a difference between external and internal slave setups. '95 and earlier will take a standard clutch that would go with a 465. The '96 and later is internal slave and all parts lookups (GM or aftermarket) show a different part number for the pressure plate.

It comes down to what year 4500 you get or shoot for. Personally I would target the '96 and later version. Internal slave setup is less cumbersome to deal with than factory external slave on the wrong side (same side as your front driveshaft which will require a body lift or tall springs to make sure you clear it) or an expensive advance adapter bell with external slave and adapter brackets.

Using $40 worth of Earl's adapters and a line you can adapt the late internal slave to the stock squarebody master cylinder.
My clutch feels just like the clutch in my '97 S10 with factory installed 5-speed since they use the same internal slave. Add in a Centerforce clutch for some holding power and it's a strong combination.
 
Last edited:
When I did my swap the 700 and nv were really close in length!
 
@longbedder, read through my CUCV thread. It was a very similar 6.2/NV4500 swap. Your 1983 cross member will need a spacer block, but everything else should fit right into place. An SM465 bell housing can be modified to fit an early GM NV4500. I used a hydro bell housing, @Chevy305 used a mechanical one on his NV4500 swap (perhaps from AA?). Having a transmission hump can be nice, but you can simply cut a hole in your existing floor. Expect a stock NP208/NP241 shifter bezel to interfere with your NV4500 shifter (several ways to solve this). Use a single-mass 6.2/6.5 flywheel and a clutch set that matches your year of transmission. Dual mass 6.5 flywheels have reliability issues (though they're nice up until they fail). Hydraulic clutch setup comes from any 1985+ manual-trans squarebody.

92-95 NV4500s use external slave cylinders. 96-up NV4500s use internal slave. 92-94 NV4500s have lower crawl gear and a one-piece top. 95-up have removable shift tower. So 95 is an oddball year. Any of them will fit into your truck, as long as you're not trying to mix-n-match bell housings.

A few different styles of internal slave cylinder exist. I wound up using a GTO slave in my NV3500 because it used a threaded fitting instead of the push-lock style. No need for splicing the hydraulic lines, I just used an M12/M10 adapter coupled to the stock squarebody hydraulic line. Again, there are several ways to accomplish this piece of the swap.

Post up specific questions as they pop into your head.
 
campfire said:
@longbedder, read through my CUCV thread. It was a very similar 6.2/NV4500 swap. Your 1983 cross member will need a spacer block, but everything else should fit right into place. An SM465 bell housing can be modified to fit an early GM NV4500. I used a hydro bell housing, @Chevy305 used a mechanical one on his NV4500 swap (perhaps from AA?). Having a transmission hump can be nice, but you can simply cut a hole in your existing floor. Expect a stock NP208/NP241 shifter bezel to interfere with your NV4500 shifter (several ways to solve this). Use a single-mass 6.2/6.5 flywheel and a clutch set that matches your year of transmission. Dual mass 6.5 flywheels have reliability issues (though they're nice up until they fail). Hydraulic clutch setup comes from any 1985+ manual-trans squarebody.

92-95 NV4500s use external slave cylinders. 96-up NV4500s use internal slave. 92-94 NV4500s have lower crawl gear and a one-piece top. 95-up have removable shift tower. So 95 is an oddball year. Any of them will fit into your truck, as long as you're not trying to mix-n-match bell housings.

A few different styles of internal slave cylinder exist. I wound up using a GTO slave in my NV3500 because it used a threaded fitting instead of the push-lock style. No need for splicing the hydraulic lines, I just used an M12/M10 adapter coupled to the stock squarebody hydraulic line. Again, there are several ways to accomplish this piece of the swap.

Post up specific questions as they pop into your head.
Click to expand...
That's right, I used the Advance Adapters bell housing with a bracket they sell to locate the mechanical clutch Z bar. It's a nice piece though they are proud of it. It'll allow you to run either a mechanical clutch linkage or a stock square body hydraulic clutch with driverside slave cylinder in the stock location. It's totally up to you how you want to set yours up.
 
So I think I'm hearing that (since I'm not in any kind of hurry) I probably wanna hold out for a '96+ complete with bellhousing?
 
longbedder said:
So I think I'm hearing that (since I'm not in any kind of hurry) I probably wanna hold out for a '96+ complete with bellhousing?
Click to expand...
Depends on availability and how soon you want to make the swap happen.


If you have time, I'd hold out for the later one.
 
ZooMad75 said:
Depends on availability and how soon you want to make the swap happen.


If you have time, I'd hold out for the later one.
Click to expand...
Put it this way: the truck works just fine today - I DD/wheel it when it's not too hot out (it never had A/C from the factory). This is just a wild and expensive hare out on the project horizon.
 
longbedder said:
So I think I'm hearing that (since I'm not in any kind of hurry) I probably wanna hold out for a '96+ complete with bellhousing?
Click to expand...

Depends on your preference. Having dealt with a few failed slave cylinders over the years, I prefer external. So much easier to service.

Especially if you're the kind of driver that dumps his truck into a swamp and rusts up the slave cylinder bore. ;)

:haha:
 
campfire said:
@longbedder, read through my CUCV thread. It was a very similar 6.2/NV4500 swap. Your 1983 cross member will need a spacer block, but everything else should fit right into place. An SM465 bell housing can be modifie

Post up specific questions as they pop into your head.
Click to expand...

good info, thank you.

Im getting ready to throw a 02 internal slave 4500 behind my sons 6.2 in his 87. Do I understand that I need a 6.2 flywheel and 02 clutch assembly? I saw you said you used the GTO throw out, is there any reason to do that in this application, or just run a stock one? Im planning on using a wilwood master and just fab a bracket up to get away from the remanufactured factory units so the master orientation will be correct

any info on what starter I will need? 6.2 with a 465 or am I going to get really lucky and be able to reuse the automatic starter?
 
Last edited:
plugugly said:
good info, thank you.

Im getting ready to throw a 02 internal slave 4500 behind my sons 6.2 in his 87. Do I understand that I need a 6.2 flywheel and 02 clutch assembly? I saw you said you used the GTO throw out, is there any reason to do that in this application, or just run a stock one? Im planning on using a wilwood master and just fab a bracket up to get away from the remanufactured factory units so the master orientation will be correct

any info on what starter I will need? 6.2 with a 465 or am I going to get really lucky and be able to reuse the automatic starter?
Click to expand...
Starter is the same.
As for the clutch yes you are correct.
If you have the stock throw out bearing you can use it, I believe some people use other throw outs for different fittings options for easier adapting to our trucks.
I haven't done mine yet but I have all the parts.
Mine is an early 94 so different setup
 
plugugly said:
lincoln huh, you are right next door.

the 465 starter is the same? Im guessing the auto and manual trans starters are different. We are swapping from an auto.
Click to expand...
The starter bolts to the engine so it doesn't matter what transmission.
The older cast iron bellhousings on the early 465 had the starter bolt to it but not the newer aluminum bellhousings
 
plugugly said:
lincoln huh, you are right next door.

the 465 starter is the same? Im guessing the auto and manual trans starters are different. We are swapping from an auto.
Click to expand...
I didn't notice you're from Rocklin, I usually check.
Cool, we should meet up sometime
 
You must log in or register to reply here.

Latest Posts

Top Bottom