NV4500 swap

[DOUG]

Finally got the tranny swapped in, NV400 5spd from a GM 3500 Duramax, 6.34 low gear.

I removed the 999 auto, converter, flexplate, cooling lines, etc... last week. Then got about prepping for the 5 spd. Swapped out the A/T pedals for M/T earlier, got the clutch master cylinder installed.

Removing the old pilot bushing (this was originally a 4spd) proved to be a challenge. Had to use the old "pack with grease and use a dowel" method, whack the dowel with a hammer and the bushing comes out...yeah right. It did eventually come out, but not without a boatload of grease pumped in behind the bushing. Installing the new one was a piece of cake.
Next I installed the flywheel, setup the clutch disc and pressure plate with new bolts, bolted up the bellhousing and starter while I was awaiting my help. He was bringing over the engine lift. The NV4500 weighs over 200lbs, no way we were going to lift this into place. The plan was to un a strap through the inspection cover in the floor of the Jeep, attach it to the trans and then use the hoist to lift it into place.
Sounds good in theory, doesn't it?
It does work, I can attest to that. It took the two of us muscling it in place, but it was the phone call made to Kurt that saved the day,,,err night. He suggested getting behind the tranny and push it with your feet. This is what got it the last 2 inches. It was getting the input shaft into the pilot bushing that was giving us a hard time.
So, we bolted the tranny to the bellhousing, then came the t-case.
It seems the NV is 3 inches longer than the A/T I had removed (man this thing is big). The t-case shifter was not going to go up through the original hole in the floor. I put the shifter in 4low (full forward) and we fanagled it into place. Stuck in 4low, I did not want to cut the floor of the 8. (more on this later)
With the t-case in I measured for driveshaft length, sure enough, the rear had to be shortened and the front had to lengthened the aforementioned 3".
The driveshafts were dropped at Montrose Machine in Wakefield for their alterations.

I set up and we bled the hydraulic clutch. This is a nice setup from Advance adapters. It's hydraulic, yet it's adjustable too.
Yesterday, I changed out the fluids in the tranny, and t-case. the NV takes special fluid, $17.00 per quart and it holds 1 gal.
Picked up the driveshafts today, installed them this afternoon, then went for a drive.

First let me say this...the NV is very noisy!!! More so than the NV3550 in the Rubicon. Driving the Jeep without the inspection cover in place and the top od the tranny poking up through the floor...you can only imagine.

But it shifts fine, took it out on the highway, the rpms have dropped considerably compared to the 3spd A/T.

I'll keep you posted as to how it goes...

[ZAEDOCK]

Awesome job Doug! I'm glad you're out and driving around.

[DOUG]

Thanks Joe, I'm happy with the way it drives, still got a couple of things to work on.

The t-case shifter was not going to go up through the original hole in the floor. I put the shifter in 4low (full forward) and we fanagled it into place. Stuck in 4low, I did not want to cut the floor of the 8. (more on this later)

Back to the shifters....the tranny shifter was angled way left, so moch so when in second gear the sknob was in the drivers seat, and the t-case shifter was in 4low with no where to go.
Broke out the oxy/acet heat and worked the heat on the shifters...then bent them til they were in the right location. Next on the list...building a tranny tunnel cover to accomodate the shifters.