1st Gen G56 Swap

[Shadrach]

The early ( 05-07 ) ratios on the "AD" G56 are 1-6. 26 2-3. 48 3-2. 10 4-1. 38 5-1. 00 6-. 79

The later ( 07. 5- current) ratios on the "AE" are 1-5. 94 2-3. 28 3-1. 98 4-1. 31 5-1. 00 6-. 74



All the Dodge Cummins ring gears are 152 teeth and the starters from both 1st gen and 2nd gen gen are 13 teeth on the drive. Shadrach

 

[Shadrach]

The front half of the rear drive shaft has now been shortened by 4" and the shaft going to the front diff was lengthened by 4". The splined coupler for the t-case fits perfectly and the NP205 bolted up just fine, the only minor problem is you will need a curved 9/16 12 point wrench to get at the top two bolts, as they are real close to the floor. The floor needs some minor hammering here also.

As the journey continues the bank account gets smaller ,and smaller, each day. At least with this truck the expenses can be written off as it is a work truck. When we get around to doing mine it will just plain eat the money. Shadrach

 

[Philip]

Shadrach what are you doing on the speedo? The G56 doesn't have a speedo drive provision. On the 4x4 truck that isn't a problem with the speedo driving off the 205.

 

[Shadrach]

SBC doesn't make a hydraulic kit for 1st gens. We tried the 94-97 kit. The reservoir for the 2nd gen trucks mounts on a vertical firewall whereas our trucks have it mounted on an angled part of the firewall. If you move the res up high enough to be on a vertical part the hood would smash it off. Our solution was to remove and clean the original res and remount it, then VERY carefully remove the hose from the new res and attach it to the old one, being VERY careful not to get any air bubbles in the line. The slave cyl appears to be the same but the rod is different in length. You might be able to keep the original setup but you would need to change the rod length and add a cap to the end of it. Shadarch

 

[MMeier]

So, now how much is into this conversion?

 

[AKimmel]

Are you going to post any pics?

 

[Shadrach]

How Much $ you ask? Well as I said I am in Canada so prices will be different. but lets just say that the trans cost about the same as a Good used CTD. As far as pix I haven't figured that out yet as I am better with engines than computers. Shadrach

 

[therabbittree]

keep up the posts. . I will help with the picture if you need me... as for $ I spend a lot just on trans... I think it was about $2800 for the trans. . I forget the receipt is somewhere,,,,then the pto / hydraulic pump and controls, tank etc stuff was almost the same as the trans price ! I had the clutch already purchase fro the old getrag but i had to send it back and upgrade it for the G56 . . etc but that was a chunk of $ too. . I know doing the driveshafts and the other misc stuff like hydraulic lines / hoses is gonna cost me a chunk too, so I'm putting it off till spring time. . and I need a set of tires too. . ha even more $$$$$ ouch. This project made me cut up some credit cards. . its WAY easy to over do it. . tring to get finances back in shape first then finish the truck ha.

Thanks

Deo

 

[Shadrach]

Shadrach what are you doing on the speedo? The G56 doesn't have a speedo drive provision. On the 4x4 truck that isn't a problem with the speedo driving off the 205.

Sorry forgot to answer your question. Your right about the NP205. When we get around to doing this on my truck I will be mounting a divorced NP205. Why you ask? Isn't your truck a 2WD? Yes it is. I have a rebuild NP205 from an older Dodge. I want it so I can have a super low rev for spotting my holiday trailer. I just have to reach over and put in LOW range. There won't be a front drive shaft, unless I ever decide to convert it to a 4X4... Scratch that idea I have enough to do already. Shadrach

 

[Shadrach]

To get the plug for the backup light switch we had to order a wiring harness, cut the plug off it and attach it to the old wires.



Mounting the 4X4 shifter caused some problems, as the three mounting bosses aren't on the new trans. We like an opportunity to "improve" things. :-laf Don't forget the shifter is on the other side on 94 and newer Dodges. We left the shifter mounting bracket on the Gutrag. There are three bosses on the G56 that was usable, their just not in the right places. A tab was welded onto the front of the shifter assy and another on the bottom at the rear to use another boss. We had to cut a hole in the bracket as well for clearance of the dowel that mates the two half of the trans case together. The rod was cut and a sleeve welded in the middle to lengthen it 4". The original hole in the floor was retained. From inside the cab it looks stock.



Regarding moving the main cross member back. I originally said we were going to make the front of the three bolt holes the back one. This would work fine for most applications. Instead, because of his PTO we just moved it back one hole, and added a thick piece of angle iron to the back of the xmember and bolted the new mount to it. That way he didn't have to move the heavy xmember that the PTO sits on. The only draw back to this is the now the trans drain plug is above the edge of the xmember. Not a real problem as it won't be getting drained as often as the engine does, and a piece of stiff plastic or cardboard as a "ramp" will let the ATF+4 fluid run into a drain pan easily.

I am working on getting pictures and part number to you. Shadrach

 

[Shadrach]

Update She Runs Oo. BUT we did encounter a minor problem. When my buddy tried to start the truck for the first time the starter just spun and the engine didn't turn over After some head scratching and some #@$%! he discovered the starter wasn't engaging the ring gear. The starter was pulled off and bench tested. It worked fine. Now what? He spent considerable time measuring and remeasuring things. The thought of pulling things apart didn't make him happy to say the least, especially since he had been down for a week and needed to get back to work. At first he thought that the mounting pad where the starter mounts on the "trans adapter" was warped so he tried to "shim" the starter, but that didn't work. The starter wasn't going to mesh with the flywheel no way no how!. The solution : Simply install a 2nd gen starter So much for the modifications we made for the starter mount holes. The fuel line and brake lines had to be moved out of the way for clearance. I am happy to say that it has now made it's maiden voyage around the block, a rather large block mind you since he lives in the country. Other than the stick being "too close" for his personal taste he says it shifts great and is a vast improvement over the Gutrag. He has also driven a 97 with a NV4500.



He ended up reusing both the upper and lower 1st gen shifter boots. The lower one is no longer available from Dodge.



I had a busy week myself but am still working on the pix thing. Shadrach

 

[therabbittree]

cool!. . If you need pic help let me know. .

 

[Shadrach]

Here are some approximate dimensions - these are with trans adapter ( and bell housing on Getrag ) mounted on the trans
Overall length G56 31. 5" G360 27. 5"
To center of shifter tower G56 18. 75" G360 13. 5"
To front edge of PTO cover G56 12. 25" G360 9. 75"
To center of bolt holes for trans mount G56 28. 75" G360 24. 75"
Hole in floor for shifter needs to be 4. 5" square and moved back 5. 25"
When mounting G56 to adapter use 3/8 x 2" bolts but first tap out holes so the thread goes all the way down the hole as the old ones were only 1. 5" long
SBC clutch came with new bolts but no washers - reuse old ones
Reuse old bolts to mount "new" trans adapter

If anyone has any specific questions, other than about pix:-laf, please ask. Shadrach

 

[Shadrach]

My buddy has been driving around with the truck through the city and some short distances on the highway. He says the rpm at highway speed ( 115-120 kms -aka 70-75 mph ) are down about 100-150. The Getrag shifter boot is stretched a bit upward because of the larger diameter isolator on the new stick. The only real time the boot is a bit " tight " is in reverse, because rev is now near your right leg. It shifts smooth and the ratios are nice. I still have to take it for a drive myself. Shadrach

 

[therabbittree]

some pics from shadrach

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[therabbittree]

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[therabbittree]

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[therabbittree]

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[therabbittree]

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These are pics shadrach got me... . looks good. . lots of helpful stuff here!... . Good stuff

 

[Shadrach]

Thanks Deo Shadrach