Engine/Transmission (1994 - 1998) '96 Dodge 4X4 Automatic to standard shift conversion checklist.

[jbrowne]

I finally finished my conversion to NV4500. Here is what I have learned. Check list follows;

Remember before doing any wiring work on your rig, be sure to remove the ground wires from the batteries.

1. Block up rear of engine.

2. remove crossmember and belly pan.

3. Remove drive shafts.

4. Drain Transmission and transfer case.

5. Un plug all wiring and tubes.

6. Remove 4WD shift boot.

7. Remove shift lever.

8. Remove transmission cooler tubes

9. Remove cooler.

10. Remove transfer case.

11. Remove automatic transmission.

12. Measure both transmissions-the difference = drive shaft work.

13. Remove any wiring that you will not need.

14. Retain Park/neutral wiring and plug. ( GR/BK, BK/WT, VT/BK)

15. Remove automatic shift linkage.

16. Install new flywheel, clutch and pressure plate.

17 Cut out necessary metal for shift tower. ( Use std. trans. shift lever boot as pattern. )

18. Install new throwout bearing.

19 Install new pilot bearing. ( Ref. #16)

20. Check NV4500 to be sure that new type fifth gear retaining nut has been installed.

21. Replace rear seal.

22. Check transfer case input spline for 29 spline. If not you will need to replace the input spline and bearing.

23. Install transmission.

24. Install transfer case.

25. Hook up vacuum tubes and speed sensor.

26. Back to Park/Neutral plug. Make a jumper wire between WT/BK (ground) and GR/TN (start). Then for back-up light, from back-up SW on left side of shift tower, solder one wire to the jumper and the other to the VT/BK wire. (back-up light)

27. Install Resavour, slave and master cylinder for clutch.

28. Hidden in the wire mess at the bottom left of the steering column you will find a green plug with a jumper in it. Get rid of the jumper and plug what is left into the wire coming out of the clutch pedal position SW.

29. Hang new clutch and brake pedals.

30. Install shift leaver boots and knobs.

31. Install rebuilt drive shafts.

32. Install crossmember and belly pan.

32. Dont forget to refill both the transmission and transfer case.

Note; I know that you will be agast at the price of the transmission oil. (I paid $21. 00 per. qt. )

Have fun and plan on being down for three weeks.

jbrowne, -- email address removed -- for any questions.

 

[Hummin Cummins]

Three Weeks

Did you have a donor truck to do an actual swap between two trucks or did you take your automatic and just replace it with a standard? I may be doing this in the near future but we are going to use 2 trucks. I am hoping that we can just swap all the nessecary parts since they are both reg. cabs. How did it turn out? I hope you like it. I know I will and I hope the reciepient of my transmission will too. Its a big job but if it helps both parties get what they want its all worth it.

Chris

 

[jbrowne]

Hey Chris;

I got all of my parts from a local wrecking yard. The 5 speed actually came from a V10. It really isn't a difficult job to swap trannies. The thing that took so long was ironing out all the little things that can come up. The input spline had to be changed in the transfer case. The bearing that carries it had to be changed. I got the input spline from Ventures Truck Parts, 1-800-464-1713, www.venturesparts.com. ($187. 00) and the bearing from the Dodge dealership. ($60. 00) I hope that the two trucks are identical and you dont have the problems that I ran into. Let me know how you make out. Mine is fine now. I am really glad to be rid of the Automatic. There are probably a couple of things that I missed in the checklist, like remove the automatics shift linlkage, but you get the drift anyway.

Jim



'96 RAM2500 converted to dually W/1 ton springs and box, 230 HP, #8 Plate, valve springs, guages etc. all I need now is the 3500 emblems for the sides and I have a 1 ton.