auto to manual swap

[Mopar_Tim]

let me first say, please excuse my extreme noobness on this.



ok for all intense purposes this is for a first gen but its really going into my trailduster.



i bought a 92 2wd donor rig but its an automatic, got to good of a deal to pass up, so right now the truck has got an auto with overdrive and i want a 4x4 nv4500. i tried to do some searches but i got a bunch or posts that sorta answered my questions.



what i need is a list of every part i am going to need to do the swap, i have got the engine, np205 (29 spline), and a front dana 60... ... ... what other parts do i need, again i am a noob when it comes to manual trannys so be detailed



thanks guys

 

[RBergman]

you might want to ask at www.nwbombers.com

a few have done it

 

[Mopar_Tim]

link does not work... ... some one here has to have done this swap.

 

[RBergman]

sorry it should now

 

[pepecat]

I know you will need the brake/clutch assy, clutch slave/master cyl assy, Flywheel (pref. w/bearing instead of pilot bushing), clutch, bellhousing, clutch fork, and pivot ball, and all associated hardware. You will probably need a new x-member, in addition to driveline modification/shortening, etc... You will also need to figure out what goodies you will need for the speedo to work. I know what I needed to swap the 727 for getrag, in a 2wd... that's all I can do to help for now. Tdr Member Loco 1 converted his auto 2wd to an nv4500 4x4 recently as well. . I believe he got most of his info from dan at quad 4x4 and these boards.

 

[Mopar_Tim]

i sent a e-mail to dan hopefully he can help me out seems like he has got just about everthing you would need on his site.

 

[Mopar_Tim]

ok this is what i have come up with so far tell me if i am right



i will need a

new flywheel - new

flywheel bolts - ?

clutch assembly - new

clutch bolts - ?

all of which has to work with a 13 inch sbc

nv4500 bell housing - will a stock second gen bell work?

clutch fork - new

clutch hydraulic system - first gen 5 speed

clutch and break pedal - got a set from a 70's pw hoping to make that work with everything else

trans mount - first gen? custom?

transfer case linkage/hardware - buy a kit ? i want twin stick anyway

and of course the transmission _ new



am i on the right track

 

[RBergman]

ok this is what i have come up with so far tell me if i am right



i will need a

new flywheel - new

flywheel bolts - ?

clutch assembly - new

clutch bolts - ?

all of which has to work with a 13 inch sbc

nv4500 bell housing - will a stock second gen bell work?

clutch fork - new

clutch hydraulic system - first gen 5 speed

clutch and break pedal - got a set from a 70's pw hoping to make that work with everything else

trans mount - first gen? custom?

transfer case linkage/hardware - buy a kit ? i want twin stick anyway

and of course the transmission _ new



am i on the right track

i went with a south benf con-o

it came with clutch , pressure plate, and a flywheel, throw out bearing

and bolts.

a stock nv4500 bellhousing will work but you will need to get a 2nd gen

engine to transmission adapter(also known as a spacer)



clutch hydraluics froma second gen if you use a stock nv4500 bellhousing

south bend also thas them



i got my transfer case linkage from quad4x4

also you will need a transfer case that was mated to a getrag

or you will have to change the in put on the automatic transfer case .





i did a getrag to nv4500 conversion with out a kit i have lots of pictures

if you want to see them just shoot me a p. m with your email address

 

[Mopar_Tim]

thanks for all the pics, i am still going through all 120 e-mails

 

[Mopar_Tim]

well i finally got through all the pics ..... looks like a real straight forward swap, thanks for those.



anyone else have any input.

 

[Sri Ram]

As I understand it, if you plan to tow, stick with the stock Sachs clutch. If you plan to up the HP, go for the SBC…

 

[Mopar_Tim]

the most towing this one will se might be a few 4 wheelers ... . the 02 is the tow rig



i will be using a sbc ... . its just which one do i want its got to be drivable with the motor stock but i dont want it slipping when i throw a few grand at the motor in mods

 

[bmoeller]

www.quad4x4.com

 

[Mopar_Tim]

bringing up a dead one ... ... but i have started the swap got a few questions



i am sure some people have thought of this ... ... but the seal on the back of the transmission that has got to be removed ... ... can you replace the seal with one that has got a larger inside diameter? i dont want to machine the coupling down



also the auto transmission lines that go up to the front of the truck for the cooler, and the lines that go to the round cylinder on the passenger side of the block (looks like it is hooked to the cooling system) is it a way to warm the transmission fluid? anyway can i just remove it ?



what do i do about the water passage at the front of the block? plug it?

 

[pepecat]

I just removed all the lines, left the heat exchanger assy there. and just disco'd the lines to the transmission cool, however it is still in place. not sure about the water line you are talking about

 

[cerberusiam]

i am sure some people have thought of this ... ... but the seal on the back of the transmission that has got to be removed ... ... can you replace the seal with one that has got a larger inside diameter? i dont want to machine the coupling down?

If I haven't forgot the setup, you don't need the seal. The 2nd gen t-case did not have a seal in the input shft cover so thats what the seal in the adapter is for. The NP205 has the seal in the cover.



One question, you did use a t-case from a manual transmision setup, right?

also the auto transmission lines that go up to the front of the truck for the cooler, and the lines that go to the round cylinder on the passenger side of the block (looks like it is hooked to the cooling system) is it a way to warm the transmission fluid? anyway can i just remove it ?



what do i do about the water passage at the front of the block? plug it?

Yep, thats essentially a trans fluid warmer. I think the fittings screw out of the block and you just plug them. Leastwise, that cooler gets removed for twins so it should be easy.

 

[Mopar_Tim]

yeah the water line that feeds the warmer ... ... . thats what i was asking about



anyone know what size plug i need? NPT? should i use a brass plug

 

[pepecat]

If you leave the warmer installed, like I did and just disconnect the transmission fluid lines, no plugging is needed of course. So I'm not sure about the plug situation

 

[Mopar_Tim]

anyone know the plug sizes ... ... i dont really want to leave the thing there if i dont have to.

 

[pepecat]

You may be on your own on this one, because not too many have done the auto to manual swap. But the plug sizes shouldn't be too hard to eyeball. We have a ton of caps/plugs/fitting at work that we use for hydraulic lines and fuel lines, and usually you can guestimate what will fit and it screws right on...