Advance Adapters AX15 User Manual

NV4500 NV3550

AX15

TRANSMISSION

and

ADAPTER

INFORMATION

BOOKLET NO. NV015

July 2009

P.O. Box 247 4320 Aerotech Center Way Paso Robles, CA 93447

FIFTEENTHFIFTEENTH

This

FIFTEENTH edition of the NV4500, NV3550, & AX15 Instruction Manual is an accumulation of Advance Adapter's

FIFTEENTHFIFTEENTH

experiences and knowledge in performing various types of conversions. The information and photos are directly related to the products offered by our company. We have put this manual together for your reference in either performing the actual conversion or trying to establish an estimate on tools required for your specific type of conversion. There are several major sections covered in this booklet along with several reprint articles that have been supplied to us through the courtesy of various magazines. The information in this guide is constantly being updated and we ask that you verify any information that may be critical to your application. We highly recommend that you acquire the individual shop manuals for your particular vehicle as support for torque, gasketing, and assembly specifications which pertain to your vehicles requirements.

SPECIAL NOTE: Catalog Contents

This manual has been put together with the best possible information available to us. Advance Adapters cannot accept the responsibility for vehicles and applications that are not standard. The contents of this brochure have been proofread before printing to minimize errors. We cannot be held responsible for errors overlooked. Please feel free to contact us with any suggestions or comments you may have regarding any portion of this manual. The information that you provide us could be useful in assisting other customers.

The artwork and copy contained in this manual is the property of Advance Adapters, Inc., and any use in part or in whole must obtain written permission from Advance Adapters. All contents of this catalog have a copyright and are reserved for Advance Adapters, Inc. only.

TABLE OF CONTENTS

NV4500 Transmission Specifications ............................................................................................................................ 3-4

Transmission Identification ................................................................................................................................................ 5-7

Summary Code Charts (Identification charts) ................................................................................................................. 8-12

Input & Output Shafts .................................................................................................................................................... 13-14

Shifters ......................................................................................................................................................................... 15

Adapter Kits & Items

Jeep Vehicles ......................................................................................................................................................... 16-27

Toyota Land Cruisers..............................................................................................................................................28-33

1966-77 Ford Broncos ................................................................................................................................................. 34

Ford Trucks .................................................................................................................................................................. 35

Chevy Trucks ..........................................................................................................................................................36-40

Dodge Trucks (Getrag 5 speed Replacements) .................................................................................................... 41-42

Toyota Trucks ......................................................................................................................................................... 43-45

Full GM Bellhousings .................................................................................................................................................... 46-47

Bellhousing Adapter Plates ........................................................................................................................................... 48-49

NV3550 Transmission Specifications ............................................................................................................................. 50

Jeep Packages ....................................................................................................................................................... 51-54

Ford 1966-77 Broncos ................................................................................................................................................. 55

AX15 Transmission Specifications & Jeep Kits .........................................................................................................56-57

Ford 1966-77 Broncos ................................................................................................................................................. 57

HOW TO CONTACT US:

(805) 238-7000 - Nationwide

(805) 238-4201 - Fax

(800) 350-2223 - Toll Free (U.S. only)

http://www.advanceadapters.com

BUSINESS HOURS: (Pacific Time)

Monday through Wednesday 8:00 a.m. to 4:30 p.m.

Thursday & Friday 8:00 a.m. to 4:00 p.m.

Closed for Lunch from 12:00 p.m. to 12:40 p.m.

Closed Saturday & Sunday

NV4500 TRANSMISSION SPECIFICATIONS

INTRODUCTION:

In 1993, General Motors and Chrysler teamed up together to manufacture a transmission referred to as the NV4500 transmission. The NV4500 were used in both the GM & Dodge truck applications. We first learned of this transmission in mid-1993. Since then, we have developed numerous transmission-to-transfer case adapters along with the necessary bellhousing adapters to use the NV4500 in almost every type of 4WD vehicle; and you can see by the size of this booklet that we consider this transmission to be a very popular conversion. This instruction manual has been provided to assist you in the products that are available for both engine and transfer case conversions. The information contained in this manual has been based on our first hand experience.

The NV4500 is a constant mesh, helical geared 5 speed manual transmission. All forward gears are fully synchronized. The Dodge version NV4500 offers a synchronized reverse gear. The later models of the GM NV4500 now offer the synchro-reverse gear. This reverse gear can be added to the earlier GM NV4500 transmissions as an option. The 5th gear has an overdrive gear ratio of .73:1. The extremely low first gear ratio along with the overdrive 5 speed combination makes this transmission very desirable, since it offers the best possible gear ratio available for on or offroad conditions.

The transmission case is made of a cast iron material and the gear case cover is an aluminum alloy. The low profile of the top cover provides excellent clearance for 4WD aftermarket conversions. Unlike the older GM and Ford 4 speeds, the shift tower location has been relocated further back, approximately 9-1/2" from the face of the transmission, providing easier accessibility.

GM ONLY GM & DODGE

GEAR RATIOS: 1993-1994 1995-2004 DIMENSIONS:

First Gear ............................ 6.34 5.61 Approximate Dry Weight ................. 195 lbs.

Second Gear ....................... 3.44 3.04 Oil Capacity .................................... 8 pints

Third Gear ........................... 1.71 1.67 Maximum G.V.W.R. .......................... 14,500 lbs.

Fourth Gear ......................... 1.1 1.1 Main Case Material ........................ Cast Iron

Fifth Gear ............................. 0.73 0.73 Main Case Length .......................... 12.375"

Reverse ............................... 6.34 5.04 Extension Housing ......................... Aluminum

Top Cover Material.......................... Aluminum

There has been considerable discussion as to the best possible gear ratios to use for the various engine and transmission combinations. Originally, GM transmissions had a 6.34:1 first gear ratio that made it the most desirable for offroad performance. These transmissions were in high demand because of this super low first gear ratio. In 1995, GM discontinued the production of the 6.34:1 ratio and now only offers a 5.61:1 gear ratio. All NV4500 GM & Dodge except the GM1995 and earlier have the first gear ratio of 5.61:1. Some of the older transmissions are still available; and by using the identification charts in this booklet, you will be able to identify the gear ratios of almost every NV4500 transmission.

TRANSMISSION LUBRICATION:

The NV4500 transmission uses approximately one gallon of synthetic oil. This oil is available at your local Dodge authorized dealer under Part No. 4874459 (quart), or your local GM authorized dealer under Part No. 12346190 (quart). Unlike regular petroleum oil that breaks down when it gets too hot, this synthetic oil is made up of different properties that do not break down. The transmissions are also equipped with synchronizer rings that are made of a fibrous material. The wrong fluid will cause the unit to develop “sticky” shifting. If the wrong fluid is used, more than likely you will have to have your transmission rebuilt.

DO NOT SUBSTITUTE any other lubricant as internal damage will occur.

NOTE: Castrol Syntech is NOT the same as Castrol Syntorq.

We sell Ams Oil MTG under P/N 715690. This is the only suitable oil substitute.

TORQUE SPECIFICATIONS:

Part Description Foot/Inch Pounds of Torque

Top Shift Cover Bolt ............................... 200 Inch pounds

Adapter Housing .................................... 40 Foot pounds

Front Drive Gear Retainer ...................... 265 Inch pounds

Main Shaft Nut 4WD ............................... 275 Foot pounds

P.T.O. Cover Bolts .................................. 30 Foot pounds

Reverse Inhibitor Bracket ...................... 95 Inch pounds

Counter Shaft Brg. Ret. Plate ................ 200 Inch pounds

Main Shaft Brg. Ret. Plate ...................... 200 Inch pounds

GASKETING SPECIFICATIONS:

In order to install the new adapter housing, top cover, and bearing retainer, we recommend using Loctite 518 Gasket Eliminator. This sealant seems to work best.

SPEEDOMETER:

Most 4WD installations provide a speedometer drive gear on the back side of the transfer case.

On 2WD transmission swaps, Dodge transmissions are the most desirable due to the mechanical speedometer drive. The later versions (1998 & newer transmissions) do not have any type of speedometer provisions. The GM 2WD NV4500 transmissions use an electronic speed sensor. These transmissions will not allow you to retain your stock speedometer drive.

BACKUP SWITCH:

All NV4500s are equipped with an electronic reverse backup switch. If your vehicle is equipped with some type of backup indicator light, it can be adapted very easily to the new NV4500 switch. The parts required to couple to this switch are P/N 300378 (1), 300378 (2 req.), and 300378-1 (2 req.).

SUSPENSION LIFTS:

Driveline angles could be a major problem when using the NV4500 primarily because of the extreme length of the new transmission. It will be very important that you consider the new adapter length before purchasing any components. Compensation for the rear driveline angle can be adjusted slightly by the use of axle degree shims and by adjusting the crossmember support down-

ward from the frame rails. DO NOT OVERLOOK the effects of the suspension lift when using a NV4500. Most complaints of

noise after a transmission swap are due to improper driveline angles.

NV4500 rebuild kit:

If you find your own NV4500, but need to freshen it up with some new bearings seals and synchronizers, we offer plies you with replacement parts for the normal

wear items of the NV4500.

P/N 715691. This kit sup-

TRANSMISSION IDENTIFICATION

The NV4500 transmission identification tag is attached to the shifter top cover. The tag provides the transmission model number, build date, and part number. Be sure not to remove the I.D. tag during the conversion. The information on this tag is essential for ordering the correct replacement parts. Since we use various transmission configurations for the different types of transfer case & bellhousing adapters, be sure to examine the application for your particular conversion before finalizing the purchase of a NV4500.

GM 4WD NV4500 (1993-94)

During the first two years of the NV4500, Chevy offered this 5 speed with a 6.34:1 1st gear; 2nd 3.44:1; 3rd 1.71:1; 4th 1:1 ratio, and a 27% overdrive. It was also the first year that Chevy changed the bellhousing-to-transmission bolt pattern. This transmission is ideal when converting your vehicle, providing an ultra-low 1st gear. GM, however, only produced this particular ratio during these years. The major complaint of this 5 speed was stiff shifting and noise in 3rd gear.

Identification of this transmission can be obtained by using the identification charts in this manual. Due to the interchangeability of other NV4500 components, we also recommend that you verify the following information. Starting at the front, this GM transmission should have a input shaft pilot tip diameter of .590”. The spline of the input is 1-1/8” diameter 10 spline and protrudes approximately 6-5/8” from the face of the transmission. This input shaft cannot be interchanged with any other NV4500 input shafts other than transmissions with the same 1st gear ratio unless you change the counter drive gear also. The front bearing retainer index is 5.125”, with a snout diameter of 1.373”, and a front bolt pattern as shown. The shifter stud on the top cover is a male threaded connection. The rear of this transmission has an aluminum adapter housing which measures 8-1/8” long; and the output shaft is 32 spline. Most transfer case adapters for this transmission will require the replacement of the tailhousing and the shortening of the output shaft.

1993-95 GM NV4500

Bellhousing Bolt Pattern

This transmission cannot be used with a Ford engine.

GM 4WD NV4500 (1995)

This transmission is identical to the 1993-94 transmission, except the 1st gear ratio had been changed to 5.61:1; 2nd 3.04:1; 3rd

1.67:1; 4th 1:1 ratio, and a 27% overdrive. The noise and shifting problems had been corrected.

Identification of this transmission can be obtained by using the identification charts in this manual. Due to the interchangeability of other NV4500 components, we also recommend that you verify the following information: Starting at the front, this GM transmission should have a input shaft pilot tip diameter of .590”. The spline of the input is 1-1/8” diameter 10 spline and protrudes approximately 6-5/8” from the face of the transmission. This input shaft can be interchanged with other NV4500 input shafts with this 5.61 1st gear ratio. The front bearing retainer index is 5.125”, with a snout diameter of 1.373”, and a front bolt pattern as above. The shifter stud on the top cover is a male threaded connection. The rear of this transmission has an aluminum adapter housing which measures 8-1/8” long; and the output shaft is 32 spline. Most transfer case adapters for this transmission will require the replacement of the tailhousing and the shortening of the output shaft.

GM 4WD NV4500 (1996 & Newer)

This transmission has the same gear ratio as the 1995 version (1st 5.61:1; 2nd 3.04:1; 3rd 1.67:1; 4th 1:1 ratio, and a 27% overdrive). Chevy once again changed the bellhousing-to-transmission bolt pattern and went to a larger bellhousing index diameter. The new bolt pattern and index are the same as the Dodge Standard Duty NV4500. These transmissions use a GM internal release bearing.

GM bellhousing used an internal release bearing that mounted to the front of this transmission. Most

bellhousing adapters for this transmission will either require the replacement of the retainer or, on some applications, an adapter retainer bolted to the front of the stock GM aluminum retainer. The shifter stud on the top cover is a male threaded connection. The rear of this transmission has an aluminum adapter housing which measures 8-1/8” long; and the output shaft is 32 spline. Most transfer case adapters for this transmission will require the replacement of the tailhousing and the shortening of the output shaft. We carry this rebuilt transmission under P/N 26-0007R. * The top shifter’s will vary on these transmission due to core supplies.

GM 2WD NV4500 (1993 & Newer)

These transmissions have the same front bolt pattern dimensions and gear ratios as the corresponding year 4WD NV4500 version.

These transmissions have a shorter tailhousing and a fixed output yoke. These tailhousings did not use a standard mechanical speedometer drive, but were equipped with an electronic speedometer setup. Connection to this speedometer must be considered.

We have found these transmissions to be best suited for full size Ford trucks that

have the independent transfer case. The speedometer on this application will remain in the stock transfer case, and the

short NV4500 tailhousing allows room for the short driveline

between the transmission and the transfer case. To fit

this transmission to a Ford bellhousing, a new

Dodge input shaft is required. input shaft will not work in the GM NV4500s with the 6.34:1 1st gear ratio. Identification of this transmission can be obtained by using the identification charts in this manual.

NOTE:

The Dodge

1996 & Up GM

1993 & Up DODGE

NV4500 Bellhousing

Bolt Pattern

GM NV4500 (Commercial Truck-Style)

Specialty aftermarket NV4500s manufactured for commercial truck applications (such as UPS trucks) may also be located in various salvage yards. The front portion of the transmission is comparable with all the various GM NV4500 transmissions; however, the tailhousing will need to be changed along with the transmission output shaft. These units can sometimes be purchased at a considerable savings, since the output yoke is not compatible for 4WD and conventional light-duty truck applications.

Dodge Standard Duty 4WD NV4500 (1993-1998)

These transmissions have the same front bolt pattern and bearing retainer index as the 1996 to current. Chevy NV4500 transmission. The gear ratios of all of the Dodge version NV4500s remained the same, which is a 1st gear of 5.61:1; 2nd 3.04:1; 3rd 1.67:1; 4th 1:1 ratio, and a 27% overdrive. These transmissions use a 7-1/2” long input shaft which allows the use of an adapter plate between a stock bellhousing and the NV4500 transmission.

Identification of this transmission can be obtained by using the identification charts in this manual. Due to the interchangeability of other NV4500 components, we recommend that you also verify the following information: Starting at the front, this Dodge transmission should have an input shaft pilot tip diameter of .750”. The spline of the input is 1-1/8” diameter 10 spline and protrudes approximately 7-1/2” from the face of the transmission (some early Dodge NV4500s had a 1”-19 spline input shaft). This input shaft can be interchanged with other NV4500 input shafts with this 5.61 1st gear ratio. The front bearing retainer index is 5.600”, with a snout diameter of 1.43” for the release bearing. Most bellhousing adapters for this transmission will either retain this stock retainer as it is or may require some machining on it. The shifter stud on the top cover is a male square connection. The rear of this transmission has an aluminum adapter housing which measures 6-1/4” long; and the output shaft is 23 spline. Our transfer case adapters for this transmission will sometimes replace this stock tailhousing or, as in many cases, this stock housing can be retained by using an adapter plate.

Dodge Standard Duty 4WD NV4500 (1999-2000)

These transmissions are identical to the 1993-1998 Dodge transmission with the exception of the transmission shift stud. Dodge changed the square style shift handle receiver to a metric 14mm threaded stud.

Dodge Standard Duty 4WD NV4500 (2001 & Newer)

These transmissions are identical to the 1999-2000 Dodge transmissions. changed to 29 splines. We carry this rebuilt transmission under P/N 26-0029R. * The top shifter’s will vary on these transmission due to core supplies.

Note:

The output shaft on 2001 & newer models was

Advance Adapters Custom Built (2001 & Newer)

These transmissions are built with a Dodge 29 spline output shaft and a GM input shaft. The transmission is also equiped with the GM front flat aluminum bearing retainer. We carry this rebuilt transmission under will vary on these transmission due to core supplies.

Dodge Standard Duty 2WD NV4500 (1993-1998)

These transmissions have the same front bolt pattern and bearing retainer index as the Dodge 4WD NV4500 transmission. The gear ratios of the Dodge 2WD version are the same as the Dodge 4WD version (1st gear 5.61:1; 2nd 3.04:1; 3rd 1.67:1; 4th 1:1 ratio, and a 27% overdrive). These transmissions use a 7-1/2” long input shaft which allows the use of an adapter plate between a stock bellhousing and the NV4500 transmission. Identification of this transmission can be obtained by using the identification charts in this manual. The tailhousing of this transmission is 13” long and uses a slip yoke with 30 splines. This transmission

works great for most 2WD installations since it uses a mechanical speedometer drive. On 1998 Standard Duty 2WD

transmissions, the speedometer pickup was moved from the tailhousing back to the rear axle. If you obtain one of these transmissions, you will be required to change the tailhousing and output shaft to components from an earlier Dodge 2WD if you wish to have a working speedometer.

Dodge Standard Duty 2WD NV4500 (1999 & Newer)

These transmissions are identical to the 1993-1998 2WD Dodge transmission with the exception of the transmission shift stud. Dodge changed the square style shift handle receiver to a metric 14mm threaded stud. On these Standard Duty 2WD transmissions, the speedometer pickup was moved from the tailhousing back to the rear axle. If you obtain one of these transmissions, you will be required to change the tailhousing and output shaft to components from an earlier Dodge 2WD if you wish to have a working speedometer.

Dodge 4WD Heavy-Duty NV4500 (1993-1998)

This transmission is normally used up to the Cummins Diesel. This transmission is best suited for Dodge 4WD Getrag 5 speed replacements and Toyota Land Cruisers retaining the stock six cylinder engine. We DO NOT advise using this transmission for other applications unless you are prepaired to change the Heavy-Duty front input and retainer.

P/N 26-0029RGM. * The top shifter’s

Identification of this transmission can be obtained by using the identification charts in this manual. Due to the

interchangeability of other NV4500 components, we recommend that you also verify the following information:

Starting at the front, this Dodge transmission should have an input shaft pilot tip diameter of .750”. The spline of the input is 1-1/4” diameter 10 spline and protrudes approximately 7-1/2” from the face of the

transmission. This input shaft can be interchanged with other NV4500 input shafts with this 5.61 1st gear ratio. The front bearing retainer index is 5.60”, and has a snout diameter of 1.75” for the release

bearing. The shifter stud on the top cover is a male square connection. The rear of this transmission has an aluminum adapter housing which measures approximately 6-1/4” long; and the output shaft is 29 spline.

Dodge 4WD Heavy-Duty NV4500 (1999 & Newer)

These transmissions are identical to the 1993-1998 Dodge H.D. transmission, with the exception of the transmission shift stud. Dodge changed the square style shift handle receiver to a metric 14mm threaded stud. We carry this rebuilt transmission under Part No. 26-0020R. * The top shifter’s will vary on these transmission due to core supplies.

Dodge 2WD Heavy-Duty NV4500 (1993-1998)

These transmissions have the same front bolt pattern and bearing retainer index as the as the Dodge 4WD Heavy-Duty NV4500 transmission. This transmission should only be used for the Cummins Diesel Getrag replacement. Identification of this transmission can be obtained by using the identification charts in this manual. The tailhousing of this transmission is 13” long

and uses a slip yoke (P/N 716087) with 31 splines. If you obtain a 1998 Heavy-Duty transmission, you will be required to change

the tailhousing and output shaft to components from an earlier Heavy-Duty Dodge 2WD if you wish to have a working speedometer.

Dodge 2WD Heavy Duty NV4500 (1999 & Newer)

These transmissions are identical to the 1993-1998 Dodge H.D. transmission with the exception of the transmission shift stud. Dodge changed the square style shift handle receiver to a metric 14mm threaded stud. On these Heavy-Duty 2WD transmissions, the speedometer pickup was moved from the tailhousing back to the rear axle. If you obtain one of these Heavy-Duty transmissions, you will be required to change the tailhousing and output shaft to components from an earlier Heavy-Duty Dodge 2WD if you wish to have a working speedometer.

DODGE NV4500 LABEL CODE SUMMARY

The following information deals with both the OEM transmission part numbers and the NV4500 part numbers. In order to assist you with identifying the various transmissions that you might encounter in a salvage yard, we have listed most of the model information provided to us by the manufacturer & our local dealer. These charts should assist you in the identification process.

P ART DODGE DODGE ENGINE

MODEL NUMBER ASSY CODE CODE (Liters)

MODEL YEAR Mid-1992 TO 1993 - 5.61:1 RATIO GEAR SET

4X2 12515 53006841 DA 3.9, 5.2, 5.9

4X4 12517 53006842 DB 3.9, 5.2, 5.9

MODEL YEAR 1994 Through 1996 - 5.61:1 RATIO GEAR SET

4X2 (Standard Duty) 18183 52108001 DC 5.2, 5.9 V8

4X2 (Heavy Duty) 18155 52108224 DD 5.9 T/D, 8.0

4X4 (Standard Duty) 18187 53006845 DE 5.2, 5.9 V8

4X4 (Heavy Duty) 18179 52108225 DF 5.9 T/D, 8.0

MODEL YEAR 1997 (Single Plane Reverse - One Piece Countershaft)

4X2 (Standard Duty) PR21197 52108194 5.2, 5.9 V8

4X2 (Heavy Duty) PR21198 52108196 5.9 T/D, 8.0

4X4 (Standard Duty) PR21199 52108195 5.2, 5.9 V8

4X4 (Heavy Duty) PR21200 52108197 5.9 T/D, 8.0

5.61:1 RATIO GEAR SET

(Last year with speedometer provisions)

An example of an early Dodge topcover indentification tag.

DODGE NV4500 LABEL CODE SUMMARY

Con’t.

P ART DODGE DODGE ENGINE

MODEL NUMBER ASSY CODE CODE (Liters)

MODEL YEAR 1998 TO 2000 (Single Plane Reverse - One Piece Countershaft)

4X2 (Standard Duty) 52108128AD 5.2, 5.8 V8

4X2 (Heavy-Duty) 52108130AD 5.9 T/D, 8.0

4X4 (Standard Duty) 52108129AD 5.2, 5.8 V8

4X4 (Heavy-Duty) 52108131AD 5.9 T/D, 8.0

*MODEL YEAR 2001 TO 2002 (Single Plane Reverse - One Piece Countershaft)

4X2 (Standard Duty) 52108128AF 5.9

4X2 (Heavy-Duty) 52108130AD 5.9 T/D, 8.0

4X4 (Standard Duty) 52108129AF 5.9

4X4 (Heavy-Duty) 52108131AD 5.9 T/D, 8.0

5.61:1 RATIO GEAR SET

*MODEL YEAR 2003 (Single Plane Reverse - One Piece Countershaft)

4X2 (Standard Duty) 52108128AE (P/N up to 2005) 5.7

4X2 (Heavy-Duty) 52108130AC (P/N up to 2004) 5.9 T/D, 8.0

4X4 (Standard Duty) 52108129AE (P/N up to 2005) 5.7

4X4 (Heavy-Duty) 52108131AC (P/N up to 2004) 5.9 T/D, 8.0

*Starting in 2001, New Venture Gear began to standardize on the use of their mainshafts. Standard Duty & Heavy-Duty 2WD models now have the same mainshaft;

and the Standard Duty & Heavy-Duty

4WD models now have the same mainshaft.

5.61:1 RATIO GEAR SET

An example of a later model Dodge topcover indentification tag.

GM NV4500 LABEL CODE SUMMARY

GM ASSY GM TYPE OF

MODEL NUMBER CODE ENGINE

MODEL YEAR Mid-1992 - 6.34:1 RATIO GEAR SET

4X2 15627134 GBW T/DIESEL/GAS C-TRUCK 15693372 GTT 6.2 DIESEL

4X4 15627135 GBX T/DIESEL/GAS K-TRUCK 15693373 GTU 6.2 DIESEL

P-TRUCK 15954757 GCY WITHOUT YOKE

15954756 GCX W/ YOKE

MODEL YEAR 1993 - 6.34:1 RATIO GEAR SET

4X2 15960760 GXW GAS C-TRUCK 15966631 GZB 6.5 T/DIESEL

4X4 15960761 GXC GAS K-TRUCK 15966632 GZC 6.5 T/DIESEL

P-TRUCK 15954757 GWY WITHOUT YOKE

15960763 GXF 6.2 DIESEL

15960764 GXG 6.2 DIESEL

15954756 GWX W/ YOKE

MODEL YEAR 1994 - 6.34:1 RATIO GEAR SET

4X2 15960760 GXB ALL EXC 6.5D C-TRUCK 15966631 GZB 6.5 DIESEL

4X4 15960761 GXC ALL EXC 6.5D K-TRUCK 15966632 GZC 6.5 DIESEL

P-TRUCK 15954757 GWY WITHOUT YOKE GMT-455 15960762 GXD

15954756 GWX W/ YOKE

MODEL YEAR 1995 - 5.61:1 RATIO GEAR SET

4X2 15691902 GAKF ALL EXC 6.5D C-TRUCK 15970869 GAKJ 6.5 DIESEL

4X4 15691901 GAKD ALL EXC 6.5D K-TRUCK 15970870 GAKK 6.5 DIESEL

4X2 15970952 GAKM WITHOUT YOKE P-TRUCK 15970950 GAKL W/ YOKE

4X2 15691903 GAKH GMT-455

MODEL YEAR 1996 - 5.61:1 RATIO GEAR SET

4X2 15970014 GAMN ALL EXC 6.5D C-TRUCK 15970015 GAMP 6.5 DIESEL

4X4 15970013 GAMM ALL EXC 6.5D K-TRUCK 15970016 GAMR 6.5 DIESEL

4X2 15974728 GAKT WITHOUT YOKE P-TRUCK 15974727 GAKS W/ YOKE

4X2 15970012 GAML GMT-455

GM NV4500 LABEL CODE SUMMARY

Con’t

GM ASSY GM TYPE OF

MODEL NUMBER CODE ENGINE

MODEL YEAR 1997 - 5.61:1 RATIO GEAR SET

4X2 15716059A GARJ ALL EXC 6.5D C-TRUCK 15716060A GARK 6.5 DIESEL

4X4 15716058A GARH ALL EXC 6.5D K-TRUCK 15716061A GARL 6.5 DIESEL

P-TRUCK 15727130A GARM WITHOUT YOKE

4X2 15716057A GARF GMT-455

4X2 15716059 GARJ GAS C-TRUCK 15027365 GAWM DIESEL

4X4 15716058 GARH GA S K-TRUCK 15027366 GAWN DIESEL

P-TRUCK 15727130 GARM WITHOUT YOKE

4X2 15716057 GARF GMT-455

4X2 15020889 GBBM GAS

4X4 15020888 GBBL GAS

P-TRUCK 15031131 GBBW WITHOUT YOKE

15727131A GARN W/ YOKE

MODEL YEAR 1998 - 5.61:1 RATIO GEAR SET

15727131 GARN W/ YOKE

MODEL YEAR 1999 - 5.61:1 RATIO GEAR SET

15020890 GBBN DIESEL

15020891 GBBP DIESEL

15020892 GBCF W/ YOKE

4X2 15020887 GBBK GMT-455

MODEL YEAR 2000 - 5.61:1 RATIO GEAR SET

4X2 15747133 GBFX GAS C-TRUCK 15747134 GBFY DIESEL

4X4 15747132 GBFR G AS K-TRUCK 15747135 GBFZ DIESEL

P-TRUCK 15031131 GBBW WITHOUT YOKE

15020892 GBCF W/ YOKE

4X2 15747131 GBFU GMT-455

GM NV4500 LABEL CODE SUMMARY

Con’t

GM ASSY GM TYPE OF MODEL NUMBER CODE ENGINE

MODEL YEAR 2001 - 5.61:1 RATIO GEAR SET

4X2 15769082 GBDR GA S

4X4 15769083 GBKS GAS

P-TRUCK 15031131 GBBW WITHOUT YOKE

4X2 (Heavy-Duty) 15049382 GBDW 8.1 GAS 4X2 GMT-455 15747131 GBFU

4X2 15769082 GBDR GA S C-TRUCK 15747232 GBDU GA S

4X4 15769083 GBKS GAS K-TRUCK 15747233 GBFS G AS

P-TRUCK 15031131 GBBW WITHOUT YOKE

4X2 (Heavy-Duty) 15049382 GBDW 8.1 GAS 4X2 GMT-455 15747131 GBFU

MODEL YEAR 2003 to 2004 - 5.61:1 RATIO GEAR SET

4X2 12572799 DFY GAS

15747232 GBDU GA S

15747233 GBFS GAS

15020892 GBCF W/ YOKE

MODEL YEAR 2002 - 5.61:1 RATIO GEAR SET

15020892 GBCF W/ YOKE

12572797 DFW GAS

4X4 12572800 DFZ GAS

12572798 DFX GAS

P-TRUCK 15031131 GBBW WITHOUT YOKE

15020892 GBCF W/ YOKE

4X2 (Heavy-Duty) 15049382 GBDW 8.1 GAS

An example of an early model GM topcover indentification tag (left) and a later model GM topcover indentification tag (right).

NV4500 INPUT & OUTPUT

SHAFTS

GM 32 TOOTH 4WD OUTPUT SHAFT

On all NV4500s that were equipped to a GM 4WD transfer case, you will find that the output shaft has 32 teeth. The adapter housing that is mounted to the back of the transmission case is 8-1/8" long. On the inside of this tailhousing, you’ll either find a vibration damper on the output shaft or a steel sleeve. Most of our transfer case adapters will require the damper or sleeve to be removed. We couple to the 31 tooth spline located under the damper or sleeve. In order to remove the vibration damper or sleeve, you must use a special socket. This socket will be required in order to remove the nut because this nut is put on with 275 ft./lbs. of torque. On transmissions with the damper, a gear puller will be required since the damper is a press fit to the output shaft. On all applications that require the removal of the damper or sleeve, we will provide a custom set collar that must be installed on the output shaft to retain the 5th gear into position.

GM 35 TOOTH 2WD OUTPUT SHAFT

All GM NV4500s that were used in 2WD vehicles will be equipped with a 35 tooth output shaft. Located on the end of the shaft will be a large balancer type yoke. We do not make any transfer case adapters to couple to this output shaft.

DODGE 23 TOOTH 4WD OUTPUT SHAFT

On all 1993-2000 NV4500s that were equipped with Dodge 4WD transfer cases, you will find that the output shaft has 23 teeth. The adapter housing that is mounted to the back of the transmission case is 6-1/4" long. On the inside of this tailhousing, you’ll find a locking nut that secures the 5th gear to the main shaft. This stock nut has undergone some design changes from the manufacturer because they have been known to loosen after time. Our adapters do not require the removal of this nut; however, you might want to make sure the nut is still properly secured. Most of our transfer case adapters do not require any modifications to the shaft or stock tailhousing.

DODGE 29 TOOTH 4WD OUTPUT SHAFT (for Heavy-Duty & 2001 Standard Duty transmissions)

On all Cummins diesel Dodge Heavy-Duty 4WD NV4500s and 2001 & up Dodge Standard Duty 4WD NV4500s, you will find that the output shaft has 29 teeth. The adapter housing that is mounted to the back of the transmission case is 6-1/4" long. On the inside of this tailhousing, you’ll find a locking nut that secures the 5th gear to the main shaft. This stock nut has undergone some design changes by the manufacturer because they have been known to loosen after time. Our adapters do not require the removal of this nut; however, you might want to make sure the nut is still properly secured. If you have one of these transmissions and plan on changing the output shaft to one out of the other model NV4500s (i.e. a GM NV4500), you will also be required to change the 5th gear assembly since it will not fit on the new main shaft. A new nut to secure this 5th gear will also be required.

DODGE 30 TOOTH 2WD OUTPUT SHAFT

On all NV4500s that were used in a Dodge 2WD vehicle, you will find that the output shaft has 30 teeth. The tailhousing that is mounted to the back of the transmission case is 13” long. This tailhousing uses a slip yoke assembly. The slip yoke can be purchased from your local dealer.

DODGE 31 TOOTH Heavy Duty 2WD OUTPUT SHAFT

On all Cummins diesel Dodge 2WD NV4500s, you will find that the output shaft has 31 teeth. The tailhousing that is mounted to the back of the transmission case is 13" long. This tailhousing uses a slip yoke assembly. The slip yoke for this transmission is a 1410 series. We stock this yoke as P/N 716087, or it can be purchased from your local dealer.

MAIN SHAFT INSTALLATION:

Depending on your application and transmission model, you may require the installation of a new transmission main shaft. The installation will require the use of a bearing puller in order to remove the rear tapered roller bearing on the main shaft. It will also require a special tool to remove the nut holding either the 5th gear or the harmonic balancer. These tools are available from your local GM or Dodge dealer depending on the make of your transmission. Although it is fairly simple and easy to exchange the main shaft on these transmissions, we recommend that you have the

new shaft installed by a qualified transmission mechanic. Your local GM and Dodge service departments are equipped with all of the necessary tools and have been trained for repairing these NV4500 transmissions. The average time to disassemble and replace the new shaft would be approximately 2 hours, provided all the tools were available.

P/N J38805 Spec. Socket for Removal of the GM 4WD Damper

NOTE:

remove even with the right tools. One of our customers simplified the removal of the nut by drilling the nut on opposite sides with a 1/4” drill. Once drilled, take a chisel and split the nut into two halves. Then the special socket will not be needed.

The nut that retains the harmonic balancer (damper) is extremely hard to

MAIN SHAFT MODIFICATIONS: Several of the adapters require you to shorten the existing transmission main

shaft while it is still installed in the transmission case. This is quite common when a GM 4WD transmission output shaft is being used. Each instruction sheet gives the exact cutoff location in order to be compatible with our components. The normal procedure for performing this operation can either be a high speed cutoff disc or a metal abrasive cutoff saw. To assist in making the exact cutting location, we suggest that you use tape and wrap it around the shaft to indicate the exact cutoff location. The tape will provide a definite location since the shaft is slowly rotated during the cutoff procedure. Once the outer surface has been penetrated, the inner core of the shaft could be cut with a regular hacksaw. All of the sharp edges should be smoothed to provide a good fit into our components.

CAUTION: During the cut off procedure, you must make sure to wear protective eye

gear to prevent sparks from causing damage to your eyes. The bearings and gears should also be protected to avoid contamination of metal debris.

MAIN SHAFT END PLAY: If the transmission you acquire requires the replacement of the transmission main shaft

or changing of the front input gear, you will need to recheck and inspect the end play tolerance on the main shaft. When installed into the main case of the transmission, the main shaft tolerance should be .002" to .006". This is very critical and you must use a dial indicator in order to determine if new shims will be required. Refer to the transmission service manual GM #17003.13 for additional information.

GM & DODGE INPUT SHAFTS: On the front of the transmission, the input shaft can vary depending on which type

of transmission is being used. We have seen three different specifications of input shafts. The input

shaft gear tooth counts are all identical on all 3 transmissions, except for the GM transmissions with the 6.34:1 gear ratio. Dodge also offered a early 19 spline input shaft 1992-93 transmissions, which

is no longer available. This 19 spline shaft is interchangeable with all Dodge units and it will require a new retainer as well.

Transmission Input Shaft

All GM transmissions 1-1/8"-10 spline/.590" pilot tip

(excludes 4x2 H.D. 2001 & newer) (GM P/N12382877 or AA P/N 52-0221)

Dodge Standard Duty transmissions 1-1/8"-10 spline/.750" pilot tip

(Dodge P/N 4882357 or AA P/N 52-0219)

Dodge Heavy-Duty transmissions 1-1/4"-10 spline/.750" pilot tip

(Dodge P/N 4882358 or AA P/N 52-0228)

NOTE:

All of the above input shafts will not work the 6.34:1 GM NV4500 transmission.

GM & DODGE FRONT RETAINERS: On the front of the transmission, both the GM and Dodge transmissions

used a different front retainer. We offer some of these stock retainers as well as some modified retainers for use with our adapter kits:

Dodge gas version transmission has a 5.600” index dia. with a 1.437” snout dia. P/N 716068. Dodge H.D. version transmission has a 5.600” index dia. with a 1.750” snout dia. P/N 716080. GM 1993-1995 transmissions have a 5.125” index dia. with a 1.377” snout dia. (we do not offer this retainer). GM 1996-2004 transmissions have a 5.600” index dia. This retainer does not have a snout. We offer a bolt-on 1.377” snout,

P/N 716067A. We also offer replacement aluminum GM retainers under P/N 716068G.

SHIFTERS

The year and the model of your NV4500 transmission (GM or Dodge) will determine the shift handle assembly you will use. Both GM and Dodge offer shift handle assemblies; however, the cost of these stock handles are not favorable. The shift handles we offer are easy to install and, if necessary, easy to modify to fit your vehicle. We offer 3 shifter configurations to fit the different models manufactured.

716050C

716050D

716050D1

P/N 716050C

(Chevy 1993 & UP)

SHIFTER KIT CONSISTS OF:

P/N 716050B - Shifter handle base P/N 716050H - Shift handle P/N 716050K - Shift knob P/N 720061 - 10mm X 1.5 50mm long stud bolt P/N 726203 - 5/8"-18 Hex jam nut

Stock GM 1993 & Up shift tower

Note; Since there are numerous

transmission rebuilder working on the NV4500. The top covers are easily switched out for one another. The shifter on this page are for the stock top cover on non rebuilt transmission. If you are buying your transmission from a rebuilder, you should verify the handle configuration so as to receive the correct handle.

P/N 716050D

(Dodge 1993-98)

SHIFTER KIT CONSISTS OF:

P/N 716050H - Shifter handle P/N 716050K - Shift knob P/N 716050S - Shift handle stud P/N 720061 - 10mm X 1.5 50mm long stud bolt P/N 726203 - 5/8"-18 Hex jam nut

SPECIAL NOTES:

1. Remove rubber boot.

2. Remove retaining cup - Push down and turn cup counter clockwise, then pull straight stud out of top cover.

3. Remove old stud by driving 1/4" roll pin out of base.

4. Slide the stock spring over the shifter stud (large end up).

5. Install Part No. 716050S into base. Reassemble using original 1/4" roll pin.

Roll Pin

Stock Dodge 1993-98 shift tower

Stock Dodge 1999-2002 shift tower

P/N 716050D1

(Dodge 1999 & Newer)

SHIFTER KIT CONSISTS OF:

P/N 716050 - Shifter handle base P/N 716050H - Shift handle P/N 716050K - Shift knob P/N 720061 - 10mm X 1.5 50mm stud bolt P/N 726203 - 5/8"-18 Hex jam nut

Stock Dodge 2003 & Newer

shift tower

ADAPTER PACKAGES & INDIVIDUAL COMPONENTS

FOR

JEEP VEHICLES

We offer complete adapter packages for the most common Jeep engine and transmission swaps along with the most common transmission retrofits. If we do not show a transmission package specifically for your application, more than likely we offer the individual components to convert your vehicle. The components in the packages that we do offer can also be purchased separately. In the applications to follow, we have listed the transmission package(s) plus the individual components, and any optional or related items that we offer. Also noted are some of the modifications you may be required to perform.

We currently offer rebuilt NV4500 transmissions. The GM 4WD NV4500 can be purchased under Part No. 26-0007R, the Dodge 4WD NV4500 under Part No. 26-0029R, and our custom built transmission with the Dodge 29 spline output shaft and the GM inputshaft is sold uner Part Number

26-0029RGM. If you wish to obtain your own transmission, please refer to the GM and Dodge identification charts for both current and past

OEM part numbers.

JEEPS 1941-1979 (Dana 18/20 - Long wheel-based vehicles only):

In order to adapt a NV4500 to these transfer cases, the transmission must be a GM 4WD NV4500. The spud shaft we manufacture

couples to the 31 spline portion of the GM output shaft. This 31 spline area is located under the vibration damper or sleeve on this output shaft. The stock output shaft must be cut to the proper stickout length of 4.498” to couple to our spud shaft. The stock GM tailhousing will not be reused, since these kits provide a new tailhousing adapter. The bearing retainer provided in the transfer case kit is ONLY for large hole transfer cases. If you have a small hole transfer case, please contact us for more information.

The transfer case linkage will need to be modified in order to fit alongside the large 5 speed transmission case. The Dana 18/ 20 used several different shift linkages, some requiring more modifications than others. Due to the length of the transmission, driveline modifications will almost always be required. A 1” to 2” body lift is usually required to obtain proper tunnel clearance.

These kits are not compatible in short wheel-based vehicles such as the CJ5 models. The only exception to this would be to use a 4 cylinder or V6 engine. The engine would then need to sit to the very forward position of the engine compartment. Even so, when we installed a NV4500 into a 1966 CJ5 with a V6, the rear driveshaft was still very short.

AMC-Jeep engine full bellhousing design. O.A.L. of 24.750”.

P/N 50-0210 - Transfer case adapter kit P/N 712568 - Bellhousing kit for GM NV4500 (1996 & newer) to AMC engine P/N 712571 - Bellhousing kit for GM NV4500 (1995 & earlier) to AMC engine P/N 716050C - Shifter handle assembly

Chevy V6 & V8 full bellhousing design. O.A.L. of 24.750”.

P/N 50-0210 - Transfer case adapter kit P/N 712576 - Bellhousing kit for GM NV4500 (1996 & newer) to Chevy V6 & V8 P/N 712577 - Bellhousing kit for GM NV4500 (1995 & earlier) to Chevy V6 & V8 P/N 716050C - Shifter handle assembly

P/N 712571

The recommended clutch components for the bellhousings listed above are found in the GM Full Conversion Bellhousing section of this manual.

JEEPS 1980-1986 (Dana 300):

In order to adapt a NV4500 to a Dana 300 transfer case, the transmission can either be a 29 spline or a 23 spline DODGE

Standard Duty 4WD NV4500. This Dodge transmission has the correct bolt pattern to bolt directly to the Dana 300 transfer

case. The 23 spline transmission has the same spline count as that of the Dana 300. The Dodge 29 spline transmission requires the installation of a new 29 spline input gear into the Dana 300.

On 1996 & newer Dodge transmissions, the internal profile of the stock tailhousing was changed. This profile change causes interference with the stock Dana 300 alignment retainer. These newer transmissions require a shorter Dana 300 retainer for proper

indexing. The kit package listed below are all based around the 1996 & newer

transmission.

JEEP ENGINE WITH A DANA 300 T/C NV4500 KITSJEEP ENGINE WITH A DANA 300 T/C NV4500 KITS

JEEP ENGINE WITH A DANA 300 T/C NV4500 KITS

JEEP ENGINE WITH A DANA 300 T/C NV4500 KITSJEEP ENGINE WITH A DANA 300 T/C NV4500 KITS

P/N 27-0003T - 29 spl. DODGE Gas NV4500 to AMC-Jeep engine

The overall assembly length is 26.125”. These kits use an adapter plate that bolts to the stock AMC bellhousing. The adapter

plate requires the use of a 1976-86 stock Jeep bellhousing from a T150 and T176 (AA P/N 712599 or Jeep P/N 8133951 or 3236291).

is retained since you are using your original bellhousing. Driveline modifications will be required with NV4500 transmission replacements. These kits are not compatible with short wheel-based vehicles such as the CJ5 models. A new index Dana 300 retainer is provided in the kit for proper indexing. Some crossmember modifications are necessary, and a body lift is recommended.

Regarding P/N 712553 adapter plate to Jeep bellhousings 8133951 or 3236291: Between 1976-86, there were several Jeeps that were equipped with a 6-1/2" bellhousing depth. This bellhousing had a Ford bolt pattern along with the Ford index diameter of 4.848". By using our adapter plate on these applications, you can easily adapt the Dodge NV4500 to your original AMC bellhousing. This adapter can be used on all AMC 258 6 cylinders and AMC V8s. The stock clutch linkage does not require modifications, since the original bellhousing is being retained. transmission, you will need to drill & tap your bellhousing in order to bolt to our adapter. A new pilot bushing is provided in the kit to fit the tip of the NV4500 input shaft. Your stock clutch components can be retained; however, a new clutch disc and pressure plate should be used. We offer Centerforce clutch disc P/N 384193, and pressure plate P/N CF361897 (for hydraulic linkages) or P/N CF361675 (for mechanical linkages) as an upgrade to a stock clutch system. The transmission must be the Dodge Standard Duty NV4500 with the 7-1/2" input shaft stickout length.

These bellhousings permit an easy adaptation to the Dodge NV4500 transmission. The original Jeep clutch linkage

This kit include:This kit include:

This kit include:

This kit include:This kit include:

P/N 384193 - AMC 10.5” clutch disc P/N 712553 - Adapter plate kit P/N 716021 - Crossmember mount for Dana 300 P/N 716048 - Crossmember spacer P/N 716221 - Retainer kit P/N 716050D1 - Shifter handle assembly P/N 52-0229 - 29 spline Dana 300 input

NOTE:

If your vehicle was equipped with a T4, T5, or SR4

Adapter plate design

P/N 716221

P/N 27-0003BT - 29 spl. DODGE Gas NV4500 to AMC-Jeep engine

The overall assembly length is 25.125”. These kits use an new custom bellhousing that bolts to the stock AMC engine. The original Jeep clutch linkage can be retained, since our bellhousing offers the same clutch linkage mounting holes as the stock bellhousing. Driveline modifications will be required with NV4500 transmission replacements. These kits are not compatible with short wheelbased vehicles such as the CJ5 models. For proper indexing, a new index Dana 300 retainer is provided in the kit. Some crossmember modifications are necessary, and a body lift is recommended. Refer to Page 26-27 for more information on the 712568 bellhousing kit.

This kit include:This kit include:

This kit include:

This kit include:This kit include:

P/N 384193 - AMC 10.5” clutch disc P/N 712568 - Full bellhousing kit P/N 716021 - Crossmember mount for Dana 300 P/N 716048 - Crossmember spacer P/N 716221 - Retainer kit P/N 716050D1 - Shifter handle assembly P/N 52-0229 - 29 spline Dana 300 input

Full bellhousing design

This kit is designed for our NV4500 transmission P/N 26-0029RGM. If you are obtaining your own transmission, you will need to order a new input shaft to work with the bellhousing. P/N 52-0221 - GM input shaft.

GM ENGINE WITH A DANA 300 T/C NV4500 KITSGM ENGINE WITH A DANA 300 T/C NV4500 KITS

GM ENGINE WITH A DANA 300 T/C NV4500 KITS

GM ENGINE WITH A DANA 300 T/C NV4500 KITSGM ENGINE WITH A DANA 300 T/C NV4500 KITS

P/N 27-0000T - 29 spl. DODGE Gas NV4500 to Chevy V6 & V8

The overall assembly length is 26.125”. These kits require the use of a stock GM bellhousing with a 5.125” index diameter. These kits use an adapter plate that couples the Dodge transmission to a standard GM bellhousing. We have included

a mounting bracket for the stock Jeep mechanical clutch linkage. If your vehicle is equipped with a hydraulic clutch, a bracket will need to be fabricated. The drawing on the following page shows the new index retainer for the Dana 300 transfer case. These kits also include a crossmember mount & spacer to properly support the transmission onto the stock crossmember. The stock crossmember will require some modifications, and a body lift is recommended.

This kit include:This kit include:

This kit include:

This kit include:This kit include:

P/N 712550 - Adapter plate kit

(For clutch components, refer to the GM Adapter Plate section of this manual)

P/N 716021 - Crossmember mount for Dana 300 P/N 716048 - Crossmember spacer P/N 716221 - Retainer kit P/N 716638 - Jeep clutch pivot P/N 716050D1 - Shifter handle assembly P/N 52-0229 - 29 spline Dana 300 input

P/N 27-0001T - 29 spl. DODGE Gas NV4500 to Chevy V6 & V8

The overall length is 25.125”. These kits use an new custom bellhousing that bolts to the GM engine. The stock Jeep clutch torque tube bracket can be mounted directly to our bellhousing. This bellhousing also has provisions for a stock Jeep Iron Duke slave cylinder. The drawing on the following page shows the new index retainer for the Dana 300 transfer case. These kits also include a crossmember mount & spacer to properly support the transmission onto the stock crossmember. The stock crossmember will require some modifications, and a body lift is recommended. Refer to Page 47 for more information on the 712576 bellhousing kit.

Adapter plate design

P/N 716021

Full bellhousing design

This kit include:This kit include:

This kit include:

This kit include:This kit include:

P/N 712576 - Bellhousing kit P/N 716021 - Crossmember mount for Dana 300 P/N 716048 - Crossmember spacer P/N 716221 - Retainer kit P/N 716050D1 - Shifter handle assembly P/N 52-0229 - 29 spline Dana 300 input

The recommended clutch components for the bellhousings listed above are found in the GM Full Conversion Bellhousing section of this manual.

P/N 716048

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