My 5spd Swap Thread

[01Cummins24v]

well guys my auto tranny is slipping and l honestly dont like it so l decided to swap an nv4500 5spd into my 97 12v auto 4x4. We are planning on starting the swap on Thursday and l plan to take as many pictures as possible to help visual learners see whats involved. l am also posting a detailed parts list with prices and where l got them so here it is.

NV4500
-Bellhousing
-98+ shifter assembly
-Pivot Ball
-Clutch Fork
-Pedals
-2pc manual trans mount
-98+ agate colored shift boot/console
$1240 Cumminsforum.com Classifieds(cummins5spd)
Flywheel/Clutch, Valair NMU70279-01-5SCE, 13" flywheel with 400hp clutch, pilot bearing, alignment tool, and throwout bearing
$619.55
Flywheel Bolts Quad4x4, P/N Qk6009
$40.45
Pressure Plate Bolts Mopar, P/N 6034555
$16
Spring Clip Mopar, P/N 4338855
$3.35
Master/Slave Assembly Rockauto.com/Wagner P/N CM140990
$178
NV241DHD 29 Spline Input Quad4x4, P/N QU10699AM
$145
NV4500 Fluid Amsoil, P/N MTGQT-EA
$64.10
241 Fluid Castrol ATF +4
$24.00
NV4500 Output Seal Mopar, P/N 4269956-AB
$9.95
Clutch Alignment Tool Southbend, P/N N/A
$14.00
Chiltons Repair Manual O'Reillys, P/N CHL20404
$24.99
Input/Output seal for T-case O'Reillys, P/N ?
$24.00

Total
$2389.39

All the parts used in my swpa are new minues the stuff bought with the trans, if you could find this stuff used it would save you quite a bit but I didnt want to deal with tracking the stuff down and hoping it was good. I am sure I will be making a few runs to the parts store for small things but this should cover most of the parts if I do run to the parts store I will post what I got and the prices.

I did not know this but the NV4500 takes a specific type of Fluid You can get it at the GM or Chrysler dealership but I found Amsoil makes a version that is supposed to be superior to the version the dealers have and it was about $30 cheaper than the dealers and Quad 4x4. Also do not waste your money on the Chiltons repair manual it does not cover this area very well.

__________________
1997 4x4, 5spd, Valair 13" single disk, 4k GSK, BHAF, #100 Plate, AFC tweaked, 6" Mitre Cut Stack, Autometer Gauges, KDP tabbed, leveling kit. 35's, Moto Metals

Ohio Coal Rollers

---

Last edited by 01Cummins24v : 11-09-2009 at 11:28 PM. Reason: Added Parts List

[PVXCummins]

Sweet deal, cant wait to see the write up and pics! I partcially helped my friend with his, and it was a blast. His name here is Whippit96 and Im sure he'll be more than willing to help with questions if you have any! Good luck!

__________________
98 4x4 12V, 47RE, Pakbrake Ex. Brake, TQ Lock up, BHAF, 4in to single 5in miter , Boost and EGT gauge, 370 Haisley Injectors, #6 Plate slid, Star wheel turned, Silencer Ring MIA, CB, 305 A/T tires New #'s 10/17/09 323 HP and 700 TQ

[01Cummins24v]

l just noticed there are not many thread about the 5spd swap with pictures and a detailed parts list, everything I found was very vague and left me thinking I should pay someone to do it for me so I figured I would do the research and try it on my own and hopefully help someone else along the way. l figured l can take some pics of the more complicated things like tearing into the transfer case and things of that nature to help other people that might be hesitant to do it and end up wasting money paying someone else to do it or worse sticking with there auto. l am not a mechanic but me and my father are pretty inclined and l have not done a 5speed swap before but l have done motor swaps and many other challenging automotive tasks. l have done a lot of research on this so hopefully it will go smoothly.

If anyone has any tips or tricks or parts that I have forgot to add please do it this is reference/parts list/build for me and anyone else who wants to do this so anything to help is more than welcomed.

__________________
1997 4x4, 5spd, Valair 13" single disk, 4k GSK, BHAF, #100 Plate, AFC tweaked, 6" Mitre Cut Stack, Autometer Gauges, KDP tabbed, leveling kit. 35's, Moto Metals

Ohio Coal Rollers

---

Last edited by 01Cummins24v : 11-02-2009 at 01:53 PM.

[JakeDiesel]

This great been waiting for somebody to do a thread like this think that it will solve alot of ?

__________________
94 Dodge 1500 black regular cab 2wd powered by a 2005 Cummins 3.9 4BTAA 27mpg (Friends) 95 Dodge 2500 4x4 boost elbow (35psi) #6 fuel plate http://www.cumminsforum.com/forum/cu...ics-truck.html

[12valveterror]

subscribed, ive been wondering how this is done, i hope you can shed light on how to get this done and with pics thats just awesome

__________________
97' 2500, 12Valve, 4x4, Auto, Dunrite Triple Disc T/C & V/B, Bilstein 5100 Shocks, DSS Stablizer, Dipricol Gauges, #0 Fuel Plate, 14cm Non-Wastegated Housing, KDP Killed, T/C Lockup Switch, 15* Timing, 2" Leveling Kit, 4" Turbo Back to 5" Mitres

[ReubyT]

Cant wait to see pics.
I should be doing my 5 or 6 speed swap by spring so this will help

[SmokinTheHippies]

i know get vert did this on his truck, actually i am pretty sure his setup is the the one that whippit installed (he sold it and went to a billet auto)

__________________
2002 2500 HO 6 spd 4x4 -433HP- Feb '09 ROTM. Gone to new home!
Thanks Holland Court Diesel!
In search of my next Pig.

http://www.youtube.com/watch?v=axAEF...=youtube_gdata
...."your half a maaaaannn!"

[PVXCummins]

Originally Posted by SmokinTheHippies

i know get vert did this on his truck, actually i am pretty sure his setup is the the one that whippit installed (he sold it and went to a billet auto)

Yup thats 100% correct, thats the setup Whippit put in his truck. I was there for the un-installation of the auto tranny, but never made it back for the install of the 5 spd.

__________________
98 4x4 12V, 47RE, Pakbrake Ex. Brake, TQ Lock up, BHAF, 4in to single 5in miter , Boost and EGT gauge, 370 Haisley Injectors, #6 Plate slid, Star wheel turned, Silencer Ring MIA, CB, 305 A/T tires New #'s 10/17/09 323 HP and 700 TQ

[MX26]

Subscribing.. And, when you're done, feel free to drop your auto off at my house. Thanks.

__________________
Trust me.... I'm a doctor.
94 12V NV4500 2wd - #100FF, BHAF, 3GSK, 4" FBD Straight
98 12V Quad Cab Shortbed SLT 4x4 - Auto with a "few" mods

[20valve]

Nice Justin. Here's some pics to help from last week when I started my swap.

The pedals. There is a giant pin that the pedals hang, or swing from. As was stated in numerous posts, you DO NOT need to remove the entire magnesium part from the dash/firewall. This second pic shows the "E" clip on the driver's side of the pedal/steering column housing. The camera was wiggled up in there for a close-up (pic #2).

The clip is pretty tough to get at, but it is do-able. To help me out, I went to the passenger side of the pin and removed that side first, allowing me to slide the pin to the driver's side about an inch (pic #3).

It's enough to get a flathead screwdriver in there and pop the clip off. Then, work the pin towards the passenger side and pull it out. There's plenty of room on that side. When you get everything out, it should look something like pic #1.

The white things with a diagonal cut in them are the bushings. There's 4 of them in the auto pedal setup, 6 in the manual. I cleaned mine free of the old grease, and put fresh stuff on there. It doesn't take much, either.

I will say putting the manual pedal assembly in is a pain in the butt. There is one wavy washer that goes inbetween the brake and clutch pedal. The easiest way for me to install it was to slip two pieces of thin plastic on both sides of the washer, and try to wiggle both pedals and the plastic up to the mounting location. Then, work the pin in from the passenger side, and slip one piece of plastic out at a time. It takes a little bit of time/patience, but it's easier than trying to just hold the washer in there by hand (I fought mine for about 1/2 an hour before it went). Once you get the pedals, bushings and the washer in, put the clips back on and re-attach the hydros/brake lever. Hopefully this helps somewhat!!!

Attached Images

	autopedalparts.jpg (36.8 KB, 41 views)
	pedalpinflush.jpg (20.3 KB, 41 views)
	pedalpinout.jpg (22.1 KB, 34 views)

__________________
Budget Build: 98 quad cab 3500 215 pump 3k GSK 0 Plate 16* timing
BHAF 4" pipe. One very tired auto (REMOVED!!!) NV4500 swap in the works Valair 13" Kevlar/Ceramic clutch HE351 swap also in progress

---

Last edited by 20valve : 11-03-2009 at 12:41 AM.

[Box5]

Nice parts list so far, this will be a good thread for people looking to do the swap.

The only tricks I learned from doing my swap were:

1. Trace the bottom of the shift boot onto some cardboard, that way you can cut the hole in the floor alot easier.

2.Make sure to get the right size input bearing for the t-case, I believe there are two widths, one for the DHD (heavy duty t-case), and DLD (light duty t-case), so make sure what t-case you have when you order.

3. The wiring is straight forward, take the 3 wire plug from the auto trans, run the black/white wire up to the neutral safety switch by the clutch pedal, and wire it to one of the wires on the Nuetral safety switch, ground the second wire that came from the switch. Now you have two wires leftover from the plug at the trans, take them and they goto the only plug on the nv4500 for reverse lights. If you don't have the male nv4500 plug, only the female thats on the trans, you can take it to a parts store and get one that fits.

4. I had to modify my t-case shift lever mount so it would hit all 4x4 ranges.

__________________
1994 3500 CTD, 5spd swap complete, 100 plate, 3gsk, 181 dv's, Banks Twin ram, 4" straight to 6" tip

[01Cummins24v]

thanks for the the tips guys as for the transfercase l called quad4x4 and gave them the type of transfer case l had which was a 241dhd and gave them my assembly number and they determined l had a case with the narrow bearing so they sent me that. l am actually planning on modifying the 97 4x4 shift lever to fit the 98+ boots, l am going to cut about 1.5" of the height off of it and shorten about 2.5" so it will sit in the 98+ console just like the one in my 01 does. l will also take pictures of this.

l only have 2 more days until we start. l am dropping it off at my dads house on thursday night and were going to drain fluids, pull driveshaft disconnect linkage and all that fun stuff then friday when l get of class is when all the real fun begins.

__________________
1997 4x4, 5spd, Valair 13" single disk, 4k GSK, BHAF, #100 Plate, AFC tweaked, 6" Mitre Cut Stack, Autometer Gauges, KDP tabbed, leveling kit. 35's, Moto Metals

Ohio Coal Rollers