Auto to Manual 5 Speed Conversion.

[DodgeCummins98]

Alright I just stuck this in General Discussion as I'm not sure where it goes. Mods please move it wherever it belongs.

I keep seeing people asking about how to solve the problem of their junk auto and wanting to go to a 5 speed. I don't believe I ever did a write up on my swap, so I'm doing it now. This should cover any 98-02 24v trucks looking to go to a 5 speed. Note that if you want a 6 speed, I don't know what the differences would be or any extra parts/work that would be required.

You need:

* Transmission
* Clutch
* Fly wheel
* Fly wheel Bolts
* Pressure plate
* Throw out bearing
* Clutch release fork
* Transmission soft mounts
* Master and Slave Cylinder
* Bellhousing
* Shifter stick and boot
* Clutch and brake pedal (only the pedals themselves, the mounting bracket is the same on auto and manual)
* Front driveshaft from a manual truck
* New input shaft for your transfer case (or just replace the whole t-case with one from a manual truck).
* (4) Quarts of fluid from MOPAR dealer, 5 quarts is preferred but this stuff is about $20 a quart.

For the interior to look stock, I had to replace one piece of the steering column trim, add the shifter console with the cup holders and stuff, and remove the automatic cup holders and install the dash pocket that comes in manual trucks.

You will NOT need a new steering column. If you remove the trim you can just knock the auto shifter off. It's held in by a tapered pin. Punch it out from the bottom and out the top. The shifter just falls off.

Now for the wiring to make it all work. The only plug needed is the Neutral safety switch off the auto tranny. It is a 3-wire plug. The middle wire on the plug will have to be run up through the fire wall and hooks to the clutch safety switch. The CSS has two wires on it, you can attach to either one of them, and then take the other one and ground it on the firewall. Now for the other two wires on the Neutral SS, These are for your reverse lights. They go to the only plug on the nv4500 transmission. That's all the wiring it takes.


I did NOT need to reflash the ECM. Never touched either one of the computers. My truck has run absolutely fine and I have seen zero need for a reflash. This seems to vary with the trucks. Some trucks seem to care less about the manual tranny, and some will light the dash up like a big Christmas tree and will need the reflash. Either way, it's not a big deal. Any dealer can reflash it for you.

COST: I paid $1800 bucks for a complete conversion out of a wrecked truck with 70k miles, plus shipping to get it to me. Came with a new stock clutch even. I had several extra parts that came with it that I didn't need and resold a few of them. I even got the t-case in the package also so I still have the one out of my truck.

There are deals out there if you have enough patience. The cost of all new parts and a fresh rebuilt/new trans would probably be about double the cost.

I was able to sell my Jasper transmission and TC for $2200 minus the shipping, so it practically paid for my conversion and then some. It helped that the trans was almost new, but it was already starting to slip with just my Juice. I decided to sell it while it was worth some good money before I trashed it by leaving it in the truck.


I hope this helps some of you looking to do the swap. It truly isn't that bad. Not much more work than swapping in a new auto after it goes out on you for the Xth time.

If anyone has anything to add, please feel free to do so. This is a pretty short write up so if there are any questions about something I didn't cover, PLEASE ask.

__________________
98.5 2500 4x4 Reg Cab, 6" GrandRock's, Adrenaline w/ Pulse, FASS 150, Isspro gauges, Auto to NV4500 swap, Leveled on 315's Cooper ST's - Engine being rebuilt
07.5 3500 6.7L G56 Manual 4x4 Quad Cab Dually

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Last edited by DodgeCummins98 : 11-27-2008 at 03:48 AM.

[PeeWee]

Originally Posted by DodgeCummins98

Alright I just stuck this in General Discussion as I'm not sure where it goes. Mods please move it wherever it belongs.

I keep seeing people asking about how to solve the problem of their junk auto and wanting to go to a 5 speed. I don't believe I ever did a write up on my swap, so I'm doing it now. This should cover any 98-02 24v trucks looking to go to a 5 speed. Note that if you want a 6 speed, I don't know what the differences would be or any extra parts/work that would be required.

You need:

* Transmission
* Clutch
* Fly wheel
* Pressure plate
* Throw out bearing
* Clutch release fork
* Master and Slave Cylinder
* Bellhousing
* Shifter stick and boot
* Clutch and brake pedal (only the pedals themselves, the mounting bracket is the same on auto and manual)
* Front driveshaft from a manual truck
* New input shaft for your transfer case (or just replace the whole t-case with one from a manual truck).
* (4) Quarts of fluid from MOPAR dealer, 5 quarts is preferred but this stuff is about $20 a quart.

For the interior to look stock, I had to replace one piece of the steering column trim, add the shifter console with the cup holders and stuff, and remove the automatic cup holders and install the dash pocket that comes in manual trucks.

You will NOT need a new steering column. If you remove the trim you can just knock the auto shifter off. It's held in by a tapered pin. Punch it out from the bottom and out the top. The shifter just falls off.

Now for the wiring to make it all work. The only plug needed is the Neutral safety switch off the auto tranny. It is a 3-wire plug. The middle wire on the plug will have to be run up through the fire wall and hooks to the clutch safety switch. The CSS has two wires on it, you can attach to either one of them, and then take the other one and ground it on the firewall. Now for the other two wires on the Neutral SS, These are for your reverse lights. They go to the only plug on the nv4500 transmission. That's all the wiring it takes.


I did NOT need to reflash the ECM. Never touched either one of the computers. My truck has run absolutely fine and I have seen zero need for a reflash. This seems to vary with the trucks. Some trucks seem to care less about the manual tranny, and some will light the dash up like a big Christmas tree and will need the reflash. Either way, it's not a big deal. Any dealer can reflash it for you.

COST: I paid $1800 bucks for a complete conversion out of a wrecked truck with 70k miles, plus shipping to get it to me. Came with a new stock clutch even. I had several extra parts that came with it that I didn't need and resold a few of them. I even got the t-case in the package also so I still have the one out of my truck.

There are deals out there if you have enough patience. The cost of all new parts and a fresh rebuilt/new trans would probably be about double the cost.

I was able to sell my Jasper transmission and TC for $2200 minus the shipping, so it practically paid for my conversion and then some. It helped that the trans was almost new, but it was already starting to slip with just my Juice. I decided to sell it while it was worth some good money before I trashed it by leaving it in the truck.


I hope this helps some of you looking to do the swap. It truly isn't that bad. Not much more work than swapping in a new auto after it goes out on you for the Xth time.

If anyone has anything to add, please feel free to do so. This is a pretty short write up so if there are any questions about something I didn't cover, PLEASE ask.

Are you stalking me? I swear to god about a half an hour ago I was telling my roommate I was hoping to god I could find some decent information on the auto-5speed swap on this board because that auto tranny is my pickups one and only character flaw. Everything else I'm in love with.....that....not so much! Thank you very much!

[cumminstacker17]

subscribed i want a manual, but there are no manual trucks for sale. but i got to wait till i get hired by CHP, Sheriff or SJPD

__________________
1999 2500 auto, S&B cold air intake, turbo back stacks, HPFP 95, Edge EZ 180k on a 53 block

[BBRam]

Thank you DodgeCummins98! Moved to the 98.5-02 Modifications Tech Article Forum. :thumbsup

__________________

03-3500, DRW, QC, 4x4, R850 BD Twins, BD IC Boots, BD Billet Flexplate, Full Billet DTT Trans, Lockup Switch, SMARTY TNT-R / TS MP-8, Wicked Diesels Eliminator Fuel System & Coolant Bypass, Floor It Stage 3 CP3 & Rail Cap, BIG Stix's by FTE, ARP Head Stud's, Springs, Fluidampr, ATS ARC-FLOW, Mag-Hytec, AFE, Boost, Drive Pressure, Pyro, Fuel Pressure, Tran's Temp, Rail Pressure Gauge, GDP Ladder Bars, GrandRock 7" Miters. (R/T .021, 60' 1.76, 1/4 ET 13.03 @ 102.05 mph)

July 2009 Cummins Forum ROTM Winner

95 1500 Sport 2wd Cummins Drag Truck under construction.

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