[RoostersCummin]

I’ve began the swap, nv4500 is getting rebuilt by a local transmission shop I’ve pulled the shafts and skid plates tomorrow I pull the trans and t case.
Luckily a guy on YouTube university has done all of this and documented it well.
I have a 4d short bed with a solid rear shaft I’d like to know what I need to lengthen the rear and shorten the front to?
Would like to get them dropped off at the driveline shop asap. Maybe someone with the same chassis can measure their shafts.
Found a burnt up 5600 trade with clutch I plan to do this upcoming weekend with the burnt up stage 2 48.if all goes well I’ll be just under 3k into this entire swap

 

[RoostersCummin]

Got the t case and trans removed today I fought that t case for days to break loose here is how I did it incase someone crosses this issue of corrosion.

 

[RoostersCummin]

 

[RoostersCummin]

Can’t find any thread on it but I’m going to attempt to run the 273 electronic t case behind a nv4500 same 29 spline as the nv4500 per my research but I have an extra manual shift t case for backup options…
Also purchased the new app sensor which needs to be done when swapping to manual or you’ll be restricted to 50% pedal per research of another swap documented, still have to reach out to smarty for the manual file.
On the early 03-04 with the 48s you need to unplug the tcm all three plugs on the firewall. And ground the brown with yellow stripe if I remember correctly on the 5 prong plug (this is the neutral safety switch) green and pink are reverse lights if your worried about that. the rest are just tied up out of the way. Now I just need to cut the hole in the floor which is pretty straightforward as it’s knotched for a manual from factory, master cylinder for clutch has a removable cover already bolted on and third pedal assembly is there just missing pedal and pin. 38 bucks from dealer website. Cut the brake pedal down or change it over. Will try to document with photos as I proceed with the following steps.

 

[bobm_4640]

I'll be watching. I've got a NV4500 and all of the bits and pieces ordered. You shouldn't have any problem running the electric shift case, it has its' own control module.
It seems like there's enough good info out there on these manual tranny swaps. I believe Smarty is the only tuner that will allow an auto to manual flash for the ECU, I heard something about EFIlive but nothing definite. Remember to not permanently ground the neutral safety switch wire, get a factory mounted clutch switch. Cruise control will not work if the wire is always grounded.
Good luck!

 

[RoostersCummin]

I'll be watching. I've got a NV4500 and all of the bits and pieces ordered. You shouldn't have any problem running the electric shift case, it has its' own control module.
It seems like there's enough good info out there on these manual tranny swaps. I believe Smarty is the only tuner that will allow an auto to manual flash for the ECU, I heard something about EFIlive but nothing definite. Remember to not permanently ground the neutral safety switch wire, get a factory mounted clutch switch. Cruise control will not work if the wire is always grounded.
Good luck!

I appreciate that information on the cruise control, especially on the t-case it’s a relief. today I rolled it outside work goes on and I’ve got another vehicle for sale to cover the price of the 30k lbs tow rated twin disc clutch kit I’m after. Also stuck waiting on my transmission guy to finish rebuilding the nv4500 I’m hoping to be in your shoes, having everything ordered or in hand when I go to retrieve my transmission. I did not cut the hole in the floor yet due to it hit -20 last weekend.

 

[RoostersCummin]

Been a little longer than expected but we’re still moving forward I have the transmission rebuilt and in hand I have a dual disc clutch I traded some axles for and heavy duty master/slave from southbend. Found out today while mocking up the bellhousing that it’s cracked and not something I’m going to reuse. Any day now fedex will deliver a new pilot bearing and throw out bearing. I ordered brake pedal pad and clutch pedal with pin from dodge for 80 bucks altogether. Tuesday I’m rolling it back inside to do all the interior work and tomorrow smarty should be emailing me the recovery file to delete the tcm.

 

[bobm_4640]

Hey you're making good progress!
I have everything complete except for the throttle position sensor wiring and the Smarty programmer (which I ordered this weekend).
With the NV4500 installed I'm having my rear driveshaft lengthened 1", that puts it in the stock position. The front shaft has plenty of spline travel/compression and doesn't need modification. I noticed some guys don't lengthen the rear shaft, but since I tow fairly heavy loads I really want the stock spline engagement.
I did have to buy a transmission mount bracket for the NV4500, as the 48RE bracket wont work. The actual rubber tranny mount does work, but not the bracket that bolts to the tranny.
The flat 6-pin connector that plugs into the 48RE has the wires for the reverse lights and the "park/neutral" wire, along with a switched 12vdc+ wire. I wired the 12vdc+ wire and the reverse light wire to the NV4500 reverse light switch, works like a charm. I also ran the "park/neutral" wire to one side of the clutch safety switch, the other side of the switch is grounded to the chassis. This is the wire that must be grounded for the engine to start, it provides a ground to the start solenoid relay.
Instead of an APPS, I'm updating to the 2005 style APS that's built-in to the accelerator pedal. KrashDH has a really good write-up on this conversion on this forum. I had to buy the 2005 accelerator pedal, a matching plug, and the pins that I will add to my ECU plugs to accommodate the new wiring. KrashDC did the conversion on a stock manual transmission truck, since my truck came stock with the automatic transmission, the ECU plugs don't have the wires needed (the pin holes in the plugs are plugged). So I have to install wired pins into the ECU plugs, I bought the pins from Digikey, and a crimper/installer kit from Amazon.
Hopefully I can get things finished-up in the next few weeks.

 

[RoostersCummin]

Hey bob thanks! you are well ahead of me at this rate, I purchased an app sensor from Geno’s garage which says it can work with either manual or auto and easily calibrated.
I’d like to see a photo of how you did your wiring if you remember next time your underneath her again. Your reverse wiring to the trans and clutch pedal grounds.
[email protected] is the email they require the year, whether it’s a cab n chassis or pickup, “manual swap” and the vin. Subject line “manual recovery file” they will email you a PayPal link to mm3 for 150$ and I have received my file took them one business day.

 

[bobm_4640]

Thanks for the Smarty info, I didn't realize I'd have to purchase a program apart from the programmer itself. I did contact Smarty support and am getting that taken care of.
Here's some photos.

This is the 6 pin flat plug that plugs into the 48RE. Only pins 1,4 and 6 are used for the tranny swap. 2 wires go to the back up switch on the manual tranny, and 1 goes to the clutch safety switch.

Not much to see really. I cut off all of the unused connectors, and terminated each wire with hot glue heat shrink, then put wire loom over the whole works. The red arrow points to the back up switch wires (pins 1 and 4 on the old plug), and the blue arrow points to the wire leading up to the clutch safety switch (pin 6 on the old plug).
Take care.