'63 K NV4500 removal / reverse build thread

['63GENIII]

This is my first time posting any type of build thread so please be patient. I've learned so much from the members on this forum without anyone asking anything in return except pictures.... so that said here we go.
I bought this truck in 2008 from a guy in Oregon. Who said he was the 2nd owner. As I drove it back to the Bay Area, I promised the 396 that if it got me home that one day I would put an overdrive in it. I ended up getting towed home from Redding but I'm still keeping my promise. Enter the NV4500.
My '63 was an Oakland built K15 that may or may not have come with a small block and 4 speed. I say small block because it uses the small block motor mounts on the sides. There is now a 396 in its place and as far as I know, the mounts have not been moved. When I bought the truck in it also had a floor shifted TH400 of questionable durability. It also has an HEI with no firewall clearance issues or dents. Out front I installed the serpentine drive from a '97 454 with the reverse rotation water pump. Theres about 2" from the factory fan to the radiator. Main reason that I mention this is that I have heard alot of talk about moving the engine forward.

['63GENIII]

I bought the transmission back in October from a guy off of C.L. I believe it to be out of a '94 c3500. Its came with a stock bellhousing, clutch and complete hydraulic clutch pedal, master and slave set up. The guy I bought it from said he had a shop look at it and it was given a clean bill of health before he installed it in his Blazer. He said it ran perfect no grinds - no popouts.
As soon as the last Christmas guest left, I began pulling out the old TH400 with the intent of a three day turnaround. I didn't take pics at the time BC I was in a huge hurry. Working on youre back on fairly steep driveway in between rain storms has a way of doing that to you. So Dec. 30th I finished bleeding the clutch for the 4th time and I took her for a ride. First thing I noticed was the incredibly short, positive throw of the 4500. The second thing was that my 2-3 shift was grinding EVERY time. I did say that he told me it was perfect right? I checked the clutch release point a few more times, made absolutely sure that I had the correct transmission fluid (because I had been warned not to use the wrong one) and then it dawned on me... When I bought it, I did at least open the inspection cover just to take a look and distinctly remember the strong gear oil smell that came out of it. When I put the synthetic stuff in, no such smell. I'm guessing that the P.O. put regular gear oil in and hosed the syncros. From what I hear, it doesn't take long. I figure that I'm pulling it out to do the syncs anyway so I figure I'll take pics in hopes of helping some of the members here that are doing their swaps.
I'll start with what it looks like installed and go backwards. Hereit is in 1st and 2nd gears. There's about 3" to the AC unit and a little over 1" to the front of the seat.
Enjoy the pics.. Chris

['63GENIII]

I bought a replacement clutch master BC the one I had was leaking and I was stalling while trying to figure out wher to put it. I ended up putting it farther to the drivers side of the brake booster and the pushrod lined up with a hole that was already in the pedal arm. I ground down the end of an old brake pushrod (so that it fit the new master), gave it a very slight bend and installed it. I could have really used on of Captainfab's cool brackets here! The clutch release point is about 1/3 of the way off the floor and has a good feel to it.

['63GENIII]

I had one of the kids help me bleed the slave, which, if you're not paying close attention (like I wasn't) can drain the little master quite quickly, making it necessary to start all over again The preformed clutch line/tubewas plenty long enoughand had small clamps that allowed it to be secured to the bellhousing bolts. The preformed bends did make it a little aggravating a few times though.
Hey John, I thought you may like this shot I took to show the clearance between the front DS and the slave. It's just over 4" to contact. I don't think that the front of my truck has that much travel anyway. I think it will be fine.

['63GENIII]

Here's the new driveshaft (halfshaft?) that mates the original T221 to the NV. 12-1/2" to be exact. The guy who built it said he didn't want to reuse the old one due to it having some pretty bad welds. Interestingly the new shaft is actually 1" longer than the one for the TH400. I'll try toadd some side by side pics later.

['63GENIII]

Here's the home made transmission jack waiting to lower the transmission. I highly recommend taking the stub shifter out before installing and removing this trans. Just makes it a little easier. I did strap the trans down to the 6x12 just to be safe. I also jerried up a trans brake (BC the driveway is about a 20-25 deg. slope). Don't laugh it worked!

[Redcap]

Now that is a sweet old truck!

['63GENIII]

Originally Posted by Redcap

Now that is a sweet old truck!

Thanks. Just trying to give it a few upgrades and keep it "old" at the same time.

['63GENIII]

Here's the hydraulic line attached to the bellhousing bolts. The clutch is a standard replacement 12-1/4" kit from Oreilly's. While it says Sachs on the boxes, the parts were all stamped Valeo. The flywheel is for a '69 396. The clutch kit came with a pilot bearing but I opted for a bronze bushing as I had heard of some issues with the needle bearings.
The second pic is of the trans hump and what I had to do to it in order to get the trans in. That was before I had learned that the stub shifter comes out . It was butchered by the P.O. anyway. As soon as it's running again, fixing the tunnel is one of the first things on the list!

['63GENIII]

Here's the old and new DS side by side. The welds on the new one are WAY cleaner than the original. Spicer Joints. The guy does killer fast work and is affordable. He had it done 2 hours after I dropped it off.
Another pic on the bench. Damn thing's heavy!

['63GENIII]

Ok. So I couldn't wait for the manual to get here Tuesday! I pulled the shifter cover and one of the inspection covers. Guess I better wait for the book. I have no idea what I'm looking at let alone what to be looking for. The gears in this thing are pretty massive! After looking at the gears though, they don't apear to be very worn or have any strange wear marks or chips that I can see. I have no idea yet if I can even see or inspect the syncros while it's still together. Should know more on Tuesday.

[Zane M]

First off, awesome truck!
I look forward to seeing the progress of this "journey".

[Yukon Jack]

Have to agree with everyone else, that is an awesome truck - I really like that body style in the 4wd flavor!

[61K10]

agree, nice truck! great build as i was thinking of doing the same to my 61k10. thanks for the build.

[argonaut]

Looking good man! I love your truck and I'm glad to see its getting a little overdrive lovin'!

['63GENIII]

Thanks Jason. Its killin me to look at that OD sittin on the workbench and not in the truck. Just tryin to find the time to get to it. Hey whats that in your avatar? Doin a frame off? I know youve got pics up here. Send a link! Chris
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[argonaut]

Yup, doing a frame off. Unfortunately my budget didn't allow for an NV4500 like I wanted... :P
My build thread is in my signature below.

[RANDY COX]

Iv'e been wanting to see pixs of your truck,Me LIKES very much,KOOL truck..

['63GENIII]

Ill get some more soon. Just took the trans apart and took a bunch of pics. Been real busy with my teenage daughters antics lately and its been cutting into my truck time. Boy I wish they were as easy to figure out as these old trucks!!!
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['63GENIII]

Ok, So I removed the rear yoke, input shaft and mainshaft as the manual showed. I can see where it could have been easier to buy the special tools, but I'm kind of a shade tree anyway and used to making things work. So far, the bearing separator and a little ingenuity has worked out great.

['63GENIII]

Here's the mainshaft on the stool. This bugger is heavy if you ever have to take one out. The manual says that if it won't "roll out" of the case after the input shaft, rear mainshaft bearing retainer and 4th gear syncros have been removed, that you must break the rear countershaft race and remove the rollers. I was able to get the race out without damage which let the countershaft move off to the side allowing the assembled mainshaft to "roll out". The second and third pics are of the third gear syncro and the gear on the side of third gear which is welded on. It looks like the gear on the side of the third gear is a little worn as the syncro has been rubbing against it. I was really hoping to not have to buy a new gear. There's also a pic of the 80$ Craigslist press which I haven't had a reason to use yet. Lastly, I shot a text to the guy who sold me the trans asking if he remembered me. The guy got back to me when he thought I'd be looking for more parts. When I told him that the "perfect working" trans he sold me had a perfectly wasted syncro..... wait for it... no response. I figured as much. I should have known he was a little punk. Oh well, this transmission will be right when it's done!

['63GENIII]

I also just received an old 465 - np205 combo that I had sitting at my brother's place up by Sac. I was thinking of using the bellhousing off of that and converting it to a hydraulic so I could get rid of the low hanging slave cyl. thats on the one currently in the truck. Now I've heard that there is a size difference in the bearing retainers of the 465 and the 4500. I read somewhere of someone having turned down the input bearing retainer on the 4500 and using the older bellhousing. Anyone have any thoughts or experience on this? Is the bolt pattern the same on the transmissions?

[argonaut]

Chris,
I'm anxious to see the assembly pictures.
Also, you can send that PTO down my way if it needs a new home!
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['63GENIII]

Originally Posted by argonaut

Chris,
I'm anxious to see the assembly pictures.
Also, you can send that PTO down my way if it needs a new home!
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You and me both Jason! The delivery date of the first shipment went from today (on the phone when I ordered) to Monday (from the ups website). Just trying to stay occupied for now. I still have one more shot for the PTO on another project. If I turn it loose, I'll give you a shout. Im gonna try to build the puller attachment tomorrow if the kids aren't trying to kill each other every time I go in the garage!

['63GENIII]

I made a puller for 3rd gear which promptly broke upon using and also bent the cage for the 3rd gear bearing. I ended up just grinding the race and using a cold chisel to get it off. Had I known that the puller wouldn't have worked, and getting the bearing off this way was so easy, I think I would have done this in the first place. The bearing was @ 30 bucks. There's also a pic of the stripped down mainshaft.