TH 350 to NV 4500 swap

[mickman77]

Ok, time for all of the research to get put into play. I'm gonna start the swap here in a couple of days in my '77 K20. I'm putting the newer 4500 in so there hopefully wont be any clutch slave issues that I've read about. I'm trying to build an almost bulletproof driveline combo. U-joints are getting upgraded to 1350's and the like...

The 400 cid has already been swapped for a 454.

Any suggestions or advice will be monstrously appreciated..

[mickman77]

Well, a few days has turned into almost 3 weeks now. The shop that is mating my 205 to 4500 is having issues with endplay in the xfer case or so I'm told. Will follow with more pics asap.

[mickman77]

Well, progress today. Here's the adapter I made to solve the clearence problem.(Got tired of waiting for the shop). If you need one of these PM me. My tranny is out of a '93 K2500 and transfer is out of an '87 K3500.

[mickman77]

And heres one of the tranny and transfer bolted together. Didn't paint the transfer because when money allows, it's coming back out and a twin stick with U-joint upgrades is going back in. Thats when it'll get painted. Tomorrow the parts will start to fly and this will be in the truck hopefully by sunday night.

[palposity]

Interesting project. Very nice work on that adapter.

[munger]

how did you make that adaptor and also can i use a dodge nv4500 for this

[mickman77]

Sorry I haven't been here much. It's been a helluva month. Between the cold and time constraints, I didn't take many pics. I do have alot of info though.

1) The trans had to be shimmed up 3.5" to get engine/tranny to sit right to avoid carb problems which led to a 2" body lift. (the transfer case was bumping the bottom of the cab)

2) Both driveshafts had to be lengthened about 2"

3) If you need the rod between the clutch master and the pedal, DON'T buy the master kit from Autozone. (I did and, the plastic end where it bolts to the pedal broke off when I was in Primm NV at 11:30 at night with no parts stores for 40 miles) Buy the Raybestos part from Checkers (out west), it's all metal.

4) Placement of the clutch master was the biggest problem. Setting it up initially, with the pedal against the floorboard and the rod level, I marked and drilled the holes. The initial pedal weight was like pushing a baby elephant. Trial and movement of the master has yielded a slightly more user friendly effort but, am still adjusting that.

5) Did I mention that I love my new 5 speed? Fuel economy has taken a significant rise IF I can keep my foot out of the 4 barrel.....

6) I really don't have any clearance issues with the pass side ext slave because the 4" suspension lift already in the truck changed all the angles and therefore no issues.

When I get the bracket for mounting the transfer shift lever, I'll snap some pics and post them on here of the installed tranny/transfer to give you an idea of how things look.

[mickman77]

Originally Posted by munger

how did you make that adaptor and also can i use a dodge nv4500 for this

I kinda cheated on this and it's supposed to be a trade secret the local tranny shop had a bunch of gaskets hanging on the wall so, I found one that all the holes aligned and used that for a template. Bought a 2.5" thick x 8" round piece of 6061 aluminum to a machinist and had them CNC the pattern out.

As far as using the Dodge 4500, I think the output is the wrong spline count. Both my parts were chevy so, not really any issues there.

[mickman77]

Long time, No update.. sorry. Well, after a little paint, exhaust and brake work, some progress has been made.