5/16 hose to run the vent up from the trans

Replace rear crank seal on the engine and the seals in the trans and transfer case

The transfer case shifter bracket, from Advanced Adaptors , about 45.00 bucks, or fab your own

beg, barrow or buy a trans jack

 

Good luck!

 

cool, Ill add the hose to my list and do the seals. Ill have a tranny Jack and a lift to do the swap on, and Ill probably just fab up the transfercase linkage. I looked at the one from advance adapters and it looks like its just for the conversion from Getrags to NV4500s and it looks like a really simple setup so Ill just do it myself.

Thanks!

 

So I found a Junkyard that can get me every part for the NV4500 exchange except the spline adapter for $1,750, so that's the road i'm taking. I should have the parts within the next two weeks and Have the tranny in the truck within two weeks after that if all goes well! I want to look at the clutch it comes with to see what shape its in but if its in bad shape does anybody have any quality but lower budget recommendations for another one? I think the truck its all coming from is a wrecked one so i'm hoping that the old clutch will get me some use so that I can get to a better $$$ situation and replace it with a high-end one then.

 

Its happening! I have the truck up on the lift as we speak! The new NV4500 is on a pallet along with the pedals, master and slave cylinder, flywheeel, adapter plate etc.

At the moment I have all of the old transmission stuff out except the two lines that run to the radiator and the cooler in front of the radiator if there is one. I got rid of the rear cooler under the passenger seat rear, and the liquid cooled cooler between the turbo and the block. I also need to get rid of the kickdown cable and some wiring as well now that I think of it.

I still have to order a clutch (posted a quote request on here) and I have the spline adapter on order and as soon as I get it all bolted up ill be going to measure for new driveshafts (or just adjusting the lengths on mine actually).

Ill be posting a write up WITH PICS on here as soon as Im done or nearly there because to my knowledge there isn't one so far. Im learning an awful lot about these trucks as I go, there's definitely a lot still to be learned. Im taking note of bolt locations, what sizes they are, any special tools needed, etc., so I can put together an effective write-up.

Also if anyone needs some transmission coolers, lines, parts, etc, I will have everything from the back of the block to the transfercase input shaft excluding a transmission that isn't toast of course...

 

None of the lines run to the radiator they go to the cooler in front of the radiator.

 

I finally got rid of every sign of the fact that there used to be an automatic transmission in that truck today. Got rid of all the coolers, got rid of all the hoses, took care of all the wiring, ordered a clutch, tore out all the carpet and the seat, and on monday ill be measuring to cut the hole in the floor and getting a seal and gasket kit for the transfercase along with an oilpan gasket because its leaking and now's the time to replace that. I'm also going to be ordering a rubber floor liner and need to find a suitable boot situation for the shifter.

 

Im considering doing this to my 91 w250 and was wondering did you replace the column or what did you end up doing? Also do you mind telling me what you have in the total switch?
Thanks in advance

 

At the moment im just disconnecting the linkage on the engine side of the firewall and leaving it but eventually ill probably get a new column.

And the list that I posted earlier in this thread is pretty accurate except I now have the clutch and found out that the best way to go is upgrade to a 13" clutch which comes with a new flywheel and everything that I paid $618 for. I paid $1750 for everything else from a junkyard that pulled everything and put it together for me. And the spline adapter is $220 and you get $70 back for sending in your old one as a core.

Its turning into a lot of work to get it all the way I want it to be but im sure it will be worth it. These are the easiest trucks in the world to do this on and everything so far has been easy, its just time consuming getting rid of all of the automatic stuff like coolers and hoses mostly. So far all of the work has gone flawlessly except for the mess of ATF I have made from all of those dripping lines and coolers. When I post the writeup with pics Ill post a link to it on this thread.

Good luck if you do it!

 

I was in the exact same place as u are last year i had a nv4500 built bought the adapter to run my autmatic 205 tcase got a southbend dual disk clutch and installed
a manual is better all around my milage is amazing now and i can conroll my gooseneck trailer with downshifts and a exhaust break