Getrealgetlifte

I am almost done with my Automatic to Manual transmission conversion. I have a 96 Dodge diesel and hated the automatic, so I did a nv4500(5speed). I have all the mechanical stuff done besides the transfer case, I am now curious on what electrical stuff needs to be done to complete this deal. I know the little stuff like the back up lights and little stuff but what else? If anyone can help with info that would be great.

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apache

Off hand I cant think of any electrical goodies besides the BU lights on my 95. Did ya address the 5th gear issue?

torquefan

I just did one on a 96. I found I had to change the t/case input shaft. (surprise!) For wiring, apart from the backup lights (pretty easy), I grounded the neutral safety switch wire at the transmission, so the starter relay would always "see" park and would operate. After doing this, the cruise control would not work, as the PCM was "seeing" park. So I disconnected the neutral safety switch wire from the PCM so it would "see" drive/reverse.
It all works well, the "trans temp" and "o/d off" lights come on at startup, and then go out, no "check engine" light, speedo and cruise work normally. If you like, you can hook up the clutch safety switch, the connector is jumped together and hidden behind the bulkhead connector under the dash. I left mine jumped together.

Getrealgetlifte

Yes heavy duty clutch, 5 gear fixed and all shined up ready to finally put more power behind it and tear $hit up!!!!

heavyboostin

When you did this swap did you folow any instructions or some kind of write up, i was thinking of doin htis when my transmission goes out but i wanted to see how much work was involved and also the cost of the swap, i ahve a 97 4x4 auto.

Getrealgetlifte

not at all!!!! I found a wrecking yard that had a 94 diesel 5 speed so I bought the tranny, bellhousing, clutch, flywheel and preesure plate. they gave me the cross member and the master and slave cylinder set up plus, every single nut or bolt that came off when they removed it from the wrecked truck. I also got the 3 pedal set too. its nice to have 2 sets of all the nuts and bolts you want I bought all this for $1700.00. I will say when doing the pedals DO NOT REMOVE YOUR WHOLE PEDAL ASSEMBLY!!!!! there is absolutely no reason to. I spent 3 hours removing it and at the end realized that all you do is pull the c clip and slipe out the rod that holds your brake pedal and replace your brake pedal with the clutch and brake pedal!!!! its up to you 3 hours or 20 min????

Then I bought a heavy duty clutch and pressure plate and got the flywheel re surfaced. about 450.00

come to find out since its the "heavy duty" 5 speed, the output shaft is too large for the automatic transfer case. Now you can have it changed out or just buy the 5 speed transfer case. I bought the 5 speed t case for 300.00 usually 700.00 from what I have been told.

Last, the 5 speed is about 4 inches shorter than the Automatic so you have make adjustment with your drivelines. I grabbed the front one off the wrecked truck!!!

With all that said... was it hard? Yea.... but doing it yourself you save atleast $2500.00- $3000.00 in shop labor. It helped me out a lot to have a friends 97 5 speed all complete to look at when I had any questions.

EASILY WORTH ALL THE BUSTED NUCKLES AND TIME UNDER THE TRUCK!!!!!!