Ok,I've got a 91.5 4x4 ctd auto but i've been looking for a 5- speed for a while.Finally i found a nv4500 with a good price so i bought it,its a 2wd 4500 out of a '95 dodge ctd,it has the bellhousing on it and i got the clutch &pressure plate with the bolts.My question is what all do i need now? do i need a second gen starter? is there an adaptor to keep from divorcing the t-case?

 

Looks like you need a Divorced NP205 and mount out of a 1972-1973 W100-W300 Truck. Shorted the rear shaft and lengthen the front axle drive shaft. The tcase shifter linkage will be custom as well.

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how'd you make that shaft?

 

oh that is just a normal ~11" driveshaft. The tube is the aft section. Same as a normal shaft but just only a inch or so of tube.

The one between my tcase and brownie is an even shorter 9" yokeshaft... No tube at all, just a yoke in a short slip.

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Did you grab it off another truck and have it majorly shortened, or use the middle shaft of the 2 piece shaft on the club cab (or your crew cab) trucks? Or buy it somewhere? That Brownie set up you have in that thing is wicked cool!

 

I didn't buy it, it came with the truck. The slip was a 1310 though. I just replced it with a 1410 slip and upgraded the np205 input to a 1410 as well. when I replaced the factory 727 with the getrag 5 speed I needed to push the transfer case back three inches otherwise the shaft was too short /steep angle = noise/vibes.

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Is there a way to marry the 2wd 4500 to my np 205 t-case?

 

not sure on teh NV4500s but it won't be cheap or easy to find the parts you need short of buying a core nv4500 4wd trans. You might need the mainshaft, tailshaft housing, coupler, etc.
You have a weak 23 spline input shaft on the np205 that came with the autos. You'll can buy a 29 spline input shaft for your np205 like what came with the 5 speed trucks but it costs almost $1000.

The cheapest way but more fab/custom is to get a divorced case. 32 splines on all three shafts on those...

It is a tough call. a 4x4 nv4500 isn't going to be easy or cheap to find and then you'll still need to figure out how to get it to mate to your np205... You could have a custom 29 to 23 spline coupler made but hm,mmm...

 

I just finished my conversion last week 1991 4x4 auto to a nv4500, the things I did not see coming were the engine adapter plate $200, the bracket mounted on the inside of the firewall for the master cyl. $50 (ripped of from a shady local reacking yard) I read conflicted posts about starters and flywheels I can tell you this I had to get a starter for a 1995 dodge RAM 5 speed $350! No core to return nether! And I had to fab up my crossmember and give my clutch pedal arm about another 1/2" more through. If I would have any idea how much the whole job would cost me I would have just bought a new truck. But that's just me I'm a poor edit full of great ideas.

 

did you use a 4wd nv4500 or a 2wd?

 

you might also want to check for the infamous 5th gear problem, since your nv45 is from a 95 year/model truck. would be easier to get it done while the tranny is out.

 

I used a nv4500 out of a 4wd