i know you gotta change the input to the t-case when goin from an auto to a manual but when swaping out the input shaft in the t-case what do you need to machine. to make to work and why? also with a nv4500 will it bolt up to my original flywheel cover? and what do i need to bolt a 205 case to a 4500 4x4 trans. other than shaft change, do they have same bolt pattern?

I couldn't find anything in the sticky bout this.

 

Hi Dan. The NP205 has the same bolt pattern as the back end of the NV4500, so they bolt right up. However, you have a splined coupler between the two that drives the transfer case and it will most likely be too long for the 4500. I removed the NP205 from the getrag that I was replacing with the 4500 and chose to remove the rear oil seal from the 4500 so that the coupler runs in gearoil, rather than running dry all the time. That way, you don't need to shorten the coupler and it bolts right up. Since there is a seal in the front of the NP205 and I run GL5 in both the tranny and the transfer case, it shouldn't make a difference whether the tranny seal is there or not. So far no problems in 8 months of use.

 

It will all bolt wright up if you change the bell to a getrag bell ( takes some mods) or and advanced adapter bell ($300 but bolts right up). It is much easyer to find a 5 speed t-case than pay for the parts ( input shaft and gear, bearing, seal and retainer, coupler,) and machine work. I have done lots of these swaps. Remove the output seal on the 4500 and over fill the trans 1qt to fill the adapter so that the trans dont end up about 1qt low as the oil is slung into it over time.

 

You can run the 4500 with a Getrag bell? What modifications are required? The bolt patterns are different?

 

OOOOOh, OK so theres more to changin the t-case over than just a shaft huh, and like the captain said what mods for the bell?? and if you remove the output seal to the 4500 will the trans and case share fluid? or is there another seal in btwn. the 2? will i reuse the adapter btwn my auto and t-case or should it be part of the junk yard trans. ill be gettin?

 

You still have the seal on the input of the 205. To make the g-rag bell work you have to mill out the bell to fir around the 4500 input bearing retainer and use a 3/16 spacer plate between the bell and trans ( to space the input shaft ) and then use the bell as a guide to drill the holes from the bell to the case ( revurse of stock case to bell set up) then tap the case and run 1/2" allen head bolts from the bell to the case. Also you have to cut off 3/4" off the end of the input bearing retainer shaft with the AA or Getrag bell to clear the clutch disk. Its not hard to do just have to take your time and do it right. The 4500 will use the adapter that is aready on the 4x4 modle and will bolt right up just like on your auto. The manual trans ( getrag and 4500) use 29-spline shafts and the auto uses 23-spline shaft on the input shafts and a smaller bearing so the case on the auto hsa to be milled out for the larger bearing and seal and the retainer takes some work too. you can buy all the parts but its $$$. if you just want to make it easy use the advanced adapter bell. also this is how I mounted the t-case shifter and it works better than the AA shifter mount.

 

thank you so much for your info im goin with an advance adapter even though my good buddy is a machinest itll take to much down time and ill price out a 4x4 t-case vs. an input shaft, seal, bearing and retainer see which is less $$ in my area.

Thanks 1stGen545

 

any time just let me know if you have any more ??? it is an easy conversion just has a few little thing that will wip your but if you dont know in advance. the pedles will just bolt right up and so will the bracket that holds the master cyl. you can also get some fittings that will alow you to use a SS braided line with AN-3 fittings if you cant find a good used line for the clutch ( new ones are $$$ ) http://www.nv4500.com/product_info.p...ducts_id/24301 is the fitting you will need you need 2 one for master and one for slave (takes same fitting).

 

this guy may have a T-case and he sas some other parts you may need if you dont have them yet https://www.dieseltruckresource.com/...ct=14950&cat=3

Or Hw dose have a 205

https://www.dieseltruckresource.com/...ct=15196&cat=2

 

thanks but i still gotta finish combing the yards around here in fl. shipping would prob. kill me for a t-case from outta state.

 

It was just incase you couldnt fine something.