How much did it cost the whole deal ?



Do these transmissions give toothaches ?

 

Dads NV5600 in his 2001 3500 has 130kish miles on his truck. Still shifts as good as the day it came off the lot. Know others who love their 4500. To each their own I guess...

 

I would have to look it all up but... too include everything....shipping, new clutch (again ) as it is a much bigger main shaft, shorten 1 drive line and extend the other all work done by me except drive lines...was about 3 Gs give or take a 100 ( 3 years ago ) cant remember..
Peter @ South Bend had to do something to the fly wheel to make the giant clutch work
Keep in mind this was the 2nd time I had to take it out (the NV) and I have other hobbies I would rather do then lay under a TRK. LOL
The patch up kits for the NV was getting ridiculous $$$ too! Plus all the work to take it apart, put the band aids in and when done there was still the mystery or misery when it would break again ....So the 6 speed has been a very good unit. Close ratio shift Pt's alone make a dream come true

 

My 2001 Dodge 3500 dumped 3 NV5600's before 112,000--had enough. Installed the Fuller FSO6406 in Jan 2008 and been driving it in 2WD and 40,000 +++ trouble free miles.

Finally got around to fabricating the transfer case adapter.

The shaft assembly went very smoothly with no errors or make-overs--got it right the first time. The adapter and shaft were assembled and fitted to the transmission and it was like bolting off the shelf parts--everything fit with no binding, slop or use of a 10 lb adjustment tool. The old saying still applies, measure twice and cut once.

I have $1,225 in this first "one-off" unit and includes purchased parts, materials and machine shop labor. This also included $127.42 in tooling hardware. A considerable amount of time was spent programming and verifying dims as we only had materials for one part.

The shaft was made from a DANA 38 tooth 7-1/2" companion flange cut to 3.50 and a broken portion of the NV5600 output shaft that was cut, press fitted and dowlled to a fabricated mating flange. The original nut used to hold the companion flange onto the Fuller output shaft is used to hold the shaft in a fixed position. Shaft will not move when assembled.

The NP241 T/C aligned and fully seated without any effort--couldn't ask for anything better.

I really had to breakdown and buy just one rattle can. I almost got into an arguement with myself about actually applying paint.:S::S::S:

If you want to view ALL of the photos, go to Transfer Case Adapter Assy pictures by sancobg - Photobucket

A very SPECIAL thanks to Richard Madrid for the machine shop work and for his ability to work from my hand drawn sketches and dims provided on the fly.

Transmission side of half shaft. Note dowel pin for indexing upon assembly

[IMG][/IMG]

T/C portion of the shaft


Assembled shaft



Plate between Bearing Retainer and T/C 700R4 Adapter
[IMG][/IMG]

Bearing Retainer & Plate
[IMG][/IMG]

Assembled Adapter
[IMG][/IMG]

Adapter & Shaft ready for install
[IMG][/IMG]

We can now actually claim, "MISSION ACCOMPLISHED".

 

I am right at 300k since the conversion in 01. Lost 5th gear and chucked the 4500. I don't tow everyday now but I have put it thru the test. It's a great transmission.

 

Copenhagenjunkie,

I believe we need to start a "Fuller Only" thread for those members that have made their conversion. I know that there are several hundred people out there that are going to keep their trucks rolling by dumping their NV4500 and NV5600's. I have also received call from guys with dead G56's.

Looks like you have the "High Miler" Award for a Fuller Conversion--congrats

 

I didn't make my conversion. It was one of the first 50 trucks converted at blumenthals in OKC. My dad's truck was in the top 10. I would go with the fuller trans tho.

 

Copenhagenjunkie,

Can you tell us something about the Conversion??

Do you know how much Bloomenthal charged to do the conversion??

 

I think it was around 3k but that was 10 yrs ago. The conversion is pretty simple actually. New clutch/flywheel, shorten/lengthen drive lines and re balance, cross member moves. 2 guys and 6 hrs.

If I was to do it again I would do it myself, back then I just didn't have the resources to tackle that.