Qs for anyone who has done the NV4500 swap

[Ball]

Hi.

I'm keen to get a m1010 that's been offered to me, but I do a lot of highway miles so I've been researching ways to get the gearing to something near reasonable. When I found out that the NV4500 can be dropped in without so much as a weld I got excited (not that there is a problem with welding )

I have some questions though:

1) Can I use a 96+ model tranny? The ratios look more appropriate for a 4.56 rear. Actually, just flat out tell me which tranny to get. I read somewhere I want one from a diesel, but can use a gasser one with some grinding. I'm not shy of grinding in either case.

2) Does the bell-housing fit without holes? I know with some retrofits (like a NV4500 in a g1 dodge) the bell-housing doesn't fit exact and you have to fill in the holes or buy a custom bell-housing.

3) What starter, flywheel, and other components do I need?

4) Any other gotchas?

Background: I live out of an AWD Astro van w/AT tires which I have thoroughly trashed off-roading (concave-d the oil pan, gas tank, hit a train, blew two side walls and the front diff last time I went to the mojave, etc.) It's great in that I still get 20mpg, but it doesn't have much room for all my stuff.

I'll also have to increase the headroom in the box somehow.

 

[cucvrus]

You may want to look in CUCV Hot rodding and modifications forum/threads. That is where I get booted to each time I talk of adding a different brush guard or a quad shock set up on an M1009. I don't know why but that happens here.

 

[Warthog]

Moved

 

[Barrman]

I can answer a few of your questions because I put a NV4500 behind a 6.2 in my M715.

You need a 4wd version of the NV4500 that will take a passenger side drop transfer case. I do not know for sure which year NV4500 will do that or maybe all will.

A 1985 K30 6.2 flywheel will work with a NV4500.

You have to have a big mouth starter nose cone. The stock 6.2 CUCV starter has the small mouth. You can get a new starter or a new nose cone.

You have to have a diesel NV4500 bellhousing. If not, the big mouth starter won't fit without grinding.

The best bellhousing is the one with the internal slave cylinder/throw out bearing. The external slave bellhousing could hit the front axle drive shaft.

Obviously, you will need a clutch pedal. Getting a complete pedal set from a manual transmission square body would be best. Even better to find one of the later years with a hydraulic clutch.

Don't reuse a junk yard clutch slave and master. Buy new. They are mostly plastic and don't last long when cared for.