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Advance Adapters 27-0032 NV4500 Retrofit Kit GM Full 79-85
Advance Adapters 27-0032 NV4500 Retrofit Kit - Replacing TH400 in GM Full Size (1979 - 1985)
install Instructions 27-0032.pdf
KIT CONSISTS OF:
No. Qty Part No. Description
1. 1 Kit PN50-0206 4WD NV4500 TO GM NP205 32T
If you’re attempting to build an unbreakable drivetrain, then the ultimate connection of a GM 4WD NV4500 to a 1971-85 NP205 (replacing the SM465 or TH350) must be considered. The adapter was engineered for heavy-duty truck applications. This installation uses the largest spline size available (the factory 32 spline GM NV4500 output shaft), and offers the maximum strength of any of the NP205 conversions. The kit requires the purchase and installation of a new 32 spline input gear and bearing (Part No. 716038). The new input bearing is approximately 1/4" larger in diameter than the stock bearing. Some machining on the transfer case is required in order to accept the larger bearing and new input gear.
This kit also is designed for the 1979 to 1985 1-ton truck with a TH400 transmission. This particular transfer case is already equipped with the proper input gear and bearing, so no machining is required.
The kit utilizes the stock 32 spline GM 4WD NV4500 output shaft. This shaft must be shortened to a stickout length of 7.625". With the output shaft shortened and the adapters installed, you will find the assembled length to be approximately 19-1/4". The new adapter uses a seal in the adapter housing and a sealed bearing in the transfer case, which is required to isolate the different fluids. The transfer case adapter kit uses two castings to couple the NV4500 to the NP205. These castings have been machined to allow for proper transfer case shift rail clearance. A shifter bracket has been provided to mount the stock NP205 shifter handle; however; you may be required to modify the handle to properly fit up into the cab of the truck.
The bellhousing in this kit bolts directly to the front of the NV4500. Since this kit was developed primarily for vehicles originally equipped with the TH400 automatic transmission, we’ve supplied a slave cylinder bracket for your clutch linkage (P/N 715535). This bracket is designed to fit 1985-1991 GM slave cylinders (GM #15615868). A hydraulic clutch system is much easier to install than a mechanical linkage. If you decide to install a mechanical linkage, you can substitute for bracket PN715534.
2. 1 Kit PN712576 NV4500-1996 GM BHSG ADAPT. KIT
3. 1 Kit PN715535 GM HYD. CLUTCH LINKAGE BRKT.
4. 1 Kit PN716050C NV4500 SHIFT HANDLE ASSY.
New Venture 4500 (NV4500) Transmissions
The New Venture Gear Corporation was developed when GM’s Muncie Transmission Division and Chrysler’s New Process Corporation joined forces to manufacture a full product line of manual transmissions. The NV4500 transmission was the highlight of this new venture. Featuring a granny low first gear coupled with a fifth gear overdrive, the stout NV4500 is truly the best of both worlds.
First introduced in 1992, the NV4500 is a constant mesh helical geared, heavy duty 5 speed transmission. All forward gears are fully synchronized. The initial Dodge version offered a synchronized reverse. The transmission case is cast iron with an aluminum top cover. The case measures 12.375 inches and features dual PTO ports. The shifter handle typically allows for better accessibility over older granny 4 speeds as it is located further rearward at 9-1/2" from the face of the transmission.
The 1992 & 1994 GM versions have a lower first gear of 6.34 and can be identified by a smaller front bolt pattern with a top to bottom measurement of 4.685". After 1995, the first gear and front bolt pattern reverted to the Dodge 5.61 first gear and the taller top to bottom 6.043" bolt hole configuration. The synchronized reverse was also added and the front bearing retainer was enlarged from 5.125" to 5.6" diameter. As a general rule, a GM NV4500 4WD transmission will always have a 32 spline rear output shaft with an 8-1/8" rear tailhousing. The input shaft is 6-5/8" 1-1/8" 10 spline with a .590" pilot tip. We have also seen a rare 1995 GM NV4500 which can be classified as a hybrid. The transmission has the lower 6.34 with the newer bolt pattern.
Dodge 4wd NV4500 transmissions have always maintained the same gear ratios and bolt patterns throughout production; however, variations occur between diesel (and V10) versus gas models. Diesel NV4500 4WD transmissions always have a 29 spine rear output shaft with a 6-1/4"" rear tailhousing. The input shaft is 7-1/2" 1-1/4" 10 spline with a .75" pilot tip. The front bearing retainer index is 5.6" with a snout diameter of 1.75".
Dodge Gas 4wd NV4500s initially were introduced with a 23 spline rear output shaft and a 6-1/4 tailhousing. The input shaft is 7-1/2", 1-1/8" 10 spline with a .75" pilot tip (we have seen very rare 1" 19 spline inputs in 1993 trucks). The front retainer is 5.6" with a 1.43" snout. In 2001, Dodge discontinued the 23 spline output shaft on the gas version NV4500, and all Dodge transmissions standardized to 29 spline.
For most conversion applications, we like the Dodge gas version transmission with a GM input shaft. This allows the shortest transmission length for most applications. The GM input shaft from a 6.34:1 early transmission will not fit the Dodge transmissions.
TRANSMISSION LUBRICATION: The NV4500 transmission uses approximately one gallon of synthetic oil. This oil is available at your local Dodge authorized dealer under Part No. 4874459 (quart), or your local GM authorized dealer under Part No. 12346190 (quart). Unlike regular petroleum oil that breaks down when it gets too hot, this synthetic oil is made up of different properties that do not break down. The transmissions are also equipped with synchronizer rings that are made of a fibrous material. The wrong fluid will cause the unit to develop “sticky” shifting. If the wrong fluid is used, more than likely you will have to have your transmission rebuilt.
DO NOT SUBSTITUTE any other lubricant as internal damage will occur. NOTE: Castrol Syntech is NOT the same as Castrol Syntorq. Castrol Oil Synthetic
TORQUE SPECIFICATIONS: Top Shift Cover Bolt 200 Inch pounds. Adapter Housing 40 Foot pounds. Front Drive Gear Retainer 265 Inch pounds. Main Shaft Nut 4WD 275 Foot pounds. P.T.O. Cover Bolts 30 Foot pounds. Reverse Inhibitor Bracket 95 Inch pounds. Counter Shaft Brg. Ret. Plate 200 Inch pounds. Main Shaft Brg. Ret. Plate 200 Inch pounds.
GASKETING SPECIFICATIONS: In order to install the new adapter housing, top cover, and bearing retainer, we recommend using Loctite 518 Gasket Eliminator. This sealant seems to work best.
SPEEDOMETER: Most 4WD installations provide a speedometer drive gear on the back side of the transfer case. On 2WD transmission swaps, Dodge transmissions are the most desirable due to the mechanical speedometer drive. The later versions (1998 & newer transmissions) do not have any type of speedometer provisions. The GM 2WD NV4500 transmissions use an electronic speed sensor. These transmissions will not allow you to retain a cable speedometer drive.
BACKUP SWITCH: All NV4500s are equipped with an electronic reverse backup switch. If your vehicle is equipped with some type of backup indicator light, it can be adapted very easily to the new NV4500 switch. The parts required to couple to this switch are PN300378 (1), PN300378 (2 req.), and PN300378-1 (2 req.).
NV4500 rebuild kit: If you find your own NV4500, but need to freshen it up with some new bearings seals and synchronizers, we offer PN715691. This kit supplies you with replacement parts for the normal wear items of the NV4500.
Forward Speeds .... 5
Dates Produced .... 1992 - 2005
Manufacturer .... New Venture Gear
Case Length .... 12.375
Stock Adapter Length .... 6.25 Dodge & 8.125 GM
Bellhousing Length ... 6.50 GM
Over All Length .... Varies due to Adapters
Case Material ... Cast Iron
Input Shaft Spline .... 1-1/8 10 spline & 1-1/4 10 spline Diesel
Input Shaft Stickout Length .... 6.625 GM & 7.50 Dodge
Pilot Diameter .... .590 GM or .750 Dodge
Length .... 1.00
Output Shaft Spline .... 4wd Model 23, 29 or 32
1st Gear Ratio .... 5.61 or (6.34 GM 92-94)
2nd Gear Ratio .... 3.04 or (3.44 GM 92-94)
3rd Gear Ratio .... 1.67 or ( 1.71 GM92-94)
4th Gear Ratio .... 1.00
5th Gear Ratio .... 0.73
Reverse Gear Ratio .... 5.04 or (6.24 GM 92-94)
Transmission Weight .... 195Lbs
Max Engine Torque .... 460
Fluid Type .... Castrol Syntorq / Amsoil MTF
Power Take Off Capable .... yes
Gross Vehicle Weight Rated .... 15,000
Input to Cluster Center Distance .... 4.291
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