Hey there everyone,

I have read a lot here and you all seem to really know your stuff so, here is my project...

I've got a 2003 4x4 Chevy Avalanche 1500 with the 5.3L (LM7) V8, i've got a custom Turbo Charger on it making 400rwhp and 450rwtq (and room to make more). I am running 33x14R18 tires/rims and have 4.56 gears. I want to go from my custom 4L80e to a manual, I have been looking at the NV4500 from a 2003 2500 HD 4x4 because it will bolt up to my motor, this i have all ready confirmed.

WILL the NV4500 stand up to the kind of power I am going to trow at it? I don't tow at the moment and the only thing I would ever tow is a small camper or boat no more then 7,000lbs. I don't go to the 1/4 mile drag track (went once with the truck) but, I do like to have fun behind the wheel and let the Turbo play sometimes. I LOVE making the Honda driving ricers cry like little girls... hehe :D

I thought about the ZF6 transmission and would LOVE that transmission since its a 6-spd but, I don't know if the bellhousing will bolt up and then I would probably have to have a custom flywheel/clutch made for it and that could get very expensive...

Any Info you can provide would be a great Help!!! THANKS!!!


P.S. Here is a picture of baby, damn I love my truck! :p:

that is a lot of custom work to do but i don't see why it wouldn't hold the power as long as you put a good clutch in it i guess you have looked to see how to mount the third pedal or do you have a donor truck lined up that has a standard in it

that is a lot of custom work to do but i don't see why it wouldn't hold the power as long as you put a good clutch in it i guess you have looked to see how to mount the third pedal or do you have a donor truck lined up that has a standard in it

Hey there,

I've got the pedal allready, the pedal from the 200-2006 2500 HD bolts into the Avalanche, even though it wasn't even a factory option! so sweet!

For a clutch, I was planning on a Centerforce Dual Friction Clutch...


Thanks

Hey there,

I've got the pedal allready, the pedal from the 200-2006 2500 HD bolts into the Avalanche, even though it wasn't even a factory option! so sweet!

For a clutch, I was planning on a Centerforce Dual Friction Clutch...


Thanks

good motor! had it in my 1500 and loved it too!! since the motor is a LS series ie camaro firebird vette why not look to see if a tremecT56 will bolt up? I could be wrong but they are strong trannies too!

good motor! had it in my 1500 and loved it too!! since the motor is a LS series ie camaro firebird vette why not look to see if a tremecT56 will bolt up? I could be wrong but they are strong trannies too!

Hey There,

I looked at that option and there are two problems with the T-56 idea:

1) No adapter out there for the 4x4 t-case to bolt up to the T-56.

2) Every transmission shop I talked to said that I would break the T-56 do to the weight of the Avalanche (5,800lbs), the torque of my motor and that I would never be able to tow anything more then a Jet ski...

Hey There,

I looked at that option and there are two problems with the T-56 idea:

1) No adapter out there for the 4x4 t-case to bolt up to the T-56.

2) Every transmission shop I talked to said that I would break the T-56 do to the weight of the Avalanche (5,800lbs), the torque of my motor and that I would never be able to tow anything more then a Jet ski...


guess I was wrong! have you tried advance adaptors?

guess I was wrong! have you tried advance adaptors?

Yep Advance said no way for the T-56


But check this out, I just talked toa local guy that makes custom clutch/flywheels set ups and he said he can give me a custom setup to work with the 5.3L and the ZF6!!!!

So, the two questions now are:

1) Does the ZF6 Bolt pattern on the bell housing match up to that of the 5.3L LM7 motor which is the same bolt pattern as the 6.0L LQ4 motor in the 2500 HD…???...??? From pictures I have seen of the ZF6 it looks the same…

2) What is the size and Spline count of the Output shaft the 4x4 version to go into the T-Case???

Hot damn, if I can drop a ZF6 into my truck I am gonna have some serious fun driving it!!!

Yep Advance said no way for the T-56


But check this out, I just talked toa local guy that makes custom clutch/flywheels set ups and he said he can give me a custom setup to work with the 5.3L and the ZF6!!!!

So, the two questions now are:

1) Does the ZF6 Bolt pattern on the bell housing match up to that of the 5.3L LM7 motor which is the same bolt pattern as the 6.0L LQ4 motor in the 2500 HD…???...??? From pictures I have seen of the ZF6 it looks the same…

2) What is the size and Spline count of the Output shaft the 4x4 version to go into the T-Case???

Hot damn, if I can drop a ZF6 into my truck I am gonna have some serious fun driving it!!!

sounds bad ass! I wish I new the answer to your question! I say go for it and fabricate what you need then post some burnout pics!!!!

if you are going to go with a ZF-6 then why not just get a tranny and T-case out of the HD at the same time or are you wanting to keep the auto 4wd. i didn't think the HD's pedal assembly would mount up but that is good that is does. you may try going into the sled pulling link or try the one for the ZF-6 and ask that there they would know more about it

if you are going to go with a ZF-6 then why not just get a tranny and T-case out of the HD at the same time or are you wanting to keep the auto 4wd. i didn't think the HD's pedal assembly would mount up but that is good that is does. you may try going into the sled pulling link or try the one for the ZF-6 and ask that there they would know more about it

I really like the NP246 Autotrac Transfer case because it is like having Traction control in the Rain. I just need to change the input gear/shaft for the ZFS6, which it looks like is 29 Spline. Trying to hunt down that part number currently...

I may also do a rebuild kit on the Transfer case while I have it apart just for good meassure...

OK, got the ZF6 and HOLLY CRAP what a Monster!!! I love it!!! This thing is Hucking Fuge!!!!

The bell housing pattern looks identical to the 4L80e (not surprised)...

Working on gathering parts still, got a local guy Shop that did some research and looks like the Clutch from the 6.0L w/the NV4500 will fit the ZF6 with out a problem. he got some tech docs with all the measurements of the ZF6 and NV4500... We were going to use the Diesel clutch but, the Gas HD clutch is waaayyy cheaper and he said it should not have any problem holding power with my set up... The one he is getting me is an upgrade over the GM HD clutch...

I am having a problem with one part though, the local Chevy dealer has been extremely helpful in my parts quest and has been hooking me up with Wholesale pricing! But, they ordered me the Input shaft from a 2003 3500truck with the ZF6 and 4wd but, it doesn't match up! The ZF6 has 29 Splines on the output shaft and the Input shaft they got me has 32 splines (that is whats used on the 4L80e's)! Funny thing is this is the part that the computer told them was for the truck.

So, this will slow me down while we try to find the right part number, anyone here happen to the part number for the 29 Spline input shaft for the Transfer Case????

Mean while I got my Auto all pulled out today, dang am I sore and tired...

Thanks

You will probably have to have your computer programmed because its going to be looking for the auto still.

You will probably have to have your computer programmed because its going to be looking for the auto still.

Borrowed my buddys laptop wth HP Tuners, already made some tweaks to the tune... Just have to see how it does after i get the transmission in...

Well, got the ZF6 installed into the truck today!!!! Went to gether pretty damn well too... So here are the parts for the set up:

- 6.0L Flywheel
- 8.1L Clutch/Pessure Plate
- ZF S6-650 from a 2003 3500 Duramax
- AutoTrac Transfer case from my 2003 Avalanche

The only issues to finish to get her driving (hopefully this week) are:
1) new Driveshafts

2) make the hole a little larger in the floor to give some side to side movment clearence for the shift tower

3)Change the clutch pedel (i used a pedel from 5-speed truck)... for some reason the ZF's Master Cylinder mounts a little diffirent then the 5-Speed's. The 5-Speed's has a Keyed Square hole and the ZF has a keyed round hole. I am hoping that the Clutch assembely is the same with just a diffirent mount for the master so, I can swap the pedels out... we'll see tomorrow when i swing by the dealer...

Please let us know how it drives!

Man this must have been one heck of a swap!

Why Not Stuff An Allison Under It? Its A 6 Speed And Would Take All The Power You Could Have Thrown At It....

Then would he have to do a 2" body lift to accomodate it?

The swap was actualy pretty strait forward, all bolt together and amlost 100% GM parts. I just had to fabricate and extension plate for the crossmember.

I have a 3inch body lift and the ZF just cleared the under body...

I had a stage-3 built 4L80e conversion (allison) but, I wanted a Manual and I wanted a strong trans. The ZF6 won't flinch at my motors power (450hp @crank), even if I up the boost and start making 800hp @crank there souldn't be any reason why the ZF would not tke it. The clutch or drive shaft should give out first... But, i'm happy with my teuck performance at the current power level...

Plus, my truck is a 1500 so, it would never be towing more then 7,000lbs and when towing I drive easy/safely...

Thats pretty sweet! You should also put more power to the ground now too! I would just really watch that 10 bolt rear end with a stick and that much power. It doesnt like much more than 350rwhp completely stock. heck i broke mine in my old 2000 GMC prerunner that had the 4.3L and a stick but i also jumped it about fifty feet and i was on the gas when i landed :damnit1:

Thats pretty sweet! You should also put more power to the ground now too! I would just really watch that 10 bolt rear end with a stick and that much power. It doesnt like much more than 350rwhp completely stock. heck i broke mine in my old 2000 GMC prerunner that had the 4.3L and a stick but i also jumped it about fifty feet and i was on the gas when i landed :damnit1:


Trying out for the Dukes of Hazzard movie?

Trying out for the Dukes of Hazzard movie?

hahaha no. THe truck was built pretty well. It was caged, had a Velocity long travel kit up front w/ about 20''s of travel and deavers out back with a trussed 10 bolt locked and regeared. It jumped really well and on the last jump of the day of course it let go. Broke the left axle and a chunk got wedged in between the ring and pinion causing it to lock up and bust the bearing cap holders off hahaha. it was NaStY!!

Thats pretty sweet! You should also put more power to the ground now too! I would just really watch that 10 bolt rear end with a stick and that much power. It doesnt like much more than 350rwhp completely stock. heck i broke mine in my old 2000 GMC prerunner that had the 4.3L and a stick but i also jumped it about fifty feet and i was on the gas when i landed :damnit1:

Yea, we'll see how long my 4.56's and Eaton LSD hold out... :p: I was thinking of doing a 3/4 ton axel swap anyways and maybe 3/4 ton front solid axel conversion next...

The swap was actualy pretty strait forward, all bolt together and amlost 100% GM parts. I just had to fabricate and extension plate for the crossmember.

I have a 3inch body lift and the ZF just cleared the under body...

I had a stage-3 built 4L80e conversion (allison) but, I wanted a Manual and I wanted a strong trans. The ZF6 won't flinch at my motors power (450hp @crank), even if I up the boost and start making 800hp @crank there souldn't be any reason why the ZF would not tke it. The clutch or drive shaft should give out first... But, i'm happy with my teuck performance at the current power level...

Plus, my truck is a 1500 so, it would never be towing more then 7,000lbs and when towing I drive easy/safely...


VERY NICE!!:D Yeah don't worry about the ZF, that thing will laugh at your 5.3:eek: Did you dyno your truck befor the swap?

VERY NICE!!:D Yeah don't worry about the ZF, that thing will laugh at your 5.3:eek: Did you dyno your truck befor the swap?

Yea, I think I heard the ZF taunting my 5.3L after the install... LoL

With my Stage-3 4L80e, Turbo running 7lbs of boost and my 33x14R18 tires I pulled 378HP and 433TQ at the rear wheels on the dyno. I am now running 9lbs of boost which according to my tuner guy at the dyno shop should put me at around at least 400HP and 460TQ I hope to see a gain with the ZF putting at least my TQ into the 500's...:D I will dyno after i get the truck running and the clutch broken in...

Next will be Meth Injection and an electronic boost controller running between 10-12lbs of boost...

I know one thing the truck was fun to drive before but, with the ZF it is going to be fawking awesome to drive!!!:ro)

Well, drove my truck for the first time last night with the ZF6 in it... all I can say is WOW! What a beast! The 8.1L Clutch just grabs like no tomorrow and the trans has such a strong feeling to it. I am still breaking in the clutch so I haven't gotton on the thorttle hard but, I can already feel a substantial power difference...

After a few days of driving I am LOVING this set up! Here is the shifter install i did, I used the Ford F-350 shifter because it posistioned it better for me... Universal leather boot, leather shift knob and then i made a trim plate out of Diamond Plate...

I don't think I even need to do the Short Shift kit, I am all ready getting used to the shifting the way it is... I haven't gone 100% thottle yet but, it is deffinitly getting a lot more power to tground and gearing is perfect...

Very nice! Where did you get the shift knob?

Very cool. Nice truck. I can't wait for that solid axle swap you mentioned. Should be the ultimate vehicle after that.


Looks like now you just need to get the column surround for the manual trucks to get rid of the automatic shifter boot :)

BattleMax, got it at Walmart of all palces..

moore87, I tried the column trim off a Silverado and it didn't fit... not sure why but, the Directional Lever hole was way off???

Well, the ZF6 and me have been getting along great... BUT... The rear axle decide it didn't want to play anymore... So, out with the 10 Blot and in with a custom 14 Bolt FF 10.5 with a Detroit Auto Locker...

I'll post up when the new axle swap is done...