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Frankenstein Did you put a 6.5 in a Camaro? A Duramax in a boat? A Cummins in a Chevy? A Powerstroke in a van? Then you must have a touch of the good Dr. Frankenstein. Post your stories, questions, discussions in here... this is intended to be a place to discuss your questions on how to, what to do, etc...


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Old 03-11-2011, 08:18 PM   #1 (permalink)
HeavyDuty6Five
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GMC NV4500 Conversion project

Ok so im converting my 1993 Sierra 3500 Ext Cab SLE w/ the 6.5 TD
It was Orginally a 2500 but have upgraded it to a 3500 suspension
I will Post Pictures soon as I Can, I want to share my parts list with everyone so im going to post it here. So Far the 4L80E is out and the NV4500 will be going in very soon. I Have a 1993 Trans fully rebuilt with the 6.34.1 Ratio.

Here is my part list, BTW if anyone is intrested with part #'s for the 3500 Conversion PM me.


4L80E to NV4500 5 Speed Conversion Parts List For My 1993 GMC Sierra 3500 6.5TD
By: HeavyDuty6Five (Diesel Place)
---------------------------------------------------------------------------------------------------------------
1993 NV4500 4x4 w/6.34.1 Ratio Trans
1993 GMC Early External Slave Bell Housing
1993 GM Clutch Pedal Assembly
AC Delco 139 Tooth Solid Mass Flywheel
Hays Super Truck Clutch Kit (90-101)
LMC Truck Clutch Master/Slave Cylinder w/Line-Pre Bled
Timken HD Ball Bearing Pilot
GM 6 Bolt Transfer Case Gasket
Transfer Case Input Seal (Double Lip) TK10517
Energy Suspension Trans Mount (3.1229R)
GM Clutch Fork Part# 12385352
GM Ball Pivot Stud Part # 15552866
GM Ball Seat Part # 15552867
GM Ball Retainer Part # 01603620
GM Slave O Ring Seal Part # 12549117
GM Clutch Pedal Return Spring Part # 15958642
GM Clutch Pedal Bracket Part # 15611292
GM Clevis Pushrod Clip Part # 93221087
GM Flywheel Dust Cover Part # 15989619
GM Flywheel Dust Cover Screws Part # 12337828
GM Bell Housing Studs Part # 15552852
GM Bell Housing Nuts Part # 11514596
GM Transmission to Bell Housing Bolts Part # 11514224
GM M/T Insulator Part # 15659649
GM M/T Trim Retainer Part # 15548584
GM M/T Boot Assembly Part # 15959690
GM M/T Shift Lever Assembly Part # 15722665
GM Transmission Mount Bolts Part # 11516845
GM Transmission Bolt Washers Part # 155531205
GM Bell Housing Clutch Hyd Line Clip Part # 00343464
GM Clutch Master Cylinder Nuts Part # 15649210
---------------------------------------------------------------------------------------------
GM Flywheel Bolts are: 7/16-20 (Qty: 6)
GM Pressure Plate Bolts are: 3/8-16 (Qty: 6)
GM Manual Transmission Retainer Screws are: M4-1.41x25 (Qty 8)
---------------------------------------------------------------------------------------------
Other Items Needed
Permatex Ultra Black or Grey
Permatex Blue Loctite
Amsoil 75-90MTG: 5 Quarts or Castrol Syntorq
----------------------------------------------------------------------------------------------
If You Need to Reseal your Transmission and Want To Inspect the Internals of the Transmission I Recommend New Bolts for the 4x4 Tail-Housing Which You Can Obtain from Quad 4x4.
I Replaced the Top Cover, Tail-Housing, and Front Retainer Bolts. You May or May Not Need to adjust Your Driveshaft’s lengths. This is a simple list of Most Parts you will need. Due to the Fact that The GM Version uses no seal in the Tail-Housing, you MUST use Double Lip Seal TK10517 or the 75-90 and ATF will Mix causing Damage to your Transmission.

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1993 GMC K3500 (Orginally a 2500)
6.5 Turbo Diesel (DB2 Turned Up) Vin:F HO
NV4500 4x4 (Orginally a 4L80E 4x4)
Borg Warner Transfer Case (Originally a NP241)
Hyd Dump Truck Bed w/ 34G Fuel Tank
Air Dog 100 System
Transfer Flow In Bed Tank 50G
HID Hi + Low Beams
2006+ Towing Mirrors W/Leds

Amsoil In Drivetrain
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Old 03-15-2011, 11:46 PM   #2 (permalink)
HeavyDuty6Five
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[IMG]

Transmission in my house, first day home, more pics tommorow, its all painted a nice fresh black and sealed up and topped up with Amsoil MTG 75-90

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1993 GMC K3500 (Orginally a 2500)
6.5 Turbo Diesel (DB2 Turned Up) Vin:F HO
NV4500 4x4 (Orginally a 4L80E 4x4)
Borg Warner Transfer Case (Originally a NP241)
Hyd Dump Truck Bed w/ 34G Fuel Tank
Air Dog 100 System
Transfer Flow In Bed Tank 50G
HID Hi + Low Beams
2006+ Towing Mirrors W/Leds

Amsoil In Drivetrain

Last edited by HeavyDuty6Five; 03-15-2011 at 11:47 PM.
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Old 04-04-2011, 01:03 PM   #3 (permalink)
HeavyDuty6Five
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Old School Oil Burners (Old SOBs) Member















__________________
1993 GMC K3500 (Orginally a 2500)
6.5 Turbo Diesel (DB2 Turned Up) Vin:F HO
NV4500 4x4 (Orginally a 4L80E 4x4)
Borg Warner Transfer Case (Originally a NP241)
Hyd Dump Truck Bed w/ 34G Fuel Tank
Air Dog 100 System
Transfer Flow In Bed Tank 50G
HID Hi + Low Beams
2006+ Towing Mirrors W/Leds

Amsoil In Drivetrain

Last edited by HeavyDuty6Five; 04-04-2011 at 01:09 PM.
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Old 04-04-2011, 08:51 PM   #4 (permalink)
HeavyDuty6Five
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Ok So far, I have the NV4500 Ready to go, painted with High Heat Paint, and I Split the T case, which was rebuilt with the Auto. Both were rebuilt in 08. I Resealed up the NP241 and resealed it and put all new seals in it. Im just waiting for the rest of the parts this thursday and friday. I am going to be using a Centerforce Clutch Kit Dual Friction and Solid Mass Flywheel. Im just trying to figure out if i have to modify the driveshafts, bc it looks like the driveshaft can be stretched at the center bearing, and that you can also slide it at the point where it mounts. Im Hoping to be driving in 2 weeks, maybe even this weekend, but will see. Ill keep you all updated
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1993 GMC K3500 (Orginally a 2500)
6.5 Turbo Diesel (DB2 Turned Up) Vin:F HO
NV4500 4x4 (Orginally a 4L80E 4x4)
Borg Warner Transfer Case (Originally a NP241)
Hyd Dump Truck Bed w/ 34G Fuel Tank
Air Dog 100 System
Transfer Flow In Bed Tank 50G
HID Hi + Low Beams
2006+ Towing Mirrors W/Leds

Amsoil In Drivetrain
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Old 04-11-2011, 11:47 AM   #5 (permalink)
HeavyDuty6Five
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Heres the pedals


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1993 GMC K3500 (Orginally a 2500)
6.5 Turbo Diesel (DB2 Turned Up) Vin:F HO
NV4500 4x4 (Orginally a 4L80E 4x4)
Borg Warner Transfer Case (Originally a NP241)
Hyd Dump Truck Bed w/ 34G Fuel Tank
Air Dog 100 System
Transfer Flow In Bed Tank 50G
HID Hi + Low Beams
2006+ Towing Mirrors W/Leds

Amsoil In Drivetrain
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Old 04-11-2011, 07:11 PM   #6 (permalink)
HeavyDuty6Five
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Clutch and Bellhousing today, ran out time had to do a few things, but heres the pics









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1993 GMC K3500 (Orginally a 2500)
6.5 Turbo Diesel (DB2 Turned Up) Vin:F HO
NV4500 4x4 (Orginally a 4L80E 4x4)
Borg Warner Transfer Case (Originally a NP241)
Hyd Dump Truck Bed w/ 34G Fuel Tank
Air Dog 100 System
Transfer Flow In Bed Tank 50G
HID Hi + Low Beams
2006+ Towing Mirrors W/Leds

Amsoil In Drivetrain
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Old 06-24-2011, 04:14 PM   #7 (permalink)
Pillow
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Nice! Please keep us posted... I have thought about this conversion as well.
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2 - 6.2 motors getting the treatment for a '71 swap.
'71 Chevy C-10 350 w T-5 manual
'79 Porsche 911 SC
'05 Cadillac CTS-V
'49 Spartan Mansion 30' travel trailer
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Old 06-24-2011, 09:40 PM   #8 (permalink)
HeavyDuty6Five
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its all done im gunna get the pics up with it running and all maybe tommorow, i actually put the trans in and found out the guy lied to me about it being rebuilt so after work one fri and sat i rebuilt it completely new syncros and bearings etc etc, has the 6.34 1st gear and .73 5th. I also bought a new top cover and shifter assyembly and added the 5th gear damper. Ill get more pics up soon, as of now its been in there since may 2 and running beautifully. It was also a very easy trans to rebuild.
__________________
1993 GMC K3500 (Orginally a 2500)
6.5 Turbo Diesel (DB2 Turned Up) Vin:F HO
NV4500 4x4 (Orginally a 4L80E 4x4)
Borg Warner Transfer Case (Originally a NP241)
Hyd Dump Truck Bed w/ 34G Fuel Tank
Air Dog 100 System
Transfer Flow In Bed Tank 50G
HID Hi + Low Beams
2006+ Towing Mirrors W/Leds

Amsoil In Drivetrain
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Old 07-14-2011, 08:12 AM   #9 (permalink)
HeavyDuty6Five
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Old School Oil Burners (Old SOBs) Member






__________________
1993 GMC K3500 (Orginally a 2500)
6.5 Turbo Diesel (DB2 Turned Up) Vin:F HO
NV4500 4x4 (Orginally a 4L80E 4x4)
Borg Warner Transfer Case (Originally a NP241)
Hyd Dump Truck Bed w/ 34G Fuel Tank
Air Dog 100 System
Transfer Flow In Bed Tank 50G
HID Hi + Low Beams
2006+ Towing Mirrors W/Leds

Amsoil In Drivetrain
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Old 07-24-2011, 01:34 AM   #10 (permalink)
97K3500
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daaaamn im jealous as hell of that. how long did it take?

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