NV4500 Swap
- Thread starter Dneel81
- Start date
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Got the bolts I needed. The lock washers - only 4 at the dealership but I went to the hardware store and bought some grade 8 lock washers to fit the bolts. They'll work just fine. Cleaned the flywheel surface and put the pressure plate and disk up tonight. Looks like tomorrow I'll be cutting up the floor of the trans tunnel after I peel back some carpet. Might actually start cutting from below the tranny shifter mount. I'm considering going back to the junk yard and taking some measurements on the holes for the transfer case shifter. At least some pictures. And the guy didn't give me the forward-most screw mount for the transfer case shifter. Again, thought about just using self-tapping sheet metal screws for that part. I'll tap the underside with some rustoleum or something so they don't rust out too fast.
The other thought I had was to drill through the holes already in the boot base and the shifter case to the metal. Obviously I couldn't leave it there but it would at least act as a template for the screws.
Making decent progress given my 120 hour/week real job.
I assume you all don't need to see a naked flywheel and then another picture of the clutch and pressure plate in place. Thats all I got done tonight.
Last night I cleaned out the tranny and flushed out all the old oil. Then put 4 quarts of the new tranny oil in it (from Quad4x4, the expensive crap) and tacked down the top with some black RTV and all the screws. She's all sealed up and ready to go. In transit from the previous owner, a top shifter screw was bent as the tranny shifted and fell forward. Got that in the mail along with the oil and a new shifter tower rubber gasket thingiemabob.
Probably need to flush the transfer case that's coming on board too. I'll have to buy some more fluid for that.
Otherwise should be coming together quickly I hope. I'll still be fiddle farting around with all the wires for now. Started her up with just the flywheel and got no less than 6 codes on the reader but I figured as much. Had the exhaust apart, sensors unplugged and all the empty harnesses down there. Ah well, if it was easy women and children would do it.
Dave
The other thought I had was to drill through the holes already in the boot base and the shifter case to the metal. Obviously I couldn't leave it there but it would at least act as a template for the screws.
Making decent progress given my 120 hour/week real job.
I assume you all don't need to see a naked flywheel and then another picture of the clutch and pressure plate in place. Thats all I got done tonight.
Last night I cleaned out the tranny and flushed out all the old oil. Then put 4 quarts of the new tranny oil in it (from Quad4x4, the expensive crap) and tacked down the top with some black RTV and all the screws. She's all sealed up and ready to go. In transit from the previous owner, a top shifter screw was bent as the tranny shifted and fell forward. Got that in the mail along with the oil and a new shifter tower rubber gasket thingiemabob.
Probably need to flush the transfer case that's coming on board too. I'll have to buy some more fluid for that.
Otherwise should be coming together quickly I hope. I'll still be fiddle farting around with all the wires for now. Started her up with just the flywheel and got no less than 6 codes on the reader but I figured as much. Had the exhaust apart, sensors unplugged and all the empty harnesses down there. Ah well, if it was easy women and children would do it.
Dave
SunlitComet
OBS Jedi-Do Good
i like naked.
Finished up the mechanical part of things last night. well, except the clutch. Everything in the drive train is in place and up. Painted the tranny and the bell...
It's not quite the snap on Cranberry lillie toolbox color but it'll do. Should anyone look up her skirt this will catch them off guard.
Gotta get a little working room here to get my fat arse in and out of this thing. Found a leak up by the parking brake/kick panel in the carpet. I'm assuming it's coming from the AC intake/hood/windshield. I'll tackle that when she's actually on the road again.
Before I got busy with the drill and jigsaw. Notice the manual 4x4 shifter lights already in place. Sorry to bug you about that SLC. I didn't know they would be there or I wouldn't have bothered you about that.
wait for it....
Ah there she is. Shifts good and tight. Seems tighter than my brother's NV3500 where the 5th gear feels like a right hook punch to get her up there.
What's left:
1. putting interior back together (stupid holes in the manual transfer case shifter are stupid hard to get lined up right to get the screws in.
2. bleeding clutch (gotta get help for that...and read how to get her done)
3. Fix the parking lights being on all the time when the battery is connected.
4. rewire the drivetrain/4x4 stuff.
5. Probably should flush and refill the xfer case since I'm not sure it has been done.
6. Figure out how to remove or cap off the transmission cooler lines that I no longer need.
Thanks guys for all the help, especially Comet. I have yet to stump you with some random question.
It's not quite the snap on Cranberry lillie toolbox color but it'll do. Should anyone look up her skirt this will catch them off guard.
Gotta get a little working room here to get my fat arse in and out of this thing. Found a leak up by the parking brake/kick panel in the carpet. I'm assuming it's coming from the AC intake/hood/windshield. I'll tackle that when she's actually on the road again.
Before I got busy with the drill and jigsaw. Notice the manual 4x4 shifter lights already in place. Sorry to bug you about that SLC. I didn't know they would be there or I wouldn't have bothered you about that.
wait for it....
Ah there she is. Shifts good and tight. Seems tighter than my brother's NV3500 where the 5th gear feels like a right hook punch to get her up there.
What's left:
1. putting interior back together (stupid holes in the manual transfer case shifter are stupid hard to get lined up right to get the screws in.
2. bleeding clutch (gotta get help for that...and read how to get her done)
3. Fix the parking lights being on all the time when the battery is connected.
4. rewire the drivetrain/4x4 stuff.
5. Probably should flush and refill the xfer case since I'm not sure it has been done.
6. Figure out how to remove or cap off the transmission cooler lines that I no longer need.
Thanks guys for all the help, especially Comet. I have yet to stump you with some random question.
Last edited:
2000tahoeZ71
Full Access Member
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- Jan 13, 2014
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That leak up under the firewall is likely coming from the cowl area. The screw that hold the black plastic thing need to be sealed. Take them out and put a little RTV on them and run them back down. Mine was doing the same thing on the passenger side.
SunlitComet
OBS Jedi-Do Good
bleed clutch as you would a brake. 231 t-case will need dexron 3
didn't get much done last night. Had trouble bleeding the clutch. Think I made a mistake when I got a junkyard clutch master cylinder. It was plastic and in retrospect I believe it was off a 4.3 out of a 97 pickup. Went to the parts ***** and bought a steel unit which seems much beefier (it's the 3/4 & 1 ton MC for GM). will swap over the clutch safety switch and see what I can get bled tonight. Then it should be drivable. At least if it's driving I'll be more motivated to figure out all the wiring crap.
Dave
Dave
The light green/black and purple/white wires on the ATC harness on the bell housing. The bellhousing i used has no input or switches. I do have an extra empty spot on the back top of the NP241. Could that be for the speed sensor? It's near the output to the main rear driveshaft. Thanks!
Dave
Got her running. Drives good. I didn't get the exhaust on the left put back together correctly as I can hear a leak however she shifts great and runs good too. Just tackling the wiring now. I'll get everything plugged back in, get her tuned, and then remove the auto switch thingiemawhats it, all the extra auto tranny stuff and see what I can get done. Thank you all for the loads of help!
Dave
Dave
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