Another NV4500 to NP205
 

I was in the garage last night tinkering with my NV4500 and NP205. It took me probably 2 years to find a round 6 bolt pattern NP205 but one finally popped up on CL. I couldn't get my wallet out fast enough! Not bad for $200! It also took me about a year to find an early NV4500 and I found that on a business trip and threw it in the trunk of the rental car to get it home! I removed the long input shaft and installed my new short input. These pictures are with an empty case as I need to go through the bearings to see what their condition is.I have a couple of other NP205s so I may swap the guts from one to the other to get the best parts. I have a cast iron 4500 to 205 adapter and it needs to be modified slightly along with the bearing retainer to allow the 205 to mate up completely. If you don't make these mods the 205 will have a slight gap and it could possibly crack the adapter if you pull the two together with the hardware. I used a die grinder to remove material on the bearing retainer face and the inside of the cast iron adapter.

Re: Another NV4500 to NP205
 

Wow it has been a long time getting all this together (literally!). Here is the complete new input and rear output assembly. I started to mod the cast iron adapter to accept the upper shift rail. It is close to being done. You can see my twin sticks in the shot. I was lucky to find another stock shifter so I welded two bolts together to mount them. I also converted the front 30 spline output to a F(T)erd 32 spline. I probably didn't need to do this but my complete drive train will be 1 ton from front to back when I'm done and the 205 is all apart so why not. Well that's all the pictures I took last night so..back to the garage!

Re: Another NV4500 to NP205
 

$200 for a round pattern 205? You stoled it! I paid $300 just for the empty case.

Re: Another NV4500 to NP205
 

The guy knew what he had too, and let it go for that...! A true fellow truck builder but changed his direction mid stream. I could have bought a JB LoMax kit and put this together two years ago, but $$.

Re: Another NV4500 to NP205
 

Ya the low max is costly. I don't like how they market it as a 205 yet in order to get the 3:1 gear ration you have to buy their case. If im paying out that much im going all the way to Atlas.

What are you plans for the truck?

Re: Another NV4500 to NP205
 

[QUOTE What are you plans for the truck?[/QUOTE]

The way I'm building it, it should be able to handle just about anything. I plan on putting a low profile camper shell on it and go explore the back country. I probably shouldn't have spent the money I did on the paint but it will look good for a while. I see in your signature you are injected also. Sounds like we have similar trucks. What do you get up to in yours? I have another thread going in this section concerning a Hickey worm drive winch so I am in the process or rebuilding that right now also. Yes, I think I have tinkeritis pretty bad.....

Re: Another NV4500 to NP205
 

Nice. I have a similar setup in the garage w/ a round 205, 96 trans, iron adapter and planetary range box.

Re: Another NV4500 to NP205
 

Planetary range box, that sound serious. When do you use that? I have a 92 NV and 4.56 gears so Ill need to be at around 33" on tires with the O/D.

Re: Another NV4500 to NP205
 

This thread sounds eerily familiar! Picked my nv4500 up on a business trip and drove it home in the trunk of a rented mustang. Twin sticks? Yep. D60,14ff and 4:56? Yep. I'm installing my Edelbrock Pro Flo this weekend.

Re: Another NV4500 to NP205
 

Great minds think alike? Yours looks like it is done and I just ordered my bearings and gasket kit for my 205. I still need to go through my NV4500 so that will be at least a couple more months for that (just in time for spring install, maybe). I ordered all my bearings from the local bearing house and got all Timken. A little more $ but I'll feel better when it's done and buttoned up. It will be the last 205 I'll rebuild.

Re: Another NV4500 to NP205
 

Plan on doing this to a Ford 205. Swap input to short shaft, then drill n tap the face of the 205. Good read!!!!

Re: Another NV4500 to NP205
 

The planetary is from another TC, like a 241. The 205 has a 1.96:1 low which some consider not low enough. The PO swapped the original 205 for a 208 for that reason. It gives the TC another low (1.96*2.6).

A similar mod is using an NP203 range box to do the same thing.

Re: Another NV4500 to NP205
 

What did you use for a bellhousing? Mech or juice clutch?

Re: Another NV4500 to NP205
 

Mileage wise? With my current Straub cam i get 11mpg. I got 12-13 with my prior Comp Cam but there were different characteristics to both.

You going ORD?

Re: Another NV4500 to NP205
 

[QUOTE=snj8198;8087068]Mileage wise? With my current Straub cam i get 11mpg. I got 12-13 with my prior Comp Cam but there were different characteristics to both.

Ok, so it wasn't built for mileage, mine either. I was asking about what do you use your truck for?

Re: Another NV4500 to NP205
 

Apologies to the OP, since I've hijacked. Please don't ask about my conversion in new posts.
Mine is from box-rocks or something like that on pirate. Good guy.

Re: Another NV4500 to NP205
 

[quote=Orange Crate;8087159]Towing, hauling, and general daily duty. The heaviest i've rolled across the scales is 19,890 lbs with a 31' toy hauler.

Re: Another NV4500 to NP205
 

[quote=snj8198;8087803]Now that is impressive. I am hoping that my truck will be able to handle similar situations if I need it to. I have an "RV" roller cam that is "all in" before 5000 rpm couple that with the 406 with TPI it "should" be able to pull a house, we will see....Painted the 205 case and the cast iron adapter last night so now I just need my bearings and gasket kit. I'm looking at NV4500 rebuild kits now....

Re: Another NV4500 to NP205
 

[quote=Orange Crate;8087828]neat! i like the 400 small blocks and roller is the only way to go now days. While building for go dont forget the whoa. Hydro boost transplanting is not that hard. Consider looking into it. 600+ ft-lbs is nice for getting the house moving but 4 wheel disks and hydro boost is nice for slowing it down again. Consider sway bars for keeping things under control through the transit too.

Re: Another NV4500 to NP205
 

[quote=snj8198;8090521]Come on now...your killin' me. I have hydroboost and four discs!

Re: Another NV4500 to NP205
 

Some progress. Got all my Timken bearings and the gasket kit installed. I have a 1350 yoke for the rear output but I still have the old stock CV and drive shaft for the front. I upgraded the front output to a 32 spline so I'll have to make a decision on what I want to do for a front drive shaft. Any suggestions? I was thinking of going with a flat flange output and then a flat 1350 bolt on yoke. The truck has a 2" lift with a D60. I would like to have all 1350 u-joints in the drive train. Damn this thing is heavy, had to use the overhead hoist to get it bolted to the NV4500....:sumo: I have a case of high temp silver paint so.....

Re: Another NV4500 to NP205
 

I used a flat flange and CV on my 85 with Dana 60. Works great.

Re: Another NV4500 to NP205
 

Great, what size joints? What is your lift? Who made your DS?

Re: Another NV4500 to NP205
 

I swapped in factory k30 (cucv) axles in to my K20. It was a direct bolt in. I believe the front joint is a 1330. Rancho 2 inch lift. I haven't swapped the trans yet but, my measurements tell me I'll need to shorten the front shaft a few inches due to the shorter overall length of the trans/t-case length.

Re: Another NV4500 to NP205
 

I missed this question. I haven't made a decision yet on the bell housing. I'd like to go with the AA BH but $$. I read the post below. He drilled his NV4500 to fit a standard 4 speed BH. You have to bolt the two together from inside the BH and install it that way but that's the way auto trans are anyway. Decisions...decisions....

http://67-72chevytrucks.com/vboard/s...d.php?t=611566

Re: Another NV4500 to NP205
 

advance adapter bell is worth it. I have it with hydraulic clutch in my 85 blazer. if you redrill the case you could end up like a guy on ck5 and the loctited torqued bolts could back out and cause catastrophic failure. unikely but would ruin it and turn it in to a terrible situation just to save a couple bucks.

I have the 32 spline flat flange with a ford superduty front driveshaft. It is 1350 spicer ujoints and a 4.25 bolt circle with the 2" pilot. fits almost any new flange out there nowadays and is very easy to find. Do some research on em but a new one can be had here locally for 400 built to your measurement. There are two different types. the rounded cv yoke ears is the ideal one.

sunsoaked, stock front yoke on the d60 is 1310 which is generally more than sufficient for most folks. but there aint no kill like overkill.

Re: Another NV4500 to NP205
 

dana44 / corp 10 bolt and dana 60 front yoke at the diff are same size all 3 . only major thing to watch for is durring axle swap to dana 60 . pinion is bigger and sits back more . so check for drive shaft length so no bottom out problems.

Re: Another NV4500 to NP205
 

Orange Crate -
that thread link you posted is mine and just to let you know ol' Black is still driven everyday with no catastrophic failures lol
Any questions just ask on my thread also I have a front maxiumizer lsd and total dana 60 rebuild comin soon.
cheers

Re: Another NV4500 to NP205
 

Thanks this info is much appreciated. I was looking at Denny's and other custom made 1350 CVs. I seriously doubt that I will ever need 1350 joints but the rest of the drivetrain is all 1 ton so what the h3ll. It would be really nice to have the AA BH as it would save some time and hassle putting it all together. It sounds like the easiest route.

Re: Another NV4500 to NP205
 

Yes, thanks again for that post. I reread it the other day just for fun, so looking forward to your D60 work. I rebuilt mine before I stuck it under the truck. Good work there on your set up, those are the ultimate option(s) I think. I've been in aviation for 30 years so I would definitely use safety wire like you did for the attachment hardware.

Re: Another NV4500 to NP205
 

How's this project going OC?

Re: Another NV4500 to NP205
 

I need mo' money....!

Re: Another NV4500 to NP205
 

Haha!

Re: Another NV4500 to NP205
 

Since it is too cold to be in the garage I'd like to post an internet find here for the NV4500 assembly manual. I can not figure out how to reduce the file size any further than 1.2Mb (down from 3.4Mb) and the limit to attach here is 275Kb. If anyone wants a copy, PM me with your email and I'll send it that way. Sorry it is for a later 2001 Dodge version but you get the idea anyway right? I think what I will do is disassemble mine and then order just the bearings/parts that I feel need to be changed instead of buying a total rebuild kit like some vendors put together. As an example one vendor has a bearing kit that goes for around $330 and that includes what they call a small parts kit. I'll see what condition my parts are in first and then go from there to try to keep the cost down. I basically did the same thing on my NP205 and bough each bearing I needed separately and that allowed me to get good old made in the USA bearings at a little extra cost for the good stuff. I know I'll need syncros for sure already. Here is a tease shot since pictures are everything....

Re: Another NV4500 to NP205
 

I'm at the point where I need to remove the main shaft bearing and the counter shaft bearing to complete my NV4500 disassembly. What have you used to remove your bearings, short of ordering the factory tool pictured.? It seems to me that a normal bearing splitter might not work due to the small clearance between the bearing and the gear face (see arrow). I made a 5th gear nut wrench that worked perfectly. I had to stand on the end of the "wrench" that is 30" long and I'm 165lbs so that is somewhere around 300ft lbs. I cut up an old 32 spline long input shaft from an NP205 as the main shaft counter hold portion. It took me about six hours total to make both out of scrap steel I had in the shop. Recycle!

Re: Another NV4500 to NP205
 

Alrighty then. I got a cheap clamshell style puller online to see if it would work and it did for two of the three bearings. The one bearing it will not work on is the tapered roller on the forward side of the counter shaft. I'll cut that one off just to save time.

Here is the new puller in action. I had to use an old piece of DOM tube as a spacer since the one provided in the kit was too long. One thing that was really frustrating is that the new tool has no place to counter hold, to stop it from spinning. I may weld a couple of flats on there for future use. So both the main and counter shafts are completely disassembled now and they both look in really good shape. I can tell this NV has been overhauled at least once before as there are a few clues like silicon sealant and a few scratches on the shafts where the bearings reside. I'll need all new bearings and syncros and a new input shaft as that is toast. The splines are really worn where the clutch disk was riding and the stub nose where it joins the flywheel pilot bearing is also trashed. I just need to sell a kidney or something to get the rebuild kit.....

Re: Another NV4500 to NP205
 

fyi that style puller needs the race set on the bearing to help it stay toghter when pulling off .

and if your doing gear setup adding & removing shims this fact is real important to not trash your new bearings .

Re: Another NV4500 to NP205
 

Yes, this kind of puller does trash your bearings, but they're OFF! and the new ones will be a lot easier to install, cool the shaft with dry ice and heat the bearing to about 350. No diff work just yet.

Re: Another NV4500 to NP205
 

cause like I said you didn't set the race on the bearing first and set the rings up correctly .

if done right you can pull off and reuse as many times as you want .

also lube the heck out of the threads with copper anti-sieze .

https://www.youtube.com/watch?v=CUqSZelTSfI

https://www.youtube.com/watch?v=mkPPwfzD8Vg

Re: Another NV4500 to NP205
 

Oh, right, the outer race should be placed back on top of the bearing and then pulled. Don't really care at this point but thanks for the tip for future reference. These bearings need to be replaced anyway due to the wear patterns. I cut the counter shaft end bearing off earlier today so now I just need a bearing and small parts kit. Donations anybody? Ha.