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Old 05-04-2018, 09:12 PM   #1
c10hevy
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1987 V2500/3500 12v nv4500 build

So after searching long and hard for a rust free truck in Iowa...I finally bit the bullet and bought a 12v swapped V3500 in Washington! I had a good friend inspect it and buy it for me. It will be here in Waterloo IA in 6 days where I can finally completely inspect this (hopefully) fine machine and get to working on the modifications that I have in store.

Currently it has:
Front frame section was boxed with 3/16" steel and custom motor mounts were made out of 1/4".

Engine:
96 12 Valve Cummins

•New Cylinder Head. With Hard Seats
Ported and polished
60lb over valve springs
ARP Head Studs
OE Cummins Gasket
• PDD 5x.014 Injectors
• DPS 62/65/12 Turbo
• #10 plate
• 4K RPM Gov. Springs
• 17.5* Timing
• 4" Exhaust with 8" Stack
• New Lift Pump
• 1 Wire 136amp Alternator

Transmission:
NV4500
•Centerforce DFX Clutch
•Single Mass Flywheel
•New Hydraulics
Upgraded:
•Input Shaft
•Main Shaft
•Cluster Shaft
•New 3rd Gear
•5th Gear Nut
•HD Synchros
•All New Bearings

Transfer Case and Axles

GM NP205
Advance Adapter Kit to mate to Dodge NV4500
Front: Dana 44 with truss. 4:09 gears
Rear: 14 Bolt Corp. 4:10 gears. Detroit Locker
New driveshafts
New brakes front and rear.
4" Lift
Custom built rear leafs

I plan on:
Downsizing the injectors to 5x.012s
Putting a normal 4" exhaust system on it with hushpower muffler
Replacing the fenders and hood with new sheetmetal
Restoring the interior
Most likely installing Suburban buckets, overhead console, and center console
Lowering it about an 1" and installing 35s
Changing out the D44 with a D60 with the works
Changing gearing to 3.73 and adding front and rear ARB
AFC live
Make a MUCH better trans crossmember


My plan is to make an exciting daily driver that can also take off to Moab or Montana and have everything built to be "unbreakable" but most importantly reliable.
Much more to come..!

Id really appreciate any feedback/advice as this is my first complete build
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Last edited by c10hevy; 05-04-2018 at 11:47 PM.
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Old 05-19-2018, 04:10 AM   #2
randy500
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Re: 1987 V2500/3500 12v nv4500 build

Looks like a neat project with a lot of the hard work done....what part of WA did it come from? Is it in your possession yet?
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Old 05-19-2018, 06:13 AM   #3
c10hevy
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Quote:
Originally Posted by randy500 View Post
Looks like a neat project with a lot of the hard work done....what part of WA did it come from? Is it in your possession yet?
Came in from loon lake area and I took possession last week. I've been driving her here and there to get things sorted and get a good shakedown.
Some parts are here and more ordered, so updates will follow.
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Old 05-22-2018, 02:27 PM   #4
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Re: 1987 V2500/3500 12v nv4500 build

Nice buy! I like your plans for the truck. It should clean up pretty nice and make a sweet truck! Once you get the AFC live, you may not need to down size your injectors.
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1976 K30 CC SWB Build Thread

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Old 05-22-2018, 10:48 PM   #5
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Re: 1987 V2500/3500 12v nv4500 build

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Originally Posted by Dieselwrencher View Post
Nice buy! I like your plans for the truck. It should clean up pretty nice and make a sweet truck! Once you get the AFC live, you may not need to down size your injectors.
Thanks! The AFC live is supposed to be delivered this weekend so we will see how it handles. I also have fit her for a grown up exhaust system. Since there isnt a Chevy Cummins exhaust kit, have you had any luck using a 1st gen or 2nd gen dodge exhaust? I bought a 41" Donaldson and am willing to fab my own, but it sure would be nice if there is something out there that would cut down on the fab time.
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Old 05-22-2018, 10:52 PM   #6
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Re: 1987 V2500/3500 12v nv4500 build

No, there is no really good kit for them. But, I can get you the mid section for a first gen dodge that will get you over the tcase. You can make the down pipe cheaper than buying one I'd almost bet. I'm betting you need one for an HX40 flange? I have used 2nd gen dodge, super duty, and even newer chevy diesel tail pipes. It really depends on how you want the tail pipe outlet to look.
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1976 K30 CC SWB Build Thread

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Old 05-22-2018, 10:57 PM   #7
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Re: 1987 V2500/3500 12v nv4500 build

Quote:
Originally Posted by Dieselwrencher View Post
No, there is no really good kit for them. But, I can get you the mid section for a first gen dodge that will get you over the tcase. You can make the down pipe cheaper than buying one I'd almost bet. I'm betting you need one for an HX40 flange? I have used 2nd gen dodge, super duty, and even newer chevy diesel tail pipes. It really depends on how you want the tail pipe outlet to look.
Ok, Ive already made the downpipe, so Ive got that covered. If I can get over the transfer case with a first gen dodge then Id be home free, it should just be a combo of muffler and a bit of straight pipe until I get to the axle. Any axle pipe should work I would assume.

Any recommendations for side exit that can fit between the leaf spring and the 31 gal suburban tank?
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Old 05-23-2018, 04:33 PM   #8
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Re: 1987 V2500/3500 12v nv4500 build

Here's a suburban I did. I used a 4" kit from a 93 dodge and I had to modify the tail pipe to fit nicely.

http://www.67-72chevytrucks.com/vboa...t=v+rig&page=6
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1972 Chevy Longhorn K30 Cheyenne Super, 359 Inline 6 cylinder, Auto Trans, Tilt, Diesel Tach/Vach, Buckets, Rare Rear 4-link and air ride option Build Thread
1976 K30 CC SWB Build Thread

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Old 07-31-2018, 09:06 PM   #9
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Re: 1987 V2500/3500 12v nv4500 build

A bit of an update.
I got the 1st gen dodge exhaust in with some cutting and welding, but I have the tailpipe touching the corner of the suburban tank. Im thinking about putting in a heat shield with spacer on the corner to push it away, I assume thats enough? Diesel does vaporize like gasoline so I think Ill be OK.

I put my new injectors in and installed the AFC live, but still cant get it to not smoke. I even turned the AFC live to the minimum and removed the pre boost screw to no avail. Then I learned that the PO adjusted the star wheel all the way forward and didnt install a longer spring! No wonder, theres no tension on the foot. So I have a TST spring on the way.

I also braved the Pella tornado to get a rough Dana 60 from Dougs 4x4. I couldnt be happier, unless I actually got to see my first tornado!

I also discovered why I have such a jerky throttle at low RPM. I only have a VERY stretched out throttle return spring. So that too is in the mail. My jerky throttle only happens when its warmed up so it might be a clogged fuel filter or possibly a bad OFV. I have a new fuel filter installed now and will have to see how the throttle return springs work before I get a new OFV.

Has anyone used the torque motorsports 2009+ dodge 3500 brake conversion on the dana 60? It seems like a great idea, just wondering about opinions.
http://www.torqmotorsports.com/Dana-60-Big-Brake-Brackets_p_263.html


Up next will be a bit boring, check and set valve lash, install 35 spline stub shafts and ARB, high steer kit and custom ORD leafs.
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Old 07-31-2018, 09:11 PM   #10
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Re: 1987 V2500/3500 12v nv4500 build

I also found out the "rebuilt" NV4500 sure as hell doesnt feel like its rebuilt. Ive been mulling over swapping into a 47RH, but then I dont think I can reuse my chevy NP205. Any thoughts/recommendations for swap vs rebuild?
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Old 07-31-2018, 10:08 PM   #11
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Re: 1987 V2500/3500 12v nv4500 build

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Originally Posted by c10hevy View Post
I also found out the "rebuilt" NV4500 sure as hell doesnt feel like its rebuilt. Ive been mulling over swapping into a 47RH, but then I dont think I can reuse my chevy NP205. Any thoughts/recommendations for swap vs rebuild?
Do you know if you have a TH400 big bearing case 205? Do you know the splines of the input of it now?

Those tornadoes were crazy that day. You were only about 24 miles from where I lived. Next time you get over this way let me know.
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Old 07-31-2018, 10:52 PM   #12
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Re: 1987 V2500/3500 12v nv4500 build

Yes it is a 32 spline figure 8 bolt pattern, thats why I want to keep it if at all possible.

I will hit you up next time, the silo across the highway from Dougs lost its roof. Pretty nuts!
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Old 08-01-2018, 12:43 AM   #13
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Re: 1987 V2500/3500 12v nv4500 build

Coming along nicely there. I just finished rebuilding a front dana 60 for my truck too. Parts for those are expensive....I see its 4.56 gears so I guess you will be re-gearing it? I used SVL gears in mine, made by Dana, most ratios are about $150, they set up nicely and seemed to be good quality.

Since your going 35 spline outers...Dennys drivehsafts has the cheapest stubs at $85 each and right now 35 spline Yukon hubs are about $280 on amazon and there is a $30 rebate on them, pretty good deal.

How is your 205 mated to the trans and is the trans chevy or dodge? I guess the chevy trans would be 32 spline output?

I rebuilt my NV4500 because I had to switch from 2wd to 4wd, really I just changed the mainshaft and the input gear but it was very simple to work on. Didn't need any special tools either since the rear bearings are not pressed on the newer mainshafts.

Last edited by randy500; 08-01-2018 at 12:57 AM. Reason: spelling SVL gears
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Old 08-01-2018, 12:45 AM   #14
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Re: 1987 V2500/3500 12v nv4500 build

There are also 2 plastic bushings in the throttle linkage that wear out, if your bellcrank has a lot of play you should change the bushings, they are cheap and available from cummins.
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Old 08-01-2018, 12:59 AM   #15
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Re: 1987 V2500/3500 12v nv4500 build

It is heavy! And that means expensive Im finding out!
I want to go to 3.54 but I can only find 3.73 for both the D60 and 14B.

Thanks for the heads up on Denny's, Ill definitely check them out.

The NV4500 is Dodge and it uses an Advance Adapter kit to mate it to the NP205.

I ordered the heavy and light throttle spring, both cummins parts, and hopefully that along with my AFC spring will control the smoke/fuel delivery. From my very preliminary assessment, these are the only things that are missing/worn out.
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Old 08-01-2018, 01:03 AM   #16
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Re: 1987 V2500/3500 12v nv4500 build

Dennys Driveshafts also has the cheapest dana U joints and should have the gears too along with free shipping over $99. They also have the cheapest king pin rebuild parts, get the part numbers from the dana 60 bella vista article on Pirate 4x4.
I got my front rotors from Summit with free shipping, I looked up the raybestos part number from rockauto and then found it on Summit, I think the rotors were $37 each, summit had to special order them so it took about 2 weeks to get them.

The long inner axle shaft is about $65 so I bought that new from dennys too. The short one I used a sleeve to repair the inner seal surface, those are about $25 from rock auto.
If you need any part numbers on that stuff just ask.
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Old 08-01-2018, 01:07 AM   #17
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Re: 1987 V2500/3500 12v nv4500 build

I had 3.73 and just changed to 3.54, my tires are 32.5" tall, I am happy enough with the change but it was better with the 3.73 gears. I'm running dana 70 rear from a first gen dodge, 65" wide which looks good on my 72 but would be a little narrow on a square body. The 14 bolt is much stronger and with your taller tires the 3.73 gears will be perfect.
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Old 08-01-2018, 01:09 AM   #18
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Re: 1987 V2500/3500 12v nv4500 build

I appreciate it Randy, but I think Im going with 14" rotors and 2 piston calipers from a ram 3500.

Im looking at Dennys now.
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Old 08-03-2018, 08:28 PM   #19
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Re: 1987 V2500/3500 12v nv4500 build

the 2011 and up 2500 vans had a 10.5 rearend option that has 3.54 gears in them. they are an aam rearend thats the same as a 14bolt. I have a set in my 14bolt that I bought off ebay, guy had a bunch of factory takeouts. hes all out now. only way I can find them now is brand new from the dealer. haven't checked on price yet though.
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Old 05-08-2019, 09:18 PM   #20
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Re: 1987 V2500/3500 12v nv4500 build

Its been a long time since my last post. New girlfriend, new house, and new job has taken up most of my time. I got the truck relocated this winter in between snow and -43 windchill days and started tearing her down.

I removed most of the front end, except the bumper because it is welded to the frame.

Then I pulled the pump and lines as well as the front cover and tappet cover to seal some leaks.
Found out that my rear pump support has been broken for who knows how long so reassembly was on hold.
I received a new OEM support and front crank seal because my crank snout was badly grooved. This last weekend I went to install everything and bump the timing back to 16 degrees, only to find that I lost the support!!
I spent 3 hours cleaning my garage up and still couldn't find it anywhere! So i ordered another and am currently waiting.

Once I get the pump in and secured and the engine buttoned up, it will be time to rework the radiator support and modify the AC bracket to move it above the Alt. I can imagine spending $600 to get one of the kits when a few beads and some plate steel will get my the same result. I took my inspiration from grw800 whose thread is located here: https://www.cumminsforum.com/forum/9...d-cummins.html

Then it will be on to a new clutch and trans support....possibly a twin stick for the np205. Not to mention finally getting around to filling up the Dana 60.
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