kit

So I pulled my old auto trans out of my '91 250 4x4 and installed a new flywheel and pressure plate and clutch, and I just tried to dry fit my bellhousing and it seem the bell housing is not deep enough and the clutch is hitting the bell. Am I missing some bell housing adapter? If so were do I find one fast, I need the truck on the road ASAP?

Philip

If your using the stock Dodge bell housing on the 4500 your going to need a 2nd gen engine adapter and the 2nd gen starter with spacer.

BTW the 2nd gen adaper has the starter in a different location. The starter is going to touch the upper part of the frame rail. You need to eather bend the rail upwards a little to clear or notch the rail.

kit

Any idea where I could find a adapter?

Richie O

Don't expect your transfer case from your auto tranny to hook up to the 4500. Wrong spline.

kit

I already swapped it out to a 29

kit

Should I start putting my auto back in or will I be able to get this adapter? Are they eas6 to find or does it take checking junkyards across the usa? Am I looking at spending 500 bucks or is it cheap? I use this truck for work and always need it.

Richie O

Read this site.


http://www.high-impact.net/transmiss...ion%20Packages



.

kit

That site didn't tell me much about going from a 1st gen auto to 2nd gen nv4500. I'm not sure if I should be looking for a new bell housing or the plate between the block and 4500 bell housing. Basically I'm wondering if I should be looking in a junk yard or a supermarket adapter place.

Onemoparnut

probably a junk yard I think they are usually a few hundred dollars

Richie O

This is from QUAD 4x4, Its a copy and paste. GOOGLE IS YOUR FRIEND.



Dodge 4x4 Cummins Diesel Automatic to Manual Conversion Information

We get a ton of requests for NV4500 and NV5600 Conversions on 1989-2002 Dodge 4x4 originally equipped with automatic transmissions. This is not quite so simple as it sounds because of transfer case incompatibility. For all trucks with NP205 transfer cases and most newer models with NP241 transfer cases, the transfer case input shaft is only a 23 spline and the manual transmissions have a 29 spline output shaft.

With the NV4500, we can install a Torque King™ 23 spline output shaft although this is not as strong as the 29 spline shaft. The best option is to install a 29 spline input shaft in the transfer case. This is pretty straight forward with the NP241, however it is not so simple with the NP205 found in 1989-1993 trucks. For these models, the bores for the input bearing and transfer case adapter must be enlarged by a machine shop to accept a larger bearing and seal, plus you will need to get a 29 spline female coupler shaft to join the transmission output shaft to the transfer case input shaft. Our QK2001 has the pieces required to convert your 23 spline NP205 to 29 spline.

In addition to the transfer case modifications, you will need a new flywheel, flywheel bolts, clutch assembly, clutch bolts, bellhousing (NV4500 only), clutch fork, clutch hydraulic system, clutch pedal, brake pedal, transmission mount, transfer case linkage, and hardware. You will need to cut the cab floor/carpet to accept the shift tower, rewire the backup lights and cruise control. In most cases you will also need to have driveline modifications done. Some models will also require crossmember relocation. NV5600 conversions in 1989-1993 trucks will also need a new flywheel housing. and custom starter as will first gen trucks using 1994 and newer bellhousings.

kit

Thanks richie o I'm not the best when it comes to internet, I found the adapter on that site you first mentioned it looks like its a bit over $200 that should do the trick, guess ill have to put it back together and tear it down again next weekend. At least the weather outside sucks.

Richie O

I have seen 2 more sites this week that sell the conversion but for the life of me I can't remember the names. Just be sure to get all your pieces before you start again.

Philip

Keep an eye on the classified adds on this site and other diesel sites. 2nd gen adapter range in prices from $50 to $100. There are many out there.

A WTB buy add will get a fast responce on about any website.

Billut

don't know how far you are from Rancho Cordova, calif., but there is a place called AAA Dodge truck and van that has used parts. I did get some stuff from them in the past, they know their stuff.

kit

I just order a engine adapter from aaa for $200 shipping included, thanks billut. Any idea how the 4x4 linkage will work? Looks like I'm losing the the place I bolted the shifter bracket on the side of the autotrans.