NV4500 NV3550 AX15 TRANSMISSION and ADAPTER INFORMATION
BOOKLET NO. NV015 July 2009 P.O. Box 247 4320 Aerotech Center Way Paso Robles, CA 93447 This FIFTEENTH edition of the NV4500, NV3550, & AX15 Instruction Manual is an accumulation of Advance Adapter's experiences and knowledge in performing various types of conversions. The information and photos are directly related to the products offered by our company.
NV4500 TRANSMISSION SPECIFICATIONS INTRODUCTION: In 1993, General Motors and Chrysler teamed up together to manufacture a transmission referred to as the NV4500 transmission. The NV4500 were used in both the GM & Dodge truck applications. We first learned of this transmission in mid-1993.
GASKETING SPECIFICATIONS: In order to install the new adapter housing, top cover, and bearing retainer, we recommend using Loctite 518 Gasket Eliminator. This sealant seems to work best. SPEEDOMETER: Most 4WD installations provide a speedometer drive gear on the back side of the transfer case. On 2WD transmission swaps, Dodge transmissions are the most desirable due to the mechanical speedometer drive. The later versions (1998 & newer transmissions) do not have any type of speedometer provisions.
TRANSMISSION IDENTIFICATION The NV4500 transmission identification tag is attached to the shifter top cover. The tag provides the transmission model number, build date, and part number. Be sure not to remove the I.D. tag during the conversion. The information on this tag is essential for ordering the correct replacement parts.
GM bellhousing used an internal release bearing that mounted to the front of this transmission. Most bellhousing adapters for this transmission will either require the replacement of the retainer or, on some applications, an adapter retainer bolted to the front of the stock GM aluminum retainer. The shifter stud on the top cover is a male threaded connection. The rear of this transmission has an aluminum adapter housing which measures 8-1/8” long; and the output shaft is 32 spline.
Advance Adapters Custom Built (2001 & Newer) These transmissions are built with a Dodge 29 spline output shaft and a GM input shaft. The transmission is also equiped with the GM front flat aluminum bearing retainer. We carry this rebuilt transmission under P/N 26-0029RGM. * The top shifter’s will vary on these transmission due to core supplies. Dodge Standard Duty 2WD NV4500 (1993-1998) These transmissions have the same front bolt pattern and bearing retainer index as the Dodge 4WD NV4500 transmission.
DODGE NV4500 LABEL CODE SUMMARY The following information deals with both the OEM transmission part numbers and the NV4500 part numbers. In order to assist you with identifying the various transmissions that you might encounter in a salvage yard, we have listed most of the model information provided to us by the manufacturer & our local dealer. These charts should assist you in the identification process. PART NUMBER MODEL DODGE ASSY CODE DODGE CODE ENGINE (Liters) MODEL YEAR Mid-1992 TO 1993 - 5.
DODGE NV4500 LABEL CODE SUMMARY Con’t. PART NUMBER MODEL DODGE ASSY CODE DODGE CODE ENGINE (Liters) MODEL YEAR 1998 TO 2000 (Single Plane Reverse - One Piece Countershaft) 5.61:1 RATIO GEAR SET 4X2 (Standard Duty) 52108128AD 5.2, 5.8 V8 4X2 (Heavy-Duty) 52108130AD 5.9 T/D, 8.0 4X4 (Standard Duty) 52108129AD 5.2, 5.8 V8 4X4 (Heavy-Duty) 52108131AD 5.9 T/D, 8.0 *MODEL YEAR 2001 TO 2002 (Single Plane Reverse - One Piece Countershaft) 5.
GM NV4500 LABEL CODE SUMMARY The following information deals with both the OEM transmission part numbers and the NV4500 part numbers. In order to assist you with identifying the various transmissions that you might encounter in a salvage yard, we have listed most of the model information provided to us by the manufacturer & our local dealer. These charts should assist you in the identification process. MODEL GM ASSY NUMBER GM CODE TYPE OF ENGINE MODEL YEAR Mid-1992 - 6.
GM NV4500 LABEL CODE SUMMARY Con’t MODEL GM ASSY NUMBER GM CODE TYPE OF ENGINE MODEL YEAR 1997 - 5.61:1 RATIO GEAR SET 4X2 C-TRUCK 15716059A 15716060A GARJ GARK ALL EXC 6.5D 6.5 DIESEL 4X4 K-TRUCK 15716058A 15716061A GARH GARL ALL EXC 6.5D 6.5 DIESEL P-TRUCK 15727130A 15727131A GARM GARN WITHOUT YOKE W/ YOKE 4X2 GMT-455 15716057A GARF MODEL YEAR 1998 - 5.
GM NV4500 LABEL CODE SUMMARY Con’t GM ASSY MODEL GM NUMBER TYPE OF CODE ENGINE MODEL YEAR 2001 - 5.61:1 RATIO GEAR SET 4X2 15769082 15747232 GBDR GBDU GAS GAS 4X4 15769083 15747233 GBKS GBFS GAS GAS P-TRUCK 15031131 15020892 GBBW GBCF WITHOUT YOKE W/ YOKE 4X2 (Heavy-Duty) 4X2 GMT-455 15049382 15747131 GBDW GBFU 8.1 GAS MODEL YEAR 2002 - 5.
NV4500 INPUT & OUTPUT SHAFTS GM 32 TOOTH 4WD OUTPUT SHAFT On all NV4500s that were equipped to a GM 4WD transfer case, you will find that the output shaft has 32 teeth. The adapter housing that is mounted to the back of the transmission case is 8-1/8" long. On the inside of this tailhousing, you’ll either find a vibration damper on the output shaft or a steel sleeve. Most of our transfer case adapters will require the damper or sleeve to be removed.
new shaft installed by a qualified transmission mechanic. Your local GM and Dodge service departments are equipped with all of the necessary tools and have been trained for repairing these NV4500 transmissions. The average time to disassemble and replace the new shaft would be approximately 2 hours, provided all the tools were available. P/N J38805 Spec. Socket for Removal of the GM 4WD Damper NOTE: The nut that retains the harmonic balancer (damper) is extremely hard to remove even with the right tools.
SHIFTERS The year and the model of your NV4500 transmission (GM or Dodge) will determine the shift handle assembly you will use. Both GM and Dodge offer shift handle assemblies; however, the cost of these stock handles are not favorable. The shift handles we offer are easy to install and, if necessary, easy to modify to fit your vehicle. 716050C We offer 3 shifter configurations to fit the different models manufactured.
ADAPTER PACKAGES & INDIVIDUAL COMPONENTS FOR JEEP VEHICLES We offer complete adapter packages for the most common Jeep engine and transmission swaps along with the most common transmission retrofits. If we do not show a transmission package specifically for your application, more than likely we offer the individual components to convert your vehicle. The components in the packages that we do offer can also be purchased separately.
JEEPS 1980-1986 (Dana 300): In order to adapt a NV4500 to a Dana 300 transfer case, the transmission can either be a 29 spline or a 23 spline DODGE Standard Duty 4WD NV4500. This Dodge transmission has the correct bolt pattern to bolt directly to the Dana 300 transfer case. The 23 spline transmission has the same spline count as that of the Dana 300. The Dodge 29 spline transmission requires the installation of a new 29 spline input gear into the Dana 300.
GM ENGINE WITH A DANA 300 T/C NV4500 KITS P/N 27-0000T - 29 spl. DODGE Gas NV4500 to Chevy V6 & V8 Adapter plate design The overall assembly length is 26.125”. These kits require the use of a stock GM bellhousing with a 5.125” index diameter. These kits use an adapter plate that couples the Dodge transmission to a standard GM bellhousing. We have included a mounting bracket for the stock Jeep mechanical clutch linkage.
P/N 50-0205 Dana 300 to a Dodge NV4500. JEEPS 1987 & UP (New Process T/C): In order to adapt a NV4500 to a New Process transfer case, the transmission can either be a 29 spline or a 23 spline DODGE Standard Duty 4WD NV4500. When replacing the Peugeot transmission, you will be required to change out the transfer case front input gear. The kits listed below come with a new 29 spline input gear. This input gear ONLY fits New Process 231 transfer cases.
JEEP APPLICATIONS & PACKAGES Regarding P/N 712557 adapter plate to the Peugeot bellhousing: Jeep Wranglers 1987 through 1989, were equipped with a French 5 speed transmission referred to as a "BA10/15". To replace the original Peugeot transmission with a NV4500, we’ve manufactured a special steel plate that allows you to use the original Peugeot Jeep bellhousing. Our adapter plate bolts to the front of the NV4500 and has two special dowel bolts to align the Peugeot bellhousing.
P/N 27-0012T - 29 spl. DODGE Gas NV4500 to Jeep 4.2L 6 cyl. Full bellhousing design (Page 24) The overall assembly length is 24.750”. The 4.2 Jeep 6 cylinder engine can be easily adapted to the NV4500 using our adapter bellhousing. The internal release bearing will be eliminated and a new external slave cylinder gets mounted on the outside of our bellhousing. Refer to Page 26-27 for more information on the 712568 bellhousing kit.
JEEP 4 CYL. ENGINE WITH A NP231 NV4500 KITS (AX5 REPLACEMENT) P/N 27-0019T - 29 spl. DODGE Gas NV4500 to Jeep 4 cylinder Adap. plate design (AX5 replacement) The overall assembly length is 25.625”. This kit is designed around the 1989-93 Jeep with the internal release bearing. If your AX5 has the external slave cylinder, we can switch the bellhousing adapter plate kit to accommodate the 1994 & later slave cylinder configuration.
Regarding P/N 712559 adapter plate to Jeep AX5 bellhousing (external release bearing only): In order to adapt the Dodge Standard Duty NV4500 to a Jeep AMC 4 cylinder engine, we found it necessary to adapt directly to the original AMC bellhousing. This adapter plate design fits the 1994 & newer AX5 bellhousing with the external slave cylinder. This adapter plate provides the correct bolt pattern and dowel pins for the stock AX5 bellhousing.
Regarding P/N 712554 adapter plate kit to Jeep AX15 bellhousing: In 1989, Jeep introduced the AX15 5 speed with the 4.0 high output engine. By using the Dodge transmission along with this new adapter plate, we are able to adapt to the original Jeep bellhousing and retain all of the original clutch components. In order to adapt the Dodge Standard Duty NV4500 to a Jeep AMC 6 cylinder engine, we found it easiest to adapt directly to the original AMC bellhousing.
floorboard for the shifters, and the skid pan will require new holes to be drilled for our crossmember support. A body lift is normally recommended for clearance. Due to the different transfer case shift controls found on Jeep Cherokees, this kit should not be used with these vehicles. These kits are also supplied with a new external slave cylinder. When coupling this new slave cylinder to your stock master cylinder, you will be required to use one of the following clutch fittings, P/N 716130 or 716130TJ.
CHEVY ENGINE WITH A NP231 NV4500 KITS (AX15/NV3550 REPLACEMENT) P/N 27-0011T - 29 spl. DODGE NV4500 to Chevy V6 & V8 Full bhsg. design (AX15 & NV3550 replacement) The overall assembly length is 24.750”. When performing an engine conversion at the same time as a NV4500 installation, driveline modifications are not normally required. Our new bellhousing uses a new external slave cylinder that bolts to the outside of the bellhousing. Refer to Page 47 for more information on the 712576 bellhousing kit.
Since the new transmission will require a special pilot bushing for the back of the AMC engine crank, this pilot bushing is furnished with each bellhousing. It is very important that you properly install this new bushing in the back of the AMC crank. These bushings are made of an oilite bronze material which DO NOT require any type of grease. If grease is applied, this material will bond the input shaft to the bearing causing internal damage.
ADAPTER PACKAGES & INDIVIDUAL COMPONENTS FOR TOYOTA LAND CRUISERS The installation of a NV4500 into Toyota Land Cruiser vehicles has proven to be a very rewarding installation. Not only does this transmission offer the desirable 27% overdrive, but it also offers the ultra low 1st gear ratio necessary for offroad performance. The wheel base of the Land Cruiser is well suited for the length of this new transmission with both the original 6 cylinder engine or a new V8 engine installation.
TOYOTA LAND CRUISER TRANSFER CASE ADAPTERS FOR 1993-2000 DODGE 23 Spline 4WD NV4500s: These kits are designed to fit the Dodge 4WD NV4500 transmission. The stock output shaft must be shortened so that when our spud shaft is assembled it does not push the stock output shaft towards the transmission causing a pre-load on the transmission bearings. The stock tailhousing is replaced with our new adapter which measures 6.375” long.
LAND CRUISER TO CHEVY V8 INSTALLATIONS (Transmission Kits): We offer assembly packages that are designed for both the GM and Dodge NV4500 transmissions. We have listed the transmission package(s) plus the individual components, and any optional or related items that we offer. If we do not show a transmission package specifically for your application, more than likely we offer the individual components to convert your vehicle. The components in the packages that we do offer can also be purchased separately.
REPLACING THE 4 Speed TRANSMISSION: P/N 27-0021G - GM NV4500 for replacing the Land Cruiser FJ40 4 speed (16 spline) Full bellhousing design When replacing the stock 4 speed, the added length of the NV4500 will, in most cases, position the engine in an ideal location to eliminate driveline modifications. The output shaft on this kit must be shortened to expose the 31 spline area located under the harmonic balancer.
BELLHOUSINGS & ADAPTER PLATE CONSIDERATIONS: When using one of our full bellhousings, we recommend that you use an 11” flywheel and clutch assembly. A Centerforce clutch and our large diameter release bearing are recommended in order to achieve proper disengagement with the Toyota Land Cruiser slave cylinder. The full bellhousing kits come complete with a pilot bushing and stock GM clutch release arm. Both the GM and Dodge assembly kits utilize a full conversion bellhousing.
Parts required for replacing the Land Cruiser FJ40/FJ60 4 speed (19 spline) Our adapter plate will only work with the stock Toyota Land Cruiser 4 speed bellhousing. The bearing retainer snout must be turned down to a 1.5” diameter. You will need to use the Land Cruiser bearing collar to fit the new Land Cruiser bearing supplied in the clutch kit. This adapter does not have provisions to retain the stock transmission crossmember.
ADAPTER PACKAGES & INDIVIDUAL COMPONENTS for 1966-77 BRONCOS We offer a complete adapter package for a Bronco transmission swap. The components in this package can also be purchased separately. We currently offer rebuilt NV4500 transmissions. The Dodge 4WD NV4500 is cataloged under Part No. 26-0029R. If you wish to obtain your own transmission, please refer to the Dodge identification charts for both current and past OEM part numbers.
ADAPTER PACKAGES & INDIVIDUAL COMPONENTS for 2WD & 4WD FORD TRUCKS We offer complete NV4500 adapter packages for Ford 4WD full size trucks and list out the components for the 2WD trucks. We currently offer rebuilt NV4500 transmissions. The Dodge 4WD NV4500 is cataloged under P/N 26-0029R. If you wish to obtain your own transmission, please refer to the Dodge identification charts for both current and past OEM part numbers. NOTE: On 1999 & newer Dodge transmissions, the handle assembly was changed.
ADAPTER PACKAGES & INDIVIDUAL COMPONENTS for CHEVY TRUCKS The adapters we manufacture are designed for the GM 4WD NV4500. We offer complete adapter packages for the most common transmission swaps. If we do not show a transmission package specifically for your application, more than likely we offer the individual components to convert your vehicle. The components in the packages that we do offer can also be purchased separately.
The NP205 input gears, no matter what vintage or model, are always the same internally. This allows you to swap the input shaft between the various model transfer cases. One difference that must be taken into consideration is the front input shaft bearing. The male 10 & 27 spline GM transfer cases used a smaller bearing than the female 32 spline transfer case. The last thing that should be noted is the bolt pattern change that occurred on the case of the GM NP205 transfer case.
GM NP205 (27 spline T/C) to GM 4WD NV4500 replacing a TH350: This package is for a GM 4WD NV4500 to the GM NP205 (1971-79), replacing the TH350 transmission. This application requires the shortening of the NV output shaft to 4.498” in length. When using this kit, we couple to the 31 spline area which is under the harmonic balancer. In order to cut the shaft, you will need to remove the tailhousing. The NP205 has a 27 spline male shaft.
GM NP205 1985-91 (32 spline T/C circular 6 bolt pattern) to GM 4WD NV4500: This NP205 was originally coupled to a SM465 or TH400: Found in 1985-91 vehicles, this transfer case has a long input gear stickout of approximately 3.50”, and a female 32 spline input. The bolt pattern is a circular-six configuration. Transfer cases with this long stickout will require a spacer adapter or a change out to the short version GM input gear when coupling to the GM NV4500.
GM BELLHOUSINGS CLUTCH LINKAGE & TRANSFER CASE BRACKETS: P/N P/N P/N P/N 712577 - Chevy NV4500 A.A. bellhousing (1993 to 95 transmissions) conversion bellhousing 712576 - Chevy NV4500 A.A.
ADAPTER PACKAGES & INDIVIDUAL COMPONENTS FOR CUMMINS DIESEL DODGE TRUCKS (REPLACING THE GETRAG 5 SPEED) Between the years of 1989 to 1992, Dodge used a German made Getrag 5 speed transmission coupled to the Cummins diesel engine. These transmissions were used in both 2WD and 4WD vehicles. The availability of re-manufactured transmissions and replacement parts have been extremely difficult to locate. We have developed a bellhousing that will permit the use of the newer Heavy-Duty NV4500 transmission.
crossmember and using a stock Chevy Turbo 350/400 automatic rubber support, you can retain your crossmember in the stock location. The Chevy mount sets into the Dodge crossmember channel. You will also need to drill two holes in the Dodge crossmember for the bolts to fit the Chevy rubber mount.
INDIVIDUAL COMPONENTS for TOYOTA TRUCKS Whether you’re keeping the stock Toyota 4 cylinder or upgrading to a Chevy or Ford engine, we can assist you with the adapters necessary to perform a NV4500 transmission swap. We offer several adapter components for Toyota 4WD trucks. We currently offer rebuilt NV4500 transmissions. The GM 4WD NV4500 can be purchased under P/N 26-0007R. If you wish to obtain your own transmission, please refer to the GM identification charts for both current and past OEM part numbers.
TOYOTA TRUCK FORD V8: We have listed the components designed to couple a Ford engine and a Toyota 21 spline transfer case. These parts are designed to work with a GM 4WD NV4500. This kit requires the use of a stock Ford bellhousing with a 4.848” index diameter. We have listed the adapter plate that bolts the NV4500 transmission to the Ford bellhousing. A new, longer input shaft is also required to compensate for the adapter plate thickness.
TOYOTA TRUCK 4 CYLINDER: If you wish to retain your 4 cylinder, we have listed the components designed to couple the NV4500 the the stock 4 cylinder. These parts are designed to work with a 1996 & Newer GM 4WD NV4500 transmission. This adapter plate works in conjunction with your stock 4 cylinder bellhousing and clutch linkage. This kit requires the use of a stock Toyota 4 cylinder bellhousing (tranny codes G52, G54 W56 & G58).
FULL GM CONVERSION BELLHOUSINGS With the introduction of the NV4500 in 1993, both GM & Dodge found it necessary to change the transmission bellhousing bolt pattern because of the overall size of the transmission. The bolt pattern on these transmissions has been spread out and enlarged in order to meet the transmission general configuration.
This bellhousing is designed for an 11” flywheel and clutch assembly. To achieve proper release and clearances, our bellhousing was designed around the Centerforce clutch components. If clutch components from other manufacturers are used, we cannot guarantee proper clutch operation. The recommended clutch components are as follows: P/N CF165552 - 11” pressure plate P/N 383735 11” clutch disc P/N N1430 Release bearing NOTE: Land Cruisers should use CF165473S pressure plate, and 716316 release bearing.
BELLHOUSING ADAPTER PLATES The adapter plates we manufacture are used primarily for the Dodge Standard Duty NV4500 transmission. This Dodge version has an input shaft that protrudes from the front of the transmission approximately 7-1/2”. Because of the length of this input shaft, we are able to couple this transmission to both a stock GM and Ford bellhousing by means of a 7/8” adapter plate. GM ADAPTER PLATES: P/N 712550 - Dodge Standard Duty NV4500 to GM 5.125" Dia.
FORD ADAPTER PLATES: P/N 712551 - Dodge Standard Duty NV4500 to Ford 4.848” Dia. bellhousing This adapter plate is designed to fit a Dodge NV4500 directly to a standard Ford bellhousing. We recommend the use of a 1985 to 1988 F150 bellhousing to work with this adapter plate. The adapter plate provides a mounting surface identical to a Ford transmission. This kit is designed around the Dodge Standard Duty 4WD version and will compensate for the 1” longer Dodge input shaft.
The NV3550 transmission is an ideal transmission for the avid four wheeler that demands reliability, good strength, and wants a simple installation. The NV3550 was designed for the 2000 to 2004 Jeep TJs when coupled up the 4.0L in-line 6 cylinder engine. This transmission was introduced as the NV3550 in 2000; however, this transmission design was originally used earlier in both the GM and Dodge pickups as the NV3500 transmission. The NV3500 was originally coupled to both the GM 4.
NV3550 to JEEP CJ5 & CJ7 APPLICATIONS: CJ5 JEEPS: Although this is a fairly long transmission for fitting into these short wheelbase vehicles, it can be accomplished when used with a GM V6 engine swap. The GM V6 is short enough to be set further forward in the frame rails and then coupled to the NV3550. The overall length of the 5 speed with the bellhousing and the transfer case adapter is 24.875” long.
The following kits are designed for the Dana 300 transfer case.
JEEP WRANGLERS AND CHEROKEES: PEUGEOT REPLACEMENTS: For the last several years, we have been recommending the World Class T5 transmission as a retrofit for the light-duty Peugeot 5 speed; however, the availability of the WCT5 has come to an end. The opportunity of using the heavier-duty NV3550 was the logical choice as the new replacement transmission for the Peugeot. The NV3550 transmission is the exact same length as the Peugeot 5 speed, which makes this transmission an ideal swap.
AX15 REPLACEMENTS: We have had requests for the NV3550 transmission as a AX15 replacement. The NV3550 has the exact same configuration as the AX15 transmission. When replacing an AX15 that has an external slave cylinder on the bellhousing, the NV3550 can be bolted directly to the stock bellhousing. For Jeeps that have the AX15 with an internal hydraulic release bearing, you will be required to purchase our bellhousing and slave cylinder kit listed below.
NV3550 to 1966-77 BRONCOS: The NV3550 transmission is an ideal transmission swap for the early Broncos. This 5 speed is rated at 300 ft./lbs. at 7200 GVW. The weight of this 5 speed is 97 lbs., which is similar to the stock 3 & 4 speed transmissions. The overall size and length make it an ideal fit. The gearing of this 5 speed is as follows: 1st 4.01:1; 2nd 2.32:1; 3rd 1.40:1; 4th 1.00:1; 5th 0.78:1, and Reverse 3.57:1.
AX15 TRANSMISSIONS: The AX15 transmission has always been a great transmission able to handle the torque and horsepower of most V8s. The biggest problem has always been the availability of new units. With the limited availability of a new NV3550, we revisited the possibly of obtaining the AisIn Warner AX15 transmission and were successful. Although the torque specifications are not listed on this transmission in any service manual, we feel it‘s similar enough to the NV3550.
1980-86 Jeep replacements: The AX15 is longer than most of the 4 and 5 speeds found in these vehicles; however, the AX15 is an excellent upgrade to these drivetrains. The adapter kit we offer for this transmission is .750” thick and allows for a couple of rotations of the Dana 300 transfer case. AX15 to Dana 300 50-8603 AX15 to Dana 300 23 spl.
