Builds Dirty Koala Build - Cummins 6BT + NV4500 + HF2AV Swap (4 Viewers)

[bigfj62]

Keep it going. I hear you on the honey do's. My Cummins is just collecting dust until I build some more shop space this winter.

 

[Dirty Koala]

It's been a while since I posted a progress update. I figured that the swap was going to be a winter project and my garage was in dire need of a revamp if I am to be working out there in the cold. The end of 2015 was spent organizing the garage, running a lot of electrical circuits, setting up good lighting and then sheet rock and painting. I then took a nice long 4 week holiday back to Australia, which brings us to now. Time to get back to work. I am having a natural gas heater getting installed next week and then good insulated garage doors within a few weeks. Once I have a nice warm shop you won't be able to keep me out of there.

Today I spent a little time out there before I got too cold, and finished up installing 5th gear, 5th/reverse synchro assembly and the rear extension housing. Almost finished rebuilding this NV4500!

 

[cruisermatt]

Looks good, what puller did you use for the 5th gear?

 

[Dirty Koala]

Looks good, what puller did you use for the 5th gear?

I have a set of mopar specialty pullers that are made by snapon, for rebuilding NV4500's but 5th gear didn't need to be pulled, it slipped right off. That is pretty common behaviour for 5th on these trans. I did need a variety of pullers, bearing splitters, punches and HD snapring pliers throughout the rebuild though.

 

[cruisermatt]

Mind is being a motherfxxxer, I've already broke a puller in it. Glad to hear yours was easier.

 

[Dirty Koala]

Mind is being a motherfxxxer, I've already broke a puller in it. Glad to hear yours was easier.

View attachment 1200986

Yeah if yours is pressed on, you won't have much luck with a 2 or 3 jaw puller. This is the setup I have and would have used if needed.

These tools are miller specialty made by snap-on.

Puller: 6444
Collar for 5th Gear: 6449

There are 6 different size collars in the set, i used most of them during the rebuild, but you only need 6449 if you are only doing the 5th gear.

 

[Wheelingnoob]

Seeing all these speciaty tools made my mind up. I'm paying someone to to rebuild mine. The cost of thoes tools would be the same as the rebuild cost.

 

[Dirty Koala]

Seeing all these speciaty tools made my mind up. I'm paying someone to to rebuild mine. The cost of thoes tools would be the same as the rebuild cost.

There is definatetly some coin in these tools, probably about a grand. To get a rebuild done by a shop it's about $1500 - $1800. I like to collect tools and wanted to do it myself...but yes the cost difference of having someone else do the job can easily be justified.

 

[Wheelingnoob]

Been quoted $800-1000 locally. I have the main shaft and new 5th gear plus lock nut.

 

[cruisermatt]

Willing to let me borrow? I'll pay shipping there and back

 

[Dirty Koala]

This evening I mounted the HF2AV adapter plate onto the rear of the extension housing, all the holes lined up nicely. I then installed the top cover and torqued to 20 ft/lbs. I ran out of toyota transaxle FIPG, so I used permatex differential and transfer case gasket maker for both. I ran through all the gears, everything appears to be working as expected.

I also bolted up my southbend 13" flywheel and clutch. Torqued the flywheel to 95 ft/lbs and pressure plate to 20 ft/lbs per SBC specs.

 

[GLTHFJ60]

That adapter is sexy!

 

[Dirty Koala]

That adapter is sexy!

The machine work is really good, the fit is perfect. Only thing left to do is fill the trans up with gear oil and bolt on the PTO cover and belhousing.

 

[onemanarmy]

Looking good. Ready to hear this thing fire.

Whats the plans for the white 80?

 

[Dirty Koala]

Looking good. Ready to hear this thing fire.

Whats the plans for the white 80?

It's almost that time. I want to have everything done that can be done, before pulling the motor. Once I get the clutch pedal sorted and the accessory bracket/water neck installed and a few other small things I will be ready to yank out the trusty old 1FZ-FE.

I am not sure what the plan is for the white 80 yet, a boosted LS and 6L80E has crossed my mind a couple times though.

 

[cruisermatt]

Only thing left to do is fill the trans up with gear oil.

NOOOOOOOOOO !!!

There is special fluid you need, it's like a cross of ATF and gear oil. You will kill your trans if you run gear oil.

 

[Dirty Koala]

NOOOOOOOOOO !!!

There is special fluid you need, it's like a cross of ATF and gear oil. You will kill your trans if you run gear oil.

Not to worry, I have the correct fluid for this NV4500. I use the term gear oil loosely.

 

[cruisermatt]

*thumbs up*

 

[ultimate cruiser]

Good luck pro with the big project keep going we need to see the engine running

 

[Dirty Koala]

37" Cooper STT Pro's arrived today. I have a set of 17" tundra split spokes that I got from a fellow mud member, once those are blasted and painted, I will get these mounted up.