6bt cummins NV4500 1996 LX450 swap

[William839]

Oh good, almost sounded like the FSS was cutting on and off , I’m looking to add an intercooler to my 4BT , just got a super HX30W so looking to reduce EGTs, it’s a tight squeeze in front so I like seeing different intercooler setups in the 80s

I think what you heard was me trying to find gears. The trans was hard to shift. I’ll be trying to tweak the clutch setup and inspect the trans. I’ll post some photos of the intercooler setup. I had the muffler shop that built the exhaust add the intercooler piping.

 

[Major Tom]

Oh good, almost sounded like the FSS was cutting on and off , I’m looking to add an intercooler to my 4BT , just got a super HX30W so looking to reduce EGTs, it’s a tight squeeze in front so I like seeing different intercooler setups in the 80s

My FSS was about 1/2” from my brake master so I deleted it and added a FSC (fuel shutoff cable) similar to an old tractor. I’ll post up the model number for the intercooler I bought from summit racing and add some photos. The pipes will fit. You may have to slightly trim your drivers inter-fender to avoid the battery box.

 

[Major Tom]

Oh good, almost sounded like the FSS was cutting on and off , I’m looking to add an intercooler to my 4BT , just got a super HX30W so looking to reduce EGTs, it’s a tight squeeze in front so I like seeing different intercooler setups in the 80s

Hey William839

Here's my intercooler info. A local exhaust did it with exhaust tubing and welded the intercooler pipe ends from the dodge to the exhaust tubing to adapt it for the three inch tubing.

 

[Major Tom]

 

[Major Tom]

I welded up the intake adapter on the motor. I know its crappy but I was in a hurry.

 

[Major Tom]

 

[Major Tom]

ISO: Front left door panel trim piece. Mine has some cracks and two broken areas. Part shown in red.

 

[William839]

Wow that came out real clean!! I dig it !! The intercooler setup I’m going for might be a little tricky , I’m gonna route it under the bumper using the Cx racing kit .

 

[Will Van]

Great work!

I would post a Wanted Ad in Classifieds for that trim piece.

 

[Major Tom]

First test getting the truck (96 lx450 12v cummins, nv4500) up to speed. I have a Toyota clutch pedal with a nv4500 master/slave for a 94-98 dodge. I’m having a hard time getting into gear. I’ve been told to put 99 dodge slave on as it has a shorter stroke which I’m planning to try. Fifth gear also has an occasional knock. In this video, I set my phone down and shift to fifth and then pick the phone back up. You’ll hear that knock a couple times.



I’m wondering if anyone else has dealt with this and may have any suggestions.

 

[PIP]

I can't tell a thing from your video.

That has got to be very loud inside without shifter boots in place.

 

[Major Tom]

I can't tell a thing from your video.

That has got to be very loud inside without shifter boots in place.

It is loud right now. I’m planning to install the shifter boots as soon as the transmission is sorted out.

 

[Will Van]

First test getting the truck (96 lx450 12v cummins, nv4500) up to speed. I have a Toyota clutch pedal with a nv4500 master/slave for a 94-98 dodge. I’m having a hard time getting into gear. I’ve been told to put 99 dodge slave on as it has a shorter stroke which I’m planning to try. Fifth gear also has an occasional knock. In this video, I set my phone down and shift to fifth and then pick the phone back up. You’ll hear that knock a couple times.



I’m wondering if anyone else has dealt with this and may have any suggestions.

@Dirty Koala - Didn’t you have an issue with clutch hydraulics? I thought you lengthened the pushrod on the master cylinder and used a slave cylinder from an NV3500?

 

[mjosoba]

I think the solution was 80 master and nv3500 slave.

 

[Major Tom]

@mjosoba @Will Van I found the @Dirty Koala post,
Post in thread 'Dirty Koala Build - Cummins 6BT + NV4500 + HF2AV Swap'
Builds - Dirty Koala Build - Cummins 6BT + NV4500 + HF2AV Swap - https://forum.ih8mud.com/threads/dirty-koala-build-cummins-6bt-nv4500-hf2av-swap.804271/post-10276356

This makes sense. I measured the stroke on the nv4500 master at 1.5” and the Toyota pedal at .75”. @Dirty Koala said the 80 master had a .75” stroke which lines up with my pedal movement. Sounds like I need to make some changes with my parts.

 

[mjosoba]

@mjosoba @Will Van I found the @Dirty Koala post,
Post in thread 'Dirty Koala Build - Cummins 6BT + NV4500 + HF2AV Swap'
Builds - Dirty Koala Build - Cummins 6BT + NV4500 + HF2AV Swap - https://forum.ih8mud.com/threads/dirty-koala-build-cummins-6bt-nv4500-hf2av-swap.804271/post-10276356

This makes sense. I measured the stroke on the nv4500 master at 1.5” and the Toyota pedal at .75”. @Dirty Koala said the 80 master had a .75” stroke which lines up with my pedal moment. Sounds like I need to make some changes with my parts.

Hope you get it sorted. SO CLOSE.

 

[Major Tom]

Dakota digital box is up and running. I used plug E7 behind the glove box. Pin 1 is a AM2 ignition circuit that is providing power to the dakota box. Dakota Digital recommended a 5 amp fuse. Pin 10 is the black going to the tachometer. I ran a wire off the alternator as the input and ran a ground wire to the passenger side ground behind the kick panel.

Photo taken through air bag access panel.

 

[Major Tom]

After speaking with several knowledgeable Mud members (will tag them as soon as the search feature is working), I took their recommendation and tried using a slave cylinder off a 1999 dodge as it has a smaller bore size than my master cylinder. Shifting improved significantly. It seems like it could still use some slight adjustments but for now I'm going to put some test miles on it. This transmission seems like a new Kimber 1911, it may need 500 to 1000 rounds through it before it's ready to go.

.

 

[Major Tom]

After trying to clean my window master switch, the driver's window was still a no-go. I read on MUD that a 1996 Camry switch had the same internals but different face plate. I found a good used 1996 camry master switch on ebay for $40 plus free shipping and we are in business.

I replaced the plastic as shown on Wits-End's Instagram account. I used some extra 3M tape I had on the shelf to attach the plastic to the door and sealed the holes with duct tape.

 

[PIP]

Nice work.

Nv4500's never get better with time. They shift the best they ever will right after a quality rebuild.

Did you rebuild it or did you have it done by a shop? What was the main and countershaft clearance set to and what was the method used to check it?

If you could explain in detail what the poor shifting is that you are experiencing I can help troubleshoot. I have extensive experience with these transmissions. Describe if the issue is same in all gears or different and same putting it into gear at a stop vs shifting while moving on the road.