QK8384 1989-1991 G360 to Dodge 29-Spline NV4500 Master Conversion Kit

QK8384 1989-1991 G360 to Dodge 29-Spline NV4500 Master Conversion Kit includes the major components required to swap from your existing 4x4 G360 transmission to the stronger and more plentiful NV4500. Includes Transmission-to-Transfer Case Adapter Housing Kit with Adapter to fit Large Bore 29-Spline New Process NP205 Transfer Cases, Gaskets, Input Seal, and Hardware; Bellhousing Kit with Heavy Duty 4WD Bellhousing, Pilot Bushing, Crossmember Mount Spacer, and Hardware; Square Shift Tower Floor Plate Kit with Aluminum Floor Plate to cover the old shift tower hole in the floorboard and accommodate the new one, Screws, and RTV Sealant; Cummins Rear Crank Seal and Install Kit with Teflon Lip Crank Seal with Plastic Seal Starter and Centering Guide, CNC Machine Installer Tool, Tool Handle, Guide Studs, Self-Tapping Screws, Drill Bit, Threadlocker, Anti-Seize, Application Brush, Crank Seal Replacement Instructions, and Hardware; and Heavy Duty Pilot Bearing with Machine Shop Instruction Note. This kit includes the major components required to swap from your 4x4 G360 to an NV4500, but exact conversion requirements vary. All parts in this kit can also be purchased individually from the Kits Components section. Common additional items are included in the Matching Parts section.

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Dan the Gear Man® Tech Notes:
Kit Components
Floorboard Plate
Pilot Bearing
Mounting Plate
Conversion Requirements
G360 to NV4500 Conversion Article
Matching Parts
Applications

Tech Note 1: Kit Components
TK11545 Transmission-to-Transfer Case Adapter Housing Kit for 1989-1993 Dodge W250, W350 New Process NP205 Transfer Cases with 29 Spline Input Shafts
QU5001 Dodge NV4500 4WD Heavy Duty Bellhousing replacing Getrag G360 5 speed transmission
TK1044 Floor Plate Kit for NV4500 4WD conversions from G360 to NV4500 transmissions with NV4500 square shift tower
QK6000 Rear Crank Seal and Install Tool Set for Cummins B Series Engines
QU51010 Heavy-Duty Ball Pilot Bearing with Install Note

Tech Note 2: Floorboard Plate
The 4x4 conversion from G360 to NV4500 transmissions with NV4500 square shift towers requires floorboard modifications for the shifter lever. The included TK1044 plate kit will cover the old hole and accommodate the new.

Tech Note 3: Pilot Bearing
1989-1993 Dodge Cummins Diesel trucks used a bronze Pilot Bushing. These Pilot Bushings quickly get worn oversize so they do not keep the transmission input shaft centered in the flywheel. These worn out Bushings are a contributing cause to the short life and extremely high failure rate of the Getrag G360 5 speed transmission. We include QU51010 Heavy Duty Ball Pilot Bearing in this kit which features thicker bearing races than regular bearings of it's size. You must take this bearing, your flywheel, and the included instruction sheet to the machine shop so the machine shop can get the proper bore.

Tech Note 4: Mounting Plate
When replacing a G360 with an NV4500 using the included Bellhousing Kit, ALWAYS check for interference between the front edge of your original flat steel mounting plate and the NV4500HD Tailshaft housing. Use a grinder to bevel the front edge of the plate as needed.

Tech Note 5: Conversion Requirements
The kit does not include a transmission as we no longer offer any complete transmission. We do offer most of the parts you should need to repair or convert your donor Dodge or Chevy NV4500 to work in this application. Two wheel drive transmissions are generally less expensive than 4x4 models, however, to convert one of these to most 4x4 applications will require at least changing the mainshaft and tailshaft housing. For most applications, a new transmission mount, clutch assembly, and transmission-to-transfer case adapter will also be required. Modifications to the crossmember, floor pan, driveshafts, and exhaust systems are needed for some applications.

Tech Note 6: G360 to NV4500 Conversion Article
Before embarking on an NV4500 retrofit installation, there are a few important things to consider when contemplating this type of conversion. See our Tech Article: 1989-1993 G360 to NV4500 Diesel Conversion.

Tech Note 7: Matching Parts
QK6016 Clutch Fork Kit
QK1003 94-04 Dodge NV4500HD 4x4 Master Overhaul Kit with Tools
QU90020 75w85w NV4500 Manual Transmission Oil, 1 Quart
QU50871 Crankseal Adapter Gaskets
QU51002 Clutch Release (Throwout) Bearing Assembly
QU10706 Late Shift Cover Assembly
QK1012 Shift Tower Kit with Shift Lever and Knob
QU10132 Reverse Light Switch
QU90002 Male Double Terminal Pigtail for Weatherproof Switches
QU5000 HD Transmission Mount Adapter
TM1003 NV4500 Service Manual, Printed
VSG1003 NV4500 Service Manual on Video
Dodge and Ram Shop Manuals on CD

Applications
Dodge:
W250, W350 Diesel Trucks with New Process NP205 Transfer Cases with Large Bore 29-Spline Input Shafts, Converting 4x4 G360 Transmission to NV4500 Transmission with Square Shift Tower: 1989, 1990, 1991