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Converting to manual trans with hydro clutch
#798604 November 16th 2022 8:37 pm
Joined: Mar 2011
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jcd74 Offline OP
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Today I found my phone. When I get it sorted I will show you how I converted to manual trans. My biggest hurdle will be posting pics. I got lucky and someone was selling a NV4500 locally. My van came with TH400 and the two share the same footprint. I have a 89 beau', BBC with the Dana/Spicer package. This will help for anyone who has manual trans and wants to switch to hydro clutch. Funny thing, if you looked the new release bearings are self adjusting now. I have now drove over 25k miles with no hang ups on the clutch and trans.

Last edited by jcd74; November 19th 2022 9:10 pm.
Re: Converting to manual trans with hydro clutch
jcd74 #798743 November 20th 2022 8:12 pm
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Does anyone know if I can turn this into a draft so I don't bomb the post feed.

Re: Converting to manual trans with hydro clutch
jcd74 #798744 November 20th 2022 10:29 pm
Joined: Jun 2010
Posts: 18,286
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Bomb away lol


SUNSHINE VANS-VAN DIEGO
ADRENALIN BY THE GALLON & CHASIN RACIN
ONE FOR THE DIRT & ONE FOR THE STREETS
'93 CHEVY G30 454 4X4 SPORTVAN EXT 146" WB
'92 CHEVY G30 454 BEAUVILLE EXT 146" WB
Re: Converting to manual trans with hydro clutch
jcd74 #798773 November 21st 2022 2:33 pm
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Ok first bomb run.

[Linked Image from live.staticflickr.com]

This is the tranny I went with, it is a NV4500. I got it at a local boneyard for 1200. My 89 G30 came with TH400 and the two share the same distance from engine to mount. This made things a lot more simple. I would not have to run around mixing and matching crossmembers and mounts. If you go with the later tranny's 3500, 4500 route, look for the newest ones. Do your research. They have many improvements and options over their lifespan. This one came from a 97 C4500. I was lucky to get the 97 as they made the changes that year. While 1200 seems a bit much on a used tranny the cores at the time where going for 2k. If tuned out to be no good I would at least have a core.

[Linked Image from live.staticflickr.com]

This is the sum of what I started with. I got the tranny, bellhousing, shifter as a package. The pedal assembly was a ebay find, claimed to be from a 78 van.

Re: Converting to manual trans with hydro clutch
jcd74 #798779 November 21st 2022 7:58 pm
Joined: Jun 2010
Posts: 18,286
Likes: 559
Offline
Joined: Jun 2010
Posts: 18,286
Likes: 559
Should put it your build thread .. to keep track of your vans journey thru time


SUNSHINE VANS-VAN DIEGO
ADRENALIN BY THE GALLON & CHASIN RACIN
ONE FOR THE DIRT & ONE FOR THE STREETS
'93 CHEVY G30 454 4X4 SPORTVAN EXT 146" WB
'92 CHEVY G30 454 BEAUVILLE EXT 146" WB
Re: Converting to manual trans with hydro clutch
jcd74 #798784 November 21st 2022 9:18 pm
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jcd74 Offline OP
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With it all apart I started get it together. I had a hard time asking people for help on a clutch. No one wants to tell you the wrong thing and installing something that was never there in the first place only makes it worse. Sema was happening at the time and I never got a response from the aftermarket until a week or two after. This ended up being to my advantage I didn't spend 900 on a clutch I'm not ready for, or hell if it was even going to work. I went with a LUK package and new flywheel of the same brand. I believe it was 250 to the door.

[Linked Image from live.staticflickr.com]

This is the new flywheel installed, you need to take the time to understand what motor you have. The one you have may not be the one that came in your van. Find if your external or internal balance and if external how much force do you need. I used ARP throughout this project. Be careful with aftermarket hardware they do little things in the name of strength. In the past I had seen flywheel bolts where the head does not fully go down to the surface because the add fillet or chamfer under the head to increase strength. Take the time to look and follow the directions from the maker. Don't forget the lube and torque wrench

[Linked Image from live.staticflickr.com]

Clutch kit installed. Count the number of splines you have, check the size of the input shaft, understand what you have. I spent a week just making a final decision. Keep in mind this took me about a year and a half to do. I never moved forward until I solved a problem or had high confidence in my choices. When installing the clutch be careful and take your time. Don't use power tools unless you know what your doing. Grease the input shaft splines, the pilot bearing if needed, Figure out which way the disk goes on (I had no frame of reference and used my best judgment, 50/50 chance) You can use the alinement tool to help hold it up, don't trust it to stay. Hold up the pressure plate and start a couple bolts. Keep checking the disk, seat the tool and the disk and add more bolts. When you have all of them in and you believe the disk is centered start tightening the bolts a little at a time working evenly your way around. Go to fast and you can break something.

[Linked Image from live.staticflickr.com]

The bellhousing got the strip tease and new coat of paint.

[Linked Image from live.staticflickr.com]

The same for the tranny. Here we go first attempt. This is a warning pic don't buy this jack.

[Linked Image from live.staticflickr.com]

I can not tell you how much fun it was to get to this point. My first thought was to make pins for alinement, I should have listened to my self! I wasted 1 weekend day and 2 moments after work. I was like I did this before, this is easy. Nope! I had bought the repair manual for 87 up C/K truck and book says buy two long bolts, cut the heads off, chamfer, install in two top holes of bellhousing and slide tranny on. Yes it was that easy. Also if you can put it in gear and turn the output shaft it helps line up the splines. The jack was a lot of fun it wobbles all over and at one point if fell backwards on the tail.

1 member likes this: frscke1
Re: Converting to manual trans with hydro clutch
frscke1 #798785 November 21st 2022 9:25 pm
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jcd74 Offline OP
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I will next spring when I get to body work. Having found these older pics and I just want to cry, That new road salt is just evil. I have to find something else for the winter.

Re: Converting to manual trans with hydro clutch
jcd74 #798803 November 22nd 2022 12:32 pm
Joined: Nov 2013
Posts: 2,286
Likes: 153
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Posts: 2,286
Likes: 153
Good job all the way, Slow and steady wins the race. Tow yard Lien sale is where I found my B250 for $1000 bucks, title is easy, saved a ton of back fees too, in Cali, not sure about New York, but something will turn up.

Hydro clutch is the way to go with that PP for sure. LOL. Good hunting and good wrenching!


BBC Blue
1990 Chevy G30 L19 7.4 EXT
Church Van, maternity division

DogVan
1988 Dodge B250
LA series 318 Wedge 5.2 TBI A500

Cabin Cruiser
'94 Dodge B350 www.xplorermotorhome.com/
Xplorer MH model 230
230 hp LA series 360 Wedge MPI 5.9 A518 OD auto

Old vans are getting pricey!
Re: Converting to manual trans with hydro clutch
jcd74 #798808 November 22nd 2022 5:59 pm
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If I drive it one more winter she's a goner! It is so much fun in the snow, I have gone 50 mph in a blizzard in 2 feet of snow on the parkways. It just plows thru everything.

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