02 Dakota 5.9L 4x4, 5-Speed Conversion??

Howdy. I have a 2002 Dakota QC, 5.9L V8, 4x4 auto, and I hate automatic transmissions. I'd really like to replace the auto with a 5-speed manual. A transfer case with a mechanical floor shifter would
be nice, too.
Options:
1. Find an NV3500 from a same year 4x4 Dakota. The 3.9 and 5.9L share the same bell housing, but what about the 4.7? I'd need a flywheel for a 5.9L. Everything else is bolt in, right? Would the transfer case match? I'd cannibalize the donor truck for driveshafts, pedals, etc.
Problem: The NV3500 isn't rated to handle the torque. I don't off road or tow extensively. Will the transmission handle my heavy right foot?
2. Find a 5-speed and transfer case combo from a 1500/2500 Ram with a 5.9L. What did they use?
Problem: I'm afraid the NV4500 might have been the only option and it won't fit under the floor pan.
3. Find a 6-speed.
Problem: I'm too poor and I've already sold my soul to the devil.
Any ideas, advice, warnings, etc?
Thanks!
-rev
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And the truck six speed is as big as a small house and about as heavy.
Al
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In the long run, your cheapest alternative is going to be selling your truck and buy the truck you want.
John
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John wrote:

Dodge never made the truck I want.
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The level of this project is HUGE. You would be better off selling the truck and buying one the way you want it.

There was no 5 speed offered with the 1500 series and the 5.9. The 2500 used the NV4500.

No bell housing available to fit the 5.9 and if you think that the NV4500 is to big....

The only real advice is to sell what you have and buy what you want. While it is not impossible to do this, the time and money you will spend attempting it will more than kill any savings over selling and buying a different truck.
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I expected a little more balls from you people. Good lord! "Sell it and get what you want." Huge project? Not likely. Every part needed is available in some form or another. No fabrication necessary. With a donor truck available, I could have it done in a day.
Thanks for the info on the 1500 Ram. It sounds like Dodge never offered anything smaller than the NV4500 with the 360. I might have to brave the NV3500 or look into something from another manufacturer, which will greatly increase the complexity of the project.
-rev
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Sounds like you have it covered them! So why are you posting here?? This swap is not a one day deal!! You will collect the parts you think you need, tear your truck apart, start assembly, then spend the next week or two collecting all the little odds and end you need to finish the job. When you get done you have a newer truck of decreased value because of your swap. Then on top of all this you have no money! Have fun!! Greg
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If you really believe this then you are only fooling yourself.

No problem and good luck.
--
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Balls??? Correct me if I'm wrong, but wasn't it you that said " I'm too poor and I've already sold my soul to the devil." You asked for an opinion, you posted a disclaimer stating that you want to do a major mechanical modification to your truck, but you don't have alot of money to spend. This project will cost alot of money no matter what tranny you put in there.
John
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It is a huge project, and while an experienced mechanic might be able to do it in a day, most cannot. Also, every part is made and available somewhere, BUT.. .where? Donor truck? Well gee, if he HAD a friggin 5spd truck, he'd be DRIVING it, not swapping its trans into another truck.
I hate to say it, but I'll agree with Tbone, this project verges on the insane, given that there are trucks already built with 5spds.

Since the NV3500 was not rated at a torque capacity that would handle the 360, it was never bolted to a 360 from the factory. However (and this is the subject of much debate) its likely that a 360 flywheel for the NV4500 will handle the NV3500. Since the 360 and 318 share castings, the NV3500 can be bolted to the 360.
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What about the PCM? Isn't the one for an automatic different form the one used in the manual?
--
Coasty

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Yep
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Coasty wrote:

When making an auto to manual conversion on a GM car, I always wired the shift indicator wiring to 'neutral'. The ECM was happy and it drove just fine. That was OBD1, though. This will be my first OBD2 conversion. If the auto has an electonic valve body then this could get interesting.
-rev
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You'll have to reflash the PCM to manual trans specs. If you have OBD2, you have electronic controls in the AT.
--
Max

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Not if said donor truck was bent in half, sitting in a junk yard.

Sure, if I want a 4.7L, 2-tone paint, and chrome bumpers.

3.7/5.2/5.9 flywheels should be the same, based on what I can find online. The 5.9 is balanced differently. If the NV3500 will fit the 318 then it'll fit the 360. The whole project is bolt together. The question is, will the NV3500 last behind the 360. Guess I'll just have to find out.
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Even if its sitting in a junkyard, he hasn't got ownership. As such, he'll be making lots of trips to look at the donor truck, adding to the insanity of the project.

Well, if you are in the used market, you have to have a set of priorities. If the drivetrain you want doesn't have the paint you want, you have to make a choice. IOW, quit whining.

Then they aren't the same, are they?

IIRC, the NV3500 was rated at 300ftlbs, and the 360 is 330 ftlbs. Coincidentally, thats probably why the NV3500 was never used behind the 360. There were variants of the NV3500 that were rated at 350ftlbs, but not in the Rams.
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--SNIP--

With Chrysler products one never knows. We have a 92 D150 at work with the Magnum V6 and a NV4500. Was under the truck looking for a leak that turned out to be a rear freeze plug and I looked at the transmission expecting to see a NV3500. The next day I took my 92 W250, 360 V8 in and parked next to it and looked them over. Same transmission, except mine is the 4 wheel drive version. The NV3500 is a lot smaller than the NV4500 the difference is obvious.
What I'd like to know is how does this stuff happen? Something I would expect in an old International truck, but not in a Dodge. A friend of mine bought a 99 B350 van about six months ago for his son's band. It has the small rear axle with out floating hubs. Like you would see in a 250 van. I thought all 350's had the big rear axle with floating hubs?
Al
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