I figured i can seal these up with a thin coat of sealer and just bolt down the input bearing retainer and the top cover.
I used Hylomar, which is think is a German product. The nice thing about that stuff is, that it stays plyable forever.
I am reusing a diy thermostat gasket i coated with Hylomar for the third time now, no leaks so far.Here's another object of interest in a NV4500 swap that retains the NP203.
The NV4500 + gas engine bellhousing is ~45mm = 1.77" longer than the TF727 automatic or NP435/445 manual transmission.
Not only does that require modification of the trans tunnel, the drive shafts, the transmission crossmember but also the transfer case shift mechanism
To adapt the NP203 transfer case shifter to a NV4500 4WD tailhousing some fabrication and modification is needed.
Don't worry, it can be done with very simple tools such as:
- angle grinder
- large hammer
- an electric drill
- welding machine
As a starting point, cut the bracket:
Then shorten the small upper arm of the piece you just parted off and cut two areas underneath the arm and the lower edge as shown:Note: The outside of the bracket is approximately 6.7" from the centerline of the output shaft.One note on the lower bolt hole:
There is a bent over lip (that's responsible for the rounded edge next to the hole) that needs to be hammered flat.
This will give you enough room for a second hole that needs to be drilled ~0.47" from the center of the first hole.
I am not giving you any really acurate measurements to do this because the tailhousing is a cast piece of aluminum and it can vary a bit.
You will have to find your own hole centers for drilling.
Here's how that fits around the reinforcing ribs of the tailhousing:
Next step is to cut a 1.77" x 6.5" strip of 0.15" thick metal plate for the filler that goes in here:
This is part ONE
I am working on part two which involves drilling the holes, aligning the plate and welding.
Part three will show a way to cope with the slightly angled cast surface of the tailhousing.