Aussie GMC C3500

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Clinton

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It needed to be about 30cm reach. I got the bearings and gears off though, but those circlips were a real PITA!

It's almost back together again I have one more hurdle I can foresee which is pressing on the bearing at the output shaft. I might knock it on with pipe.

I should be right for parts now thanks Rick, but I'll let you know if I get really stuck.
 

Clinton

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I' m almost there with the NV4500 rebuild. I did leave a few things in place, like the countershaft, some bearings and seals as they were in great condition. The box has been rebuilt at some stage as it's in great shape but there are some tell-tale signs it's been opened.

Just ordered a torque wrench capable of small numbers and it will be ready to go together.
Photo two is the old mainshaft which I cut down to fit the puller - also in very good condition.
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Clinton

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Okay so it's turning into a NV4500 rebuild thread but anyway - it's done! Now for the tricky part, installing it in a right hand drive. I'm putting a bet on it that it will be the only diesel manual GMT400 in Australia, no one else would be stupid enough.

Of note: the Bundy Rum egg nog got me through the hard times.
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The gears are a little hard to shift 'notchy' and 5th is a little hard to find. I'm thinking the new synchronisers might be the cause. It had the 5th synch replaced with a bronze, so certainly had been worked on before.
 

Clinton

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You probably can't see it in the photos but the input shaft is pretty badly worn where the pilot bearing sits. It seemed okay but then when I checked with a bearing it wobbled about so I've ordered another input shaft.

While the shaft is really easy to change, I'm worried my end play might be different, as in too tight, and removing the tail housing, 5th gear clutch pack, bearings and speedo ring are not something I'm in a hurry to do again.

I'll check endplay but my guess is it will be pretty tight, like zero end play!
 

Clinton

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New input shaft is in, plus a new bearing. End play hopefully not necessary and its not noticeably harder to spin which is a good thing. Temped to sell it all and buy a Ford 7.3 with a manual already in it, but lets see if this pays off!
 

Clinton

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I keep finding new things I should replace. This time it was flywheel and pressure plate bolts. Hi Mopar, I'll have to check our what you mean. Over here the RHD dashes are usually moulded so depending who did the conversion there are often many different looks. About the only one mass made was our Suburban - but can't say I'm a fan of that dash.
 
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