I'm thinking about putting an NV4500 into my 76 D100. I parted out a complete low mile 91 D200 a year ago and got everything, trans, bell, flywheel, pedal's, cross-member, hydraulic master and slave cylinders, floor pan hump, etc. I done many A and B-body auto to manual swaps over the years. My concern is this: 1)Any changes between the 76 cab and the 91 regarding the pedal brackets?
Has anyone done this swap? I know I'll most likely need to have my driveshaft modified but have a great local shop for that. Both trucks have 360's so flywheel isn't an issue.
Thanks in advance

All 318 and 5.2 engines are neutral balance, but the 5.9 and 360 are not the same, IIRC. Best to check it out first!

sounds like you have everything covered.

when I swapped the NV4500 in my 85 stepside I ran into header issue on driver side with the hedman 79080 2x truck header. #7 tube would not let me install ANY starter with the NV4500 hydro bell.

I used hedman 79170 for 72-93 4x4 or a 2x truck chassis.

another issue I fixed was the cross member needing moved back 2" for the 5 speed tail housing.

I trimmed the stock 727 auto mount then turned it around backwards keeping the cross member in the stock location.

I did trim the edge off the cross member to clear the tail housing. trimmed flat it gives about a 1/2 clearance.

if you move the cross member back 2" you will need to drill 8 holes to keep the side braces(which is a good idea for chassis stiffness/flexing)

fire wall hole is needed to mount clutch M/C- the 4 dimples for the M/C mounting bracket should be on the colum brace/mount but not drilled on a 76. , maybe? I know the 85 had the dimples not drilled but my 91-auto cab had them drilled with hole plug on FW.

I used a floor tunnel hump from a mid 80s ramcharger 4x4 to make a bolt in floor patch. it was auto 4x4 so I had to cut a hole for the shifter nad a patch for transfer shifter hole.

the granny 4 speed hole is not correct for the 5 speed shifter I had to do a lot of measurements on the 2 before cutting for the 5 speed.

I have all the pics if you want to see the couple tricks I used

heres the headers

another good thing about the hedman 79170 4x4 header is when changing the oil the filter does not dump on any of the tubes on that side. and you can r&r the mini starter with out R&R the header like the other header brands.

here are some of the trans mount issues/fix

1 good thing on the hedman 79170 set is no oil gets on the tubes when changing oil filter.

I think you would be better off finding a 4x4 hump/floor patch out of a mid 70s truck. the front 1/2 should be the same as any reg cab floor pan with the club cab having a back 1/2 floor pan.

I cut a hole to fit the cab on the chassis then cut/fit my 4x4 hump to fit in the cab over lapping on the contours of the auto floor pan. drill by bolt holes the trimed the hole out under the patch. I can add a 4x4 and shifter in the future.

IIRC the pedals all mount the same.

this set up is from a 88 d100 v6 5 speed in a 91 auto trans cab

the clutch arm has the flat stock added to reach over to clutch M/C

I would think the hardest thing is drill the 4 holes to mout the bracket.

I have this cab striped down to nothing and mine were already drilled.

Scratch
Thank you very much for the details and pictures. I remember now reading about your project a while ago. this helps a bunch

Bob