Hey, guys. My wife has found a truck she wants. We were kinda looking for something to build a light trail rig/overlander with. She's buying a small slide-in "cowboy" camper. The truck is a 2002 regular cab 1500, short bed, 360/auto/4wd, SLT with about 250k miles, just what we're looking for. It's a little rough, needs a little TLC, but it runs and drives, and I can get it for about $2500 from a guy down the road. Check engine and air bad lights are on, but I haven't had a chance to look into either. I also have a stroker crank for the 360, should I ever decide to go that far with it.

My big concern is that 46re. I've never heard anything good about them and most guys I've known who have/had them had them replaced or rebuilt about every 150k miles. I would also prefer a manual in this truck. If I buy it, I would just be expecting that trans to go at any time. I helped a buddy swap out the 46rh in his 94 several years ago. It was a 2wd, but I remember it being a fairly simple swap, and he's still loving that old truck.

If this were a second gen truck, I think I would be fine, but this being a 3rd gen with the old drivetrain I'm just not certain, and it's hard to find info online. Is this swap still as easy as it was in my buddy's 94? I realize this is a 4wd, and that may add a little more complexity when selecting parts...

From what I could find an NV4500 is probably the best bet here, still trying to figure out if I could reuse the transfer case. Would I be able to use one from a 2nd gen 2500 360 truck, and just look for pedals, etc from a 3rd gen truck? or am I way off and just need to forget this?

thanks for any help. I searched around and didn't see anything. If I missed it, please point me in the right direction, or if you know of any sites that might have the info.

Are you certain it's a 2002, and/or a 1500 series truck? I didn't think the 5.9 was available in a 1500 series after 2001.

My opinion is this: I own a 2001 1500, 5.2, 4WD auto (46RE) and I wouldn't trade it for anything on the market today (well, maybe ;)). Having said that, I caused my transmission to fail at about 125,000 miles. I got a shoddy rebuild that lasted 49,000 miles (another story). BUT, I'm confident in the recent rebuild by a local (not franchise) shop. Use good, upgraded internals and it'll be fine.

Nothing wrong with the 46RE.

Apples and oranges but I did the swap on my 5.9 '00 Durango. Bought an '01 Dakota with a rusted out frame so I would have everything. It had the electric transfer case so I used my '00 case. 5 spd. was shorter so I wound up lengthening the rear shaft and shortening the front. Had a problem finding a V8 manual trans computer. Ordered several from reman companies that never arrived. Bought a used one off car-part.com that lasted a couple of years then died. Went back to an auto computer so I could drive it, CEL and all. Problem with that was the computer thought it was in neutral or park and would go into fuel-cut at about 4500 rpm's. It was a beast with the manual computer.
Point being, I would try to find a wrecked '02-'03 truck so you would have everything needed. I don't think those years were available with 5 spd.'s and 5.9's unless you went to a 2500 or 3500.
IIRC, Guitar Jones sent me a link showing a swap grid and available aftermarket harnesses. (I'm getting old and it's been a few years so if GJ didn't, my apologies.)

https://www.hotwireauto.com/chrysler-harnesses

Edit- quick check at car-part.com does not show a 5.9 available with manual trans in an '03 2500 (body style like yours) or 3500. You will probably need a harness from hotwire if you want a manual trans truck that will perform.


Tim

It was available in 2002, might be a few in early 2003's? The V10 continued until the end of 2003. Manual swap, IMHO, too much trouble for too little gain.

Thanks, guys. Yes, definitely a 2002 1500. Hemi didn't come around till 2003 to replace it.

I've been looking around for transmissions and swap parts, and not finding much. I think we're just going to pass and keep looking. I have enough projects as it is. I found a 99 318/5-spd regular cab, short bed I might go look at. I'm sure there are plenty of happy folks with 46re's, but I'm not taking my chances.

The 1500 would most likely have the AX15/NV3500 trans. 2500 & 3500 got the NV4500.
And yes I sent you the swap grid.

X2! There is plenty you can do to improve them. And and a lot of failures are caused by HEAT .

Both of my brothers 90s "2nd" gen(94&98) 5 speed trucks had NV3500s , the 92D150 he had and the 92 and 93D150's my uncle had came with NV4500s the AX15(NP2500) never made it behind the V8s only the V6 in the rams and the I4/V6s in the early Dakota's 96 and later V6 Dakotas got the NV3500 also.

if I were closer to Mo, I'd buy that 99 5speed, and wouldn't think twice about it, Would love one myself.

I know you're passing on the 02 truck, but for the record all you would need is the set up from a1500 V6 or 4.7 Manual truck. or any 2500/3500 , need to change the bellhousing if you get it from a Cummings truck..... about 5 years back my brother swapped his 02,4wd 5.2 truck over to a Manual trans , he used the trans and transfer case out of a 04 4wd 2500 Cummings truck , he needed to get SBM bellhousing and 5.2 Flywheel, I don't remember if it was a NV4500 or a G56 trans. the hardest part was finding good RCSB 4wd rear driveshafts, the front he used from the donor truck and had the yoke modified.