John,
I have swapped a 2002 5.9 originally with an auto trans into a '96 RAM 1500
with the standard 5 speed. You are correct, there is no source of data
available for this change. I can tell you it was very much a success, but I
discovered some interesting info. First of course, is the flywheel
difference, but my solution was not to buy a new flywheel. I had the
flywheel from the 5.2, which I used, but I noted the angular placement of
the 5.9 bobweight on the flex plate. I measured the size of this in all
three dimensions. I then removed the same amount of material from the back
of the 5.2 flywheel 180 degrees from the angular placement of the bobweight.
I did this on my vertical milling machine. I then installed the flywheel
with no balance issues. I could place a glass of water on the air cleaner
and not see a ripple at idle. Worst case would be that I ruined the flywheel
and had to buy a new one for $300. I had nothing to lose and it worked
perfectly.

The second thing I did to solve the ECM issue was to use the 5.2 computer
for the manual trans without any change, but I used the 5.9 injectors on the
5.9 and to do that, I had to change all the connectors on the 5.2 wiring
harness and that worked perfectly. I not only ended up with much more power,
but my fuel economy went from 15 MPG to 17 MPG. The extra 40 foot pounds of
torque right off idle makes the combination so much more drivable I was
amazed.

In your case, you will probaly have to swap the ECM for a manual one, but it
does not have to be for the 5.9. As just stated, the 5.2 works just as well.
and there are many more of those in the bone yard. You may find that the 5.2
ECM requires a second water temp sensor in the inlet manifold. If so, you
can drill and tap the existing manifold and just use another of the same
sensor currently in use on the 5.9. I hope this helps.
Steve

from a 98 5.9/5spd/4WD Ram (or Dakota?)

be mega horsepower, maybe 400 at most.

different flywheels,

different flywheel P/N# for the 5.9 Magnum.

stock 5.9?

a 5.2, a 5.9 or a 5.9 Magnum?

are the horsepower ratings and which years will fit

more suitable for off road use?

as the Ram?

originally came with an auto?

inputs or can

or whatever?

involved.

Great info Steve!  You came through onc
again

OK, I've boosted my knowledge base in the last week so in spite o
the length of this post I think there's really only two or three mai
questions that should be pretty easy to answer

The only issues now: 1) Still not sure what trans I’m looking for. 2
One more basic ECM/PCM question. 3) How do I find out if a used tran
is close ratio

Lots of little question below here but again, I really only need tw
or three answered.  I’m mostly concerned with finding a trans
preferably close ratio, that will work.  I don’t really need answer
or info about all the various trans listed here unless there’s mor
than one application for my swap. If you have the time and inf
though, that's good too

Was the 5spd Ram you put the 5.9 into a 4WD truck? If it is 4WD wha
trans is it and how much horsepower are you putting through it
I’m looking to do some performance mods but I’m not talking crazy H
here. I’d be lucky if I got anywhere near 350HP

Again, I'm hoping to use Dodge parts from a donor truck. Not goin
for a mega-dollar buildup here
Maybe I’m chasing a ghost but I’m almost sure I had seen 150
Laramies with 5.9 Magnum/5spd/4WD for sale (very rarely) in our loca
WantAds. If so, what 5spd would be in that?
Or is it like this?
5.9Magnums/4WD only have autos
5.9/5spd/4WD only have non-Magnum 5.9
5.9Magnum 5spd are only made for 2WD trucks? I hope not

Other trans questions
Any of the following applicable
NVG3500 - Different from the NV3500
NV3500 – Only good for 400HP or even less
NV3500 has fixed bell housing and the NV3550 is removable
NV3550 – Was not used as a factory Dodge application, but can b
adapted
NV4500 – Can this trans be regeared with a more streetable close rati
gearset
NV35xx series can be close or wide ratio? If true how do I find ou
which ratio a used trans has

Electronics question
So engine and trans functions are controlled through the ECM but th
PCM is a whole different animal
 And as long as I can find an ECM from a V8 5spd it won’t give CEL
so I can pass inspection?
That leaves only two questions
Am I correct in assuming the ECM does not know if it’s in a 2WD or
4WD truck
Won’t the ECM have the wrong performance mapping if it isn’t from
5.9 Magnum

I thought the PCM did the whole deal. Shows how much I know
Like I said, kinda new to hotrodding computerized vehicles.

Again, thank you very much for your time and effort - Joh

I heard that the first ZJ's in '93 had an option for a 5-speed on the
6-cylinder models so you might score a set of pedals and a center
console from a boneyard.  Having done an auto-to-manual conversion,
that's a big deal.

As far as I can tell, the 5.9L was never offered in a 1/2 ton model
with a 5-speed because the NV3500 is not rated for the torque.  The 5-
speed 5.9L models are in 3/4 ton and are NV4500.  The NV4500 most
likely will not fit under the floor of a ZJ.  A buddy of mine put an
NV4500 in a YJ and takes up most of the space even with a 3" body
lift.  I wanted a 5-speed 4wd 5.9L Dakota but it was never made,
probably because the transmission wont fit under the floor.

So, you could use the NV3500 and hope it doesn't break.  Everybody
said a T5 wouldn't live behind a Chevy 350 but I tried it anyways.  It
broke.

On Jul 12, 9:18 am, diesel...@aol-dot-com.no-spam.invalid (Z88Z)
wrote:

from a 98 5.9/5spd/4WD Ram (or Dakota?)

be mega horsepower, maybe 400 at most.

different flywheels,

different flywheel P/N# for the 5.9 Magnum.

stock 5.9?

a 5.2, a 5.9 or a 5.9 Magnum?

are the horsepower ratings and which years will fit

more suitable for off road use?

as the Ram?

originally came with an auto?

inputs or can

or whatever?

involved.

Thanks Reverend and Steve

OK, I’m getting somewhere now but still have a few questions. Kind o
a three steps forward, one step back process

Last engine questions

Is there non-Magnum gas 5.9 also or are all the 5.9 motors after 199
(or so) either Magnum or diesel?
I believe the 6cyl and, 8cyls have the same bellhousing to block bol
pattern.  Is the diesel 5.9 the same too

So, I’m finally figuring out the NV4500 was the only a manua
transmission available behind any kind of 5.9, and that was a diese
5.9
Anyone know if a 5.9 to NV4500 bellhousing would fit an NV3550
HighImpact shows an AX15 bellhousing for adapting an NV3550 to the 5.
& 5.9

http://www.high-impact.net/transmission_and_gear/nv3550_Chrysler%205_2l-5_9l.ht

That’s hard to figure. You can use a trans from a wrangler behind
5.9 but the trans that come behind a 5.2 isn’t strong enough for th
5.9

This is where I got the flywheel info I was talking about. It mention
two 5.9s: (page 132

http://www.mopar.ca/accessories/performance/2007%20Performance%20Catalogue.pd

http://www.mopartsracing.com/parts/trans.htm

And an interesting quote about using the NV3500 from NotchLX a
bionicdodge
The transmission has an integrated bellhousing and it's rated fo
300ft/lbs of torque. It uses a hydraulic clutch system. (good fo
your leg
These units are a mid-grade transmission that does remarkably well i
a stock application. However once the power is turned up on thes
suckers you might want to pick up a spare. I ran at 320RWHP an
375RWTQ for over 10,000miles and bolted on slicks once a week for
year with 3,000rpm clutch drops and never had a single problem out o
mine... The clutches went before the tranny gave any signs o
disintegration. The Centerforce dual friction clutch holds up prett
good to the added power and is definitely a lot more crisp on th
shifts than the stocker. Others haven't been as lucky
I've heard of people blowing out their 5spd with littl
to no mods??? Depends on what kind of day they were having at the Ne
Ventures shop on the day your transmission rolled out. Plenty o
people are running modded 318, 287, 360, and 408 engines in front o
these units with good results, however the genera
consensus says "O-YOUNG PADOWAN~ PLAY WITH FIRE AND YOU WILL B
BURNED EVENTUALLY

Reverend - I'm familiar with early ZJ 5spd parts. That's what I wa
planning on. I think XJ pedals work too.  I believe the swap could b
done using the original console though.  I have a few interior pi
from someone who did the 5.9 5spd ZJ conversion with an NV4500

Doesn't look like he cut the tunnel?

Heard a rumor some later ZJ export diesel models had manual trans so
that could be a possible pedal and console parts source but I haven't
looked into that yet.

Now my last bit of confusion (for the time being!) :-)

Is the ECM or ECU a different animal than the PCM or are they just
different names for the same thing?
I’m afraid I’ll lose the high performance mapping if I use the 5.2
ECM.

Looks like it’s gonna be a lot of work!!

Thanks again folks - John

View the attachments for this post at: http://www.jlaforums.com/viewtopic.php?p=9094145#9094145

all the 5.9 motors after 199

5.9 gas engine, they are two very different animals.  The 5.9 diese
is the Cummins engine and it has NOTHING in common with the DC 36
Magnum gas engine.  I doubt that they would make the A engine onc
the Magnum engine cam out

and found out it’s a V6!  I assume it does not have the same bol
pattern as the V8s

rebranded as the Magnum V6 and V8 in the 1990s.

and the 5.9 Magnum and no “stock" vs “HP” motors

motors and high performance versions and the HP versions wer
designated as Magnums, (going back even further they were given th
Commando designation!

bellhousing to block bolt pattern.  Is the diesel 5.9 the same too

bolt pattern

bolt pattern the same as the I6

it ever used on the 3.9 V6?

only manual transmission available behind any kind of 5.9, and tha
was a diesel 5.9

the 5.9 gas engine as well

fit an NV3550

the NV3500 is a on

NV3550 to the 5.2 & 5.9

the NV4500 bell housing would fit) was the NV3550, not the NV3500

the NV3550

applications

from an AX15 to fit the 5.9.

but might not handle the 5.9 whereas the NV3550 is made for
Wrangler (I6 motor?) but can handle the 5.9

internals

NotchLX a

slicks once a week for a year with 3,000rpm clutch drops and neve
had a single problem out o

littl

360, and 408 engines in front of these units with good results

put a little less strain on the transmission.

From his post sig I’m pretty sure he’s talking about his Dakota.
Either way, 320RWHP is nothing to sneeze at. If people are spending
the money on a 408 most likely it’s putting out some good ponies
too.
Maybe the NV3500 would stand up to the strain.  I doubt I’ll be going
too crazy with the horsepower on my ZJ.  It might see a bit of
spirited driving but it certainly won’t see street racing or quarter
mile use.

As far as the PCM goes, I can use one from a 5.9/5spd Ram but it would
have to be reflashed with my VIN?   In MA I’m pretty sure the whole
emissions inspection on OBDII vehicles is done by the VIN which is
read directly from the port.

TBone - Thanks again, all replies are appreciated - John

Theres two versions of the NV3500.
http://dodgeram.org/tech/transmission/nv3500_spec.htm - this page only
lists Ram specs.  IIRC Dakotas use the narrow ratio trans.  I dunno if
the NV3500HD is used in any production vehicles.

I personally have had very good service from the NV3500.  I test drove a
few that shifted like crap (mostly wide ratio 1500s).  I believe there
are QC issues, but if you can find a good unit you'll get solid
performance from the transmission.

I wouldn't fear using it in your described application with basic "use
your head" rules like don't hog the throttle in overdrive, don't dump
the clutch, don't tow huge loads in OD uphill, etc.  A manual
transmission's life span is almost exclusively dictated by the driver.

Also, be sure to buy the proper NV3500 transmission fluid.  Its not
*that* expensive, and its considered a lifetime lubrication.  I have 80k
on mine and its still topped off and clean.

only

if

drove a

there

"use

don't dump

driver

have 80k

Thanks for the reply

So you think the NV3550 in a Ram would be the wider ratio and th
Dakota would be closer ratio?   If that's the case, since I wan
something more streetable it would probably be a good idea to use th
Dakota transmission

I guess quality control can be a big issue with those transmissions.
I figure I should have decent luck with it as long as I don't get
bad one to start with
No clutch dumping for me. I figure I'll be driving it more like
sports car.   Hoping to lower it a bit, sway bars, springs etc

We bought an 5.0 5spd Mustang GT new in 86' and got 215K miles out o
the original clutch. Never dumped the clutch and spun the tires ver
rarely, usually by accident.  It did see a lot of "spirite
driving" and some powershifting from time to time
Of course in it's last days I was the only one that could get it i
gear.  When I sold it in 2000 it still had the new clutch in the bac
seat that I had been carrying around for six months

As far as towing goes, No way!  In fact I'll probably take the to
package off.  I have no use for towing anything and that way my e
can't ask me to use the 5.9 to help her move again! LOL!

Thanks again for the reply - Joh