Doing some research for an LS1 swap in my '97 Wrangler and want to keep a manual transmission. The current AX5/NP231 will surely not be up to the task of transferring power of a H/C LS1 with my driving style. Since I will have to swap x-case input shafts to use another Jeep transmission (AX15/NV3550) I thought just using a GMT800 manual trans/x-case would be a much simpler route and could easily get off the shelf wear items (clutch/slave/etc). Maybe my Google-foo is not strong enough, but I cannot find record of anyone doing this in a TJ nor can I find actual dimensions of the full size NV3500/241 combo or an S10 3500/231 combo. I think I would prefer the S10 combo for the close ratio trans and weight savings of the 231 but read that for some reason it will not bolt up to an LS (maybe that only applies to the 4cyl, not the 4.3L V6?). I am worried that this combo is too long for a TJ or it could be it is such a no-brainer no one is mentioning it.

I know several of you guys are running 4wd manual setups here so hopefully you already have this info to share or wouldn't mind pulling a tape measure next time you are under your truck.

 

I don't have an nv3500 anymore but when it was swapped out for an nv4500 no changes to the driveshaft or transfer case mount were needed. Therefore they should be the same and I can get you a measurement this evening if you would like.

 

I read thru the 3500-4500 swap thread hoping there would be some dimensions in there. While you are under there, could you give me an estimated angle the 241 is clocked at? No rush either, It will likely be this fall before I start the swap. I just want to get the transmission solution figured out and had some time to look into it today.

 

No problem at all, that's all that is current still in my RCSB so it will be easy. I will take a bunch of pics too.

I swear I have seen an nv3500 5.3 (Aluminum block) TJ somewhere, maybe 4Wheel and off-road mag. It's possible it was an LJ though.

 

That extra 15" on an LJ sure helps. I talked to a few conversation shops at a Jeep event and they all shrugged their shoulders on a strong manual option for a TJ other than the $6K SilverSport TR4050 4wd package. I was able to talk to SST at LSFest and check out their TJ. It is a really nice setup but uses a proprietary flywheel/clutch/slave so would have to go thru them for replacements. The price and special consumables make it hard for me to choose it as a viable option.

 

I actually swapped my 04 tahoe with a full size nv3500 and np241c driver side drop tcase with custom shifter that I can go measure when I get a chance. If I recall right, the s10 shifter will sit further back than the full size nv3500 and it has less splines. 27ish splines don't quote me on that vs 32 full size spline count out the back of the shaft. The np241 can be out of a 4l80e equiped vehicle, or you can swap the input shaft from a 27 to a 32 spline to match the nv3500 if it came from a 4l60e. I went with a 241 just because the planetary in my 246 was weaker at 4 vs 6 pinions and I wanted a manual Tcase.

 

i thought most of the full size GMT800 trucks normally used np261 manual t-cases, and i ain't quite sure of the differences with mating a 241 in its place.
he's correct above in that the S10 3500s had a smaller tailshaft while the fullsize had a 32spline.

either version should still have the standard SBC bolt pattern.

 

Length is the same as a 4L60/246 combo

so any LS swapped Jeep rocking a 4L60 and 241 will also take a 3500/241 pack

I'm also looking into this for a Ranger. For... reasons.

 

I thought the 4l60/246 combo would be the same, I know I've seen some TJs with that setup.