Category Archives: School Bus Project

A blog with School Bus project progress updates.

Transfer Case Hi / Low shift.

The Series Land Rover High / Low shift lever fulcrum is attached to the transmission. Having converted to a NV4500 leaves me with no attachment point. Here is a picture of a stock truck The tab on the stock transmission … Continue reading

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Painting Brackets and Crossmember

Erich Neal made some beautiful parts for my frame. I painted them with Zero Rust to well stave off rust.

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Hood Hinge

I have decided to go with a new hood hinge. I added steel to the bulkhead to support the hinge. Here are some pictures of the process. 

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The School Bus Moved

   Sadly it did not move under its own power. Thank you Gord’n and the crew at Lamorna Garage is Seattle for letting me store the 109 in your lot. Thanks to Erich Neal for housing it this year.   … Continue reading

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Nv4500 part 600

Setting the torque was very tough. Lowering the lift beam on the housing keep it steady enough to torque the nut.  Copious amounts of Red Loctite prior to installing the nut for the last time. Keeping the housing steady. Use … Continue reading

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Remote oil filter

The stock oil filter port for the Cummins 6at block I have will not clear the right frame rail.  I have used the stock oil filter attachment to make an aluminum plate  The bolt holes are 11/32 matching the stock … Continue reading

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Nv4500 part 500

.004 end play. Absolutely perfect. .002-.006 is the allowance Used .017 total shim. I bought a 1 7/8 Proto socket at Pacific Industrial and modified it to turn the 5th gear retention nut. I started by turning the rear flat so … Continue reading

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NV4500 Part 3

Check to verify the main shaft has .002 to .004 end play             Clean 5th gear retainer nut with break clean and dry Clean main shaft threads and dry be sure concave washer has inner … Continue reading

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NV4500 assembly cont. 

New input seal from Quad 4×4 This bearing race was the perfect size to press the seal into the NV4500 front cover. Cleaned up front cover ready to have the seal pressed in b   Went in very easily. I would not … Continue reading

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Hood extension brackets

In order to fit all this fun and excitement under the hood I am extending it 4 inches. I have designed brackets using Timm Cooper’s guidance that will support the hood properly. Below are the first pieces Fresh off the … Continue reading

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