Exploring options for my '99 B3500. I want two more forward gears to eliminate hunting and improve economy on my 650 mi/day trip.

My first thought was an Allison. Stand alone controllers are available, but it's expen$ive ($1500 for just the controller).

Then I thought about a 6 speed stick from a truck like a NV3500. I could pick one up cheap and it would last a lot longer. Has anyone swapped in a manual? I thought I saw reference to a factory pedal assembly once, but can't seem to find it again?? Maybe an aftermarket like a Wilwood? Clutch requirements?

What might I be missing? Other options?

Thanks.

 

As far as I know the 94 and later vans were all equiped with automatics.

An Allison with the controller would be nice if you want to stay with the automatic.

The manual would be cheaper but still require as you pointed out putting in a custom pedal set to add the clutch pedal. Hydraulic are the easiest clutches to add, though IMO a rod or cable can be more durable.

Question is what do you have to spend and what are your preference? Either will require custom modification in order to do it. Also how long do you plan on driving this van, will you recoup your investment back in the fuel savings during that time?

 

If you are looking for better mpg, I would suggest reading my thread of MPG Improved for some good hints. My B2500 is the Heavy Duty type based on your B3500 chassis. ie, 8-lug wheels, bigger calipers and discs, etc. It was getting 12mpg hwy. After much of the tweaking, it now gets 19.7mpg on the hwy.

 

You want to spend $2,000 on a mod in order to save $100 in gas?

 

You all raise valid points concerning the cost. My van has 150k on it now, and is likely due for a trans rebuild any time now. By careful shopping I could get a NV3500 for less than a rebuild.

Also, Alloro, my calculations suggest I'll be saving $100 every two weeks with this swap (my route has me driving 150k/yr). If I can keep it to $2000 as you suggest, I'll reach payback in less than a year. Let's also not forget the reduced maintenance costs of the manual.

 

That's different. I had the impression this was a one time long trip your were taking, where you were doing it in 650 mile a day increments.

Have you given thought to just getting a mini-cargo van that'll give you 25+ MPG?

 

Unfortunately, I'm barely big enough to fit it all right now. A mini or midsize would never work!

 

To try to get a bit more specific on the manual swap:

Does anybody know if the smaller brake pedal from the pre-'94 manual shift vans will fit my newer one?

Is there enough structure under the dash to support a clutch pedal assembly?

 

Have you looked at the thread that Stev pointed out? That might be the wisest and cheapest option. He gained 7mpg doing his simple mods to a HD B2500, that is very impressive. You should be able to do the same mods and as he stated in that thread to go over 20 plus mpg.

Also if yours is needing overhaul soon I would look and see if you can buy a beefier rebuild kit to go into the transmission.
http://www.transmissioncenter.net/st...s.htm#518-47RE
http://www.transmissionsone.com/
Hope these give you some ideas on the transmission.

 

Yes, I've read his thread a few times (as well as others on like EcoModder). Many tricks from it have been implemented, but the biggest key to his economy is driving 65mph--something I cannot do.

While this thread has mostly taken the economy perspective (which is an important factor in this decision) my desire to improve drivability and control on some of these grades I face is equally motivating--something a rebuild won't help with. Maybe I should just sell the van and find the one out of a million CNG powered trucks out there with a stick shift and pull a trailer