Early Bronco NV3550 5-Speed Swap Kit

This page is dedicated to providing instructions to install the NV3550 5-Speed Manual Transmission into a 66-77 Ford Bronco. For additional assistance, we have also published a 7 part video series with step by step installation of our NV3550 Early Bronco Transmission Conversion. You can purchase this conversion by following the below link:

PURCHASE: 66-77 Ford Bronco NV3550 5-Speed Manual Transmission Conversion Kit

You can download these instructions as a PDF here: NV3550 Transmission for Early Ford Bronco Installation

NV3550 Transmission 5 Speed is Great for an Early Ford Bronco

The NV3550 transmission is an ideal transmission swap for the early Broncos. This 5 speed is rated at 300 ft./lbs. at 7200 GVW. A stock Bronco weighs 4200 GVW. When installed into a Bronco, the NV3550 can then handle an even a higher torque rating due to the lower vehicle weight – so strength is not an issue. The weight of this 5 speed is 97 lbs., which is similar to the stock 3 speed & 4 speed transmissions. The overall size and length make it an ideal fit. This transmission will adapt to either the stock Dana 20 or to our Atlas transfer case.

NV3550 Transmission Gearing of This 5 Speed is as Follows

1st —  4.01
2nd — 2.32
3rd — 1.40
4th — 1.00
5th — 0.78
Rev — 3.57

NV 3550 Transmission Low Gear Ratio Options

Vehicle with 4.56 axle and Dana 20 (2.46:1)

1st — 4.01 — 44.99:1
2nd — 2.32 — 26.03:1
3rd — 1.40 — 15.70:1
4th — 1.00 — 11.22:1
5th — 0.78 — 8.76:1

Vehicle with 4.56 axle and Atlas (4.30:1)

1st — 4.01 –78.62:1
2nd — 2.32 — 45.49:1
3rd — 1.40 — 27.45:1
4th — 1.00 — 19.60:1
5th — 0.78 — 14.87:1

Freeway speed information:

(Vehicle with 33″ tires and 4.56 gears in 5th gear would have the following RPM’s)

55 — 1993
65 — 2355
70 — 2537
75 — 2718

Gear Oil for the NV3550 Transmission

The NV3550 uses a special gear oil only available from your Chrysler dealer under Part No. 4874464.

NV3550 Transmission Kit Consists of:

No.QtyPart No.Description
1. — 1 — 26-3550 — NV3550 TRANSMISSION
4. — 1 Kit — 716000 — NV3550 CROSSMEMBER MOUNT KIT
5. — 1 Kit — 716099 — SHIFTER HANDLE

1. No driveline modifications necessary.
2. The NV3550 assembly is 1/4″ shorter than the factory 3 speed or 4 speed.
3. The NV3550 is slightly taller than the stock 3 or 4 speed. A 1″ body lift is recommended for the best transmission alignment.

SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific type of conversions. Modifications to any of the components will void any possible warranty or return privileges. If you do not fully understand modifications or changes that will be required to complete your conversion, we strongly recommend that you contact our sales department for more information. This instruction sheet is only to be used for the assembly of Advance Adapter components. We recommend that a service manual pertaining to your vehicle be obtained for specific torque values, wiring diagrams and other related equipment. These manuals are normally available at automotive dealerships and parts stores.

66-77 Bronco NV 3550 - Figure 1

66-77 Early Ford Bronco NV3550 Transmission – Figure 1

Procedures to Install the NV3550 Transmission in your Early Ford Bronco

STEP 1: Preparing the NV3550 transmission for the bellhousing adapter

Match the bellhousing adapter to the front of the NV3550. Mark the transmission where the top two holes of the adapter meet the front flange. A small notch will need to be ground into the flange to provide clearance for the bolts. Carefully use an angle or die grinder to grind the clearance for the bolts.

NOTE: The NV3550 transmission has an aluminum case. This material grinds very easily.

66-77 Bronco NV 3550 - Step 1

66-77 Bronco NV 3550 – Step 1

STEP 2: Bellhousing adapter plate installation

Install the bellhousing adapter plate to the NV3550 using (9) Allen bolts supplied.

NOTE: Use Loctite.

66-77 Bronco NV 3550 - Step 2

66-77 Bronco NV 3550 – Step 2

STEP 3: Removing the original transmission

Remove the driveshafts, shifter cables, and exhaust (if necessary).
Remove the original transmission and transfer case assembly from the vehicle. Leave the bellhousing in the vehicle.

66-77 Bronco NV 3550 - Step 3

66-77 Bronco NV 3550 – Step 3

STEP 4: Transfer case adapter to Dana 20

Remove the transfer case adapter and stub shaft from the original transmission. Apply the new AA gasket to the transfer case. Aligning the transfer case adapter with the most clockwise holes will match to the factory indexing (lowest setting). You can use the other set of holes for a higher rotation; however, this can cause some problems with body
clearance, frame clearance, and transfer case shifter linkage alignment. The higher rotation does give you better ground clearance and is a nicer fit on to the new crossmember mount provided. Once you have chosen the rotation, use Loctite and install the (6) Allen bolts.

66-77 Bronco NV 3550 - Step 4

66-77 Bronco NV 3550 – Assembled – Step 4

STEP 5: Installing the adapter and transfer case assembly to the NV3550

Grease the NV3550 tail shaft splines and install the stub shaft & bearing assembly. Apply light grease to the o-ring and attach the transfer case to the transmission with (6) bolts using Loctite. Use the driver’s side top 2 bolts to attach the transfer case shifter bracket.

STEP 6: Prepare the body for the shifter hole

Measure the NV3550 (with the front adapter plate installed) from the edge to the shift tower. It is best to make a template. Measure the location on the body to be cut for the new shifter.

NOTE: To find your measurement, it is best to do this with the bellhousing still installed.

66-77 Bronco NV 3550 - Step 6

66-77 Bronco NV 3550 – Step 6

STEP 7: Removing the bellhousing & clutch assembly

NOTE: It is recommended that the flywheel be turned and new throw out bearing be installed with the new clutch disk.

STEP 8: Checking flywheel pilot shaft hole depth

The NV3550 has a slightly longer pilot shaft than the factory 3 speed. The
factory Ford flywheel should have enough depth to accommodate this; however, if it does not, up to 1/4″ may have to be trimmed off the end of the shaft. A simple angle grinder with a cutoff wheel is suitable.

66-77 Bronco NV 3550 - Step 8

66-77 Bronco NV 3550 – Step 8

STEP 9: Modifying the factory bellhousing to match the NV3550 Transmission

Match the bellhousing to the transmission to measure the clearance.

1. Drill holes at the bottom of the existing vent hole to widen it.

2. Use a die grinder to smooth out the hole shape.

66-77 Bronco NV 3550 - Step 9

66-77 Bronco NV 3550 – Step 9

3. The final shape should be large enough to clear the front shift rail of the NV3550 transmission. This relief should not be cut down into the bellhousing index diameter.

Match the bellhousing again to the transmission to confirm clearance when bolted together.

STEP 10: Installing the new clutch & bellhousing assembly

Use Loctite on the flywheel bolts if they were removed. Remove the original pilot bushing from the flywheel and install the new AA pilot bushing (do not grease pilot bushing).

Install the new disc and pressure plate to the flywheel. Install the new throw out bearing and arm to the bellhousing and grease with an anti-seize lube.

Install the bellhousing and torque to factory specifications.

Step 11: Installing the shifter into the body hole

Remove the shift tower from the NV3550 (4 bolts). Slide it through the hole in the body and use a string to hold it in place. This makes the transmission installation easier , as the shifter tower does not interfere with the body. When removing the shifter tower, make sure the shifter hole on the transmission is covered to keep debris out of the transmission.

66-77 Bronco NV 3550 - Step 11

66-77 Bronco NV 3550 – Step 11

STEP 12: Installing the NV3550 transmission assembly into the Bronco

We recommend using a transmission jack. Once the transmission has been installed and bolted to the bellhousing, you will be required to reinstall the transmission shift tower.

66-77 Bronco NV 3550 - Step 12

66-77 Bronco NV 3550 – Step 12

STEP 13: Installation of the NV3550 transmission crossmember

For installation, click on: Installation of the Transmission Crossmember page.

66-77 Bronco NV 3550 - Step 13

66-77 Bronco NV 3550 – Step 13