Re: AWD maual??
You are probably not going to get much from these guys.
They've got the BW4472, not the NV136, so they don't have any experience.
I personally have a 1999 Olds Bravada, and it too has the NV136. Ultimately, I plan on swapping the 4.3l V6 for a 6.0l LSx series V8, which means the 4L60E tranny is likely to need to be replaced. I plan on going to the 4L80E, and either keeping the NV136 (and changing transmission output shafts) or upgrading to a heavier tcase (like the NV246). Haven't figured out which as of yet.
By the way, New Venture / New Process identifies transfer cases like this:
1st digit: # of speeds. NV(1)36 is a single speed, NV(2)42 is a 2 speed.
2nd digit: Strength rating. NV1(3)6 is fairly light duty. NV2(6)2 is about as heavy as they get.
3rd digit: Style of tcase. NV13(6) is an "active transfer case" with electric clutch. NV14(9) (as used in the Silverado SS is a viscous coupling type transfer case. NV24(2) is a standard part time 4wd box, used in a number of applications, including the Hummer (the original).
You will be pretty much on your own as far as fitup goes. There aren't too many other folks doing this, especially with a manual. And there are a couple of good reasons.
1.) AWD isn't all that popular (obviously here is an exception). Most "performance" folks think smokey burnouts are cool. You can't do that with most of the AWD systems on the market.
2.) Manual transmission will likely have and cause big time durability problems.
A.) The front and rear axles in these trucks are close to being marginal with an automatic. Add the shock loading of a manual and they're likely to start giving you trouble.
B.) The 700R4 transmission isn't known for being a super stout transmission, but it holds up reasonably well to AWD duty. How does the NV3500 compare? I don't know, you'll have to figure that out. But I'd be afraid of breaking transmissions, especially with very little tire slipage to protect the transmission gearsets, and the potential for huge shock loadings (from something like a 5000rpm clutch drop).
C.) The clutch has the potential to be all kinds of fun. All that traction will mean that ALL slippage will happen at the clutch. There won't be any tire spin (until you get to ridiculous power levels). Either way, I'd say a factory clutch doesn't have much of a chance, and I'm not sure what offerings are available to fit the NV3500 input shaft. You'll have to do some consulting there too.
3.) The manual transmission will likely be slower (at least in a Sy or Ty, which is where you're posting). Sy's and Ty's benefit from boosted launches, which are only possible by loading the motor up against the brakes. Not something you'd want to try with a manual (too many pedals, not enough feet, plus I expect you'd run into clutch durability problems). Now in the case of your Bravada, you won't be needing to worry about boosted launches, so it won't necessarily be slower. So, you're not likely to get much help from these folks here, because its a anti-performance modification for them.
Just my $0.02, take it for what its worth (not a whole heck of a lot)
'JustDreamin'
