(Top) Worn Factory Shaft
(Bottom) New Factory Shaft
Torque King Mainshaft Set
Order your PRINTED,
FULL COLOR 100+ Pages.
NV4500 Service Manual Order on our
4x4 Service Manual Page. Covers: Disassembly,
Inspection, Exploded Views, Parts Guide, Assembly, Cover
Service,
Torque King®
Installation, Service Notes, Specifications, FAQ, Tech
Articles, and more!
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ALSO Available in
Download pdf. format. Full Color,
116 total pages.
NV4500 Service Manual from
4x4repairmanuals.com
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"Losing" fifth gear is a common
complaint from trailer towing 1994-1998 Dodge Ram owners
and those with enhanced horsepower Cummins engines.
The problem is less frequent on 1999 and newer trucks
with the revised factory 5th gear nut. While the nut is
often blamed, the part failing is really the factory mainshaft.
As you can see in the photo on the left, the very short 3/4"
long splines on the factory mainshaft do not provide sufficient
support for the fifth gear under high loads. In the area below
the gear teeth, only the tip of the involuted gear splines are
in contact with the mainshaft. Once the gear wears into the
shaft, there is no way to prevent the gear from working the nut
loose. Installing a new 5th gear and/or nut on a worn mainshaft
is only a short term repair and the imbalance caused by the
wobbling gear often results in accelerated transmission wear
and/or transfer case damage. Welding the
gear on a worn shaft doesn't work, nor does loctite.
The permanent solution is our new
Torque King® Mainshaft
which will completely support the special
press fit fifth gear. With our new shaft, 5th gear loss will not
occur. Removal and disassembly of the transmission is required.
Want to rebuild your transmission yourself?
Use one of our Master Rebuild Kits with a Dan the Gear Man™
step-by-step VHS video service
guide found on our NV4500 Kit page for professional results!
MORE HORSEPOWER?
If you have an enhanced horsepower truck with power
output over 600 ft-lbs. of torque and/or 275hp, we
recommend you retrofit your truck with a NV5600 or
Mercedes 6 speed.
The maximum factory torque rating for NV4500HD transmissions is 460 ft/lbs.
(About 235 hp). The design does seem to be capable of up to 600 ft/lbs
with little loss of durability. However, as the horsepower and torque
increases beyond 275hp/600ft-lbs torque, the size of the bearings,
synchronizers, gears, and splines are no longer adequate. Rarely does a
NV4500 fail catastrophically even at double the factory ratings, but the
fact is, most grossly overloaded 4500’s will not last even 100,000 miles
without a rebuild.
Yes, we can eliminate typical fifth gear failures with our
Torque King®
mainshaft and gear sets, and yes, we can even supply larger input
shafts, but there is no practical way to increase the capacity of the
other components. Except for competition pulling, stock input shaft
breakage with the NV4500 is extremely rare. Stock mainshaft breakage is even
rarer.
When subjected to repeated overloads, accelerated spline, bearing and
synchronizer wear will occur. COUNTERSHAFT 5th gear failures and
5th gear tooth breakage are a distinct possibility on overloaded
transmissions
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Bring Your Dodge In
& Have Your NV4500HD
Rebuilt & Upgraded In Our Shop! |
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REBUILD & MAINSHAFT UPGRADE SERVICE
SPECIAL for '94-'03 DODGE with CUMMINS:
Labor includes removal of the transmission and
clutch, transmission disassembly, cleaning and
reassembly, replacement of both the clutch release
bearing and clutch pilot bearing, reinstallation of all
parts in vehicle and a 1 hour break-in road test.
Brand New Parts include our new
Torque King® Gold mainshaft, fifth gear, and retaining
retaining nuts, genuine NVG synchronizer rings, Timken®
tapered roller bearings, Torrington™ needle bearings
(the original equipment bearing suppliers to NVG),
National® input seal, CR™ output seal, complete small
parts kit, Castrol Syntorq LT oil for transmission, oil
for transfer case, double seal clutch pilot bearing, and clutch
release bearing assembly. One year, unlimited mileage
warranty on materials and workmanship. With the exception
of our own Torque King mainshaft,
we only use genuine, American made New Venture NV4500 gears and
parts in our rebuilds.
Dan the Gear Man Service
Tip: I strongly recommend you have two more upgrade options
installed. (A) The original needle pilot bearing is
marginal under heavy use. We offer an exchange flywheel
bored for our heavy-duty QU51010 sealed Ball Pilot
Bearing. (B) Extend the life of your transmission by
having us install the astonishingly effective QK1000
filter to cleanse your transmission oil of metallic and
non-metallic particles. |
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POPULAR INSTALLED OPTIONS WITH UPGRADE SERVICE SPECIAL |
 QU51010
Ball
Pilot Bearing
 QK1000
Transmission Filter Kit
 Clutches
 Pivot
Ball Kit |
Due to a worldwide
shortage of genuine New Venture parts we will no longer be able
to rebuild your NV4500 transmission as of December 2007.
We will resume rebuilding NV4500 transmissions if and when
quality parts again become available!
Have us customize your upgrade with these quality
installed options:
QK1000 Transmission Filter Kit incl. spare
element.......
Exchange Flywheel with QU51010 Ball Pilot
Bearing.
Grind Flywheel Surface (includes
R&R)..............
Stock
Clutch.........................................................................CALL
South Bend MU0090R 350hp Rated
Clutch..................
MU0090ConO South Bend 400hp Rated Clutch........
QU10556 Rear Crankshaft Seal
Installed...............
QK6005 Clutch Fork Pivot Ball & Spring
Kit...........
*Exchange flywheel price includes removal of original
flywheel, installation of exchange resurfaced
flywheel with ball pilot bearing.
**required when replacing clutch
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