General Motors/Chrysler NV4500 5-Speed Manual Transmission Service & Repair Manual

NV4500 TRANSMISSION SERVICE DAN GUARINO TM1003 4X4 TECHNICAL MANUAL 4x4 Tech Inc. Roberts, Montana U.S.A. www.4x4techinfo.com COPYRIGHT © 2005-2006 4X4 TECH INC. UNAUTHORIZED REPRODUCTION OR DUPLICATION PROHIBITED 4X4 TECH INC.

Copyright © 2005-2006 by 4x4 Tech Incorporated. Roberts, Montana All Rights Reserved. No part of this publication may be reproduced in any way without the ex- press written permission of 4x4 Tech Inc.. Published by Clear Creek Publishing Printed version is printed and Bound in the United States of America Electronic Compact Disc version is recorded in the United States of America

Table of Contents Disassembly 1 Inspection 23 Expanded Views 26 Gear and Shaft Guide 32 Small Parts Illustrated Guide 35 Assembly 40 Shift Cover Service 72 Torque King® Installation 85 Shop Notes 93 Specifications 98 Frequently Asked Questions 99 Fifth Gear Failures and Solutions 102 Catastrophic Manual Transmission Failures 110 Install Tips for Dodge 1994-2002 113 Special Tool List 115

This manual is intended as an aide to performing a specific service procedure. It is not a replacement for vehicle manufacturer service manuals. Working on vehicles and vehicle components is dan- gerous. It has certain inherent risks, including serious bodily injury and death. This manual is not a substi- tute for common sense, experience, and careful prepa- ration. You are responsible for taking appropriate safety precautions before and during working on your vehicle or vehicle components. If you do not already know how to safely work on your vehicle, please have the work done by a professional automotive techni- cian. Copyright © 2005-2006 4x4 Tech Inc. All Rights Reserved. www.4x4techinfo.com Copyright © 2005-2006 4x4 Tech Inc. All Rights Reserved. www.4x4techinfo.com Copyright © 2005-2006 4x4 Tech Inc. All Rights Reserved. www.4x4techinfo.com

Before starting disassembly, drain the oil by removing the lowest bolt from either PTO cover (Early models have a drain plug on the right side). Clean off accumulated dirt, grease and grime from exterior of transmission. Support the transmission in a holding fixture or place on a sturdy work bench. Have a table or cart next to your work area that you can lay out the parts you remove from the transmission. Check to make sure you have the proper tools on hand. DISASSEMBLY 1 Copyright © 2005-2006 4x4 Tech Inc. All Rights Reserved. www.4x4techinfo.com The original conception of the NV4500 called for 3 ratio options plus a 6 speed, double overdrive version. Only the medium and wide ratio 5 speed ever saw production. Dodge used the medium ratio NV4500 from 1992 to 2004 and in a few 2005 trucks. GM used the wide ratio from 1992-1994, then switched to the medium ratio for 1995. A number of de- sign changes were made over the years to improve function and minimize noise, vibration, and harshness. The last production vehicles to use the NV4500 were the 2007 Chevy Silver- ado Classic and 2007 GMC Sierra Classic trucks with the MW3 transmission option. ABOUT THE TRANSMISSION YOU ARE ABOUT TO SERVICE Copyright © 2005-2006 4x4 Tech Inc. All Rights Reserved. www.4x4techinfo.com Copyright © 2005-2006 4x4 Tech Inc. All Rights Reserved. www.4x4techinfo.com

Use a ½” socket to remove the 10 top cover bolts. Be sure to keep track of the position and orientation of each of the top cover clips. Tool Recommendation: ½” Socket Ratchet or impact wrench Insert a suitable tool into the square pry notches in the top cover, and pry up cover assembly. Tool Recommendation: Prybar or other suitable tool Remove cover assembly. Position the transmission on the bench so a drain pan can be placed under the rear housing. Remove the rear cover bolts. Tool Recommendation: QT1020 12 point impact socket Universal Joint and 6” Extension 2 Copyright © 2005-2006 4x4 Tech Inc. All Rights Reserved. www.4x4techinfo.com Copyright © 2005-2006 4x4 Tech Inc. All Rights Reserved. www.4x4techinfo.com Copyright © 2005-2006 4x4 Tech Inc. All Rights Reserved. www.4x4techinfo.com GM 4x2: Refer to Shop Note on page 95. If the bolt heads are rounded off, refer to Shop Note on page 95.

Use a soft-faced hammer to loosen the sealant between the housing and transmission case. Tool Recommendation: QT9018 5lb. Dead Blow Hammer Pull the housing off the alignment pins. (Arrow points to residual oil draining from case. BE SURE to have drain pan positioned to catch oil) Secure the transmission to a sturdy bench with a ratchet strap. Tool Recommendation: Nylon ratchet strap Remove any lock or set screws from the main shaft nut. Dodge HD models with the crossbolt (shown) require either a T27 Torx® bit or 5/32” hex bit. Aftermarket nuts use several different size set screws depending upon manufacturer. 3 Copyright © 2005-2006 4x4 Tech Inc. All Rights Reserved. www.4x4techinfo.com Copyright © 2005-2006 4x4 Tech Inc. All Rights Reserved. www.4x4techinfo.com Copyright © 2005-2006 4x4 Tech Inc. All Rights Reserved. www.4x4techinfo.com

Place the correct mainshaft nut wrench or socket on the main shaft nut and remove the nut. T2001: Dodge HD ½ drive T2002: Dodge LD, GM w/damper QT2028 GM 4x4 with damper T2036 Dodge HD ¾ drive See Tool List on page 115 for more details If the nut won’t break free, you can hit the wrench with a hammer. Place the transmission upright. Drive out the 3/16” roll pin from the cast iron 5th gear lug. Tool Recommendation: QT9300 3/16”x8” Punch 16 oz. Hammer 4 Copyright © 2005-2006 4x4 Tech Inc. All Rights Reserved. www.4x4techinfo.com Copyright © 2005-2006 4x4 Tech Inc. All Rights Reserved. www.4x4techinfo.com Copyright © 2005-2006 4x4 Tech Inc. All Rights Reserved. www.4x4techinfo.com GM 4x4: Refer to Shop Note on page 95

Remove the lock ring from the back of the countershaft. Tool Recommendation: QT2030 Lock Ring Pliers Carefully work the countershaft 5th gear assembly off the countershaft. Simultaneously work the inner cast iron 5th gear shift lug off the shift rail. Remove the 5th gear shift fork. Remove 5th gear clutch. 5 Copyright © 2005-2006 4x4 Tech Inc. All Rights Reserved. www.4x4techinfo.com Copyright © 2005-2006 4x4 Tech Inc. All Rights Reserved. www.4x4techinfo.com Copyright © 2005-2006 4x4 Tech Inc. All Rights Reserved. www.4x4techinfo.com

Remove the 5th gear synchronizer ring. Remove the 5th gear bearing. Remove thrust washer locating pin from countershaft. Tool Recommendation: Needle nose pliers We recommend marking the matching synchronizer and gear parts with an engraving tool before further disassembly. Tool Recommendation: Carbide tipped electric engraver 6 Copyright © 2005-2006 4x4 Tech Inc. All Rights Reserved. www.4x4techinfo.com Copyright © 2005-2006 4x4 Tech Inc. All Rights Reserved. www.4x4techinfo.com Copyright © 2005-2006 4x4 Tech Inc. All Rights Reserved. www.4x4techinfo.com

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General Motors/Chrysler NV4500 5-Speed Manual Transmission Service & Repair Manual

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