Huge update!!
Last week I got around to the NV4500 rebuild and swap.
My plan was to make a rebuild thread, however I kept forgetting to take pictures but I did get a service manual with tons of information on these transmissions. So if anybody is interested in a copy, pm me and we'll discuss.
There are also a couple rebuild threads over on a dodge and/or cummins forum.
Anyway back to business,
Teardown was fairly self-explanatory, just took a bit of creativity with tools.
While I had everything apart, it got a decent cleaning with brake clean and lots of rags.
The rebuild went actually pretty smooth for the most part. I just took my sweet time during the entire process and stayed as organized as I could. Most difficult part was dealing with the springs and tabs for the synchros.
Pics (some didn't come out too well):
Tag on PTO cover:
You must be registered for see images attach
Shift cover somewhat clean (neutral position):
You must be registered for see images attach
4wd Extension Housing Removed:
You must be registered for see images attach
Pulling 5th gear on Mainshaft:
You must be registered for see images attach
Random parts and Organizational method:
You must be registered for see images attach
Modified puller:
You must be registered for see images attach
Mainshaft and Countershaft pre-rebuild:
You must be registered for see images attach
Pretty much empty case pre-clean:
You must be registered for see images attach
Bare Mainshaft:
You must be registered for see images attach
All three shafts, cleaned and rebuilt:
You must be registered for see images attach
Somewhat clean case:
You must be registered for see images attach
Checking Countershaft endplay:
You must be registered for see images attach
And because I told him I would post this, Jeremy (1998regcab) guessed the exact endplay.
Installing Mainshaft:
You must be registered for see images attach
Mainshaft installed:
You must be registered for see images attach
New pivot ball and shifter stub boot vs. old:
You must be registered for see images attach
Tapping stripped Transmission to Bellhousing bolt holes:
You must be registered for see images attach
Shift cover and Ext. Housing Installed, ready for swap. Also, I ran out of Black RTV so red had to do.
You must be registered for see images attach
As for the infamous 5th gear nut.. I ended up using red loctite and impacting that sob as much as it would go. If this fails, I am not apposed to trying another method.
Then out came the 3500. During this time, I decided to give the transfer case a much needed cleaning, with a wire wheel and brake clean. Replace the u-joint at the rear axle. Half ass clean the drivetrain tunnel. Inspect the pressure plate, oh and hallow out my clogged catalytic converter. No pics sorry.
Fluids used, yes plural..:
You must be registered for see images attach
Installing bellhousing:
You must be registered for see images attach
INSTALLED NV4500!!! (before t-case and driveshaft):
You must be registered for see images attach
Swap went better than I thought it would... Besides dropping the transmission a couple times.. hint the mixed fluid... haha
Couple modifications:
First I had to cut a bit of the floor for the shifter stub. I used wire ***** to cut back an inch or so, and lineman pliers to bend it back into place. Not pretty but It is covered by carpet and interior boot.
You must be registered for see images attach
Also, the 4500 is apparently deeper than the 3500. I had to extend the down pipe on one side of the exhaust. Oh well I've been contemplating new exhaust anyway.
Overall I'm very pleased with the entire rebuild and swap. The truck is a freakin blast to drive again. There is a bit of gear noise, but it's bearable.
The next couple days I drove the truck ~100ish miles. Worked wonderfully, shifted flawlessly.
Swap was absolutely worth every minute.
