Engine/Transmission (1994 - 1998) 5th gear gone, what are my options?

[Woodenhead]

Well fifth gear fell off on the way home tonight. I have 195,000 miles on the truck and had the nut replaced with the updated one at around 125,000 miles and had no problems before that so I guess even the fancy nut isn't always fool proof.



So as I see it these are my options:

1. Replace the gear with another nut and just wait for it to keep falling off. From what I understand, once it happens it'll keep happening.



2. Replace main shaft with a fully splined. With almost 200,000 miles on the truck I may as well have the transmission rebuilt at the same time. Any clues on the cost of this?



3. Do the NV5600 conversion. I'm guessing my clutch will need to be replaced when I do this because I have the 1-1/4 inch input shaft and the NV5600 would have the 1-3/8 inch shaft (right?). Drive shafts will need to be lengthened/shortened and a cross member will need to be installed. Among other items. I've been looking for an excuse to do a 6 speed conversion so maybe I should just put the money towards that now. Any clues on the cost of this?



Either way I'm going to need to find a good shop to do the work. I have a shop to do the work in and am capable but I don't think this is something to do on my own.

I'm in Soap Lake, Wa and have another post to try and find a shop.



Any comments on the above? I'll be spending the night doing searches and learning about my options but any further info. would be greatly appreciated.



Taker easy,

Mike

 

[Vaughn MacKenzie]

3. Do the NV5600 conversion. I'm guessing my clutch will need to be replaced when I do this because I have the 1-1/4 inch input shaft and the NV5600 would have the 1-3/8 inch shaft (right?).

. . . unless you're lucky enough to snag a 6-speed out of a '99 or '00 Ram (odds aren't real great especially a '99). I think you can get the right clutch from Piers that matches the larger input shaft, and matches the smaller 5-speed flywheel. I think the 6-speed '99-'00 were the same as the 5-speed then went larger in '01. If it wasn't too difficult and doable I would look for a larger flywheel to do the swap with.



If I keep my '96 a long time I might look into a 6-speed upgrade. But for now I'm having fun seeing how many miles I can coax out of my virgin 5th gear-- 400k is looming on the horizon

 

[Woodenhead]

Thanks for the reply Vaughn. I have a 13" South Bend Con FE so I don't think the flywheel will be a problem. However the clutch is for a 1. 25' input shaft so like you said if I get a transmission from a 99-00 ram I guess I'll be OK otherwise it'll cost me a clutch too. I plan on more upgrades in the future (oring head and twins) so I guess I should just go with the bigger input shaft and clutch now.

 

[Joseph Donnelly]

By the time it is odne, the 6 speed conversion will cost many thousands. 1-800-std-tran can exchange yours for a rebuilt NV4500 with the good mainshaft and a better nut for a reasonable price, well under $2k including shipping both ways.

 

[Vaughn MacKenzie]

Mike I met a guy who did a conversion on his 99, as I recall he had over $4500 into it and he had been patient and watched for a good price on a used 6-speed.



I've had 2 6-speed trucks and while I wish I had the extra gear, I don't miss it that much. If you want durability, once you get the upgraded transmission from Standard Trans that won't be an issue.



Vaughn

 

[Woodenhead]

Looks like maybe another 4500 may be the way to go. If I do order one from Standard Trans I guess I should get the cast iron tail stock at the same time. How's the NV4500 hold up at 600+hp? I'm obviously not there now but one day this truck will be replaced and end up in the shop as a "project" truck.

 

[BTighe]

i think i read somewhere that the 99-00 6 speed transmission was weak. i think they stopped offering it untill 01. 5 i could be wrong though.

 

[JGheen]

Looks like maybe another 4500 may be the way to go. If I do order one from Standard Trans I guess I should get the cast iron tail stock at the same time. How's the NV4500 hold up at 600+hp? I'm obviously not there now but one day this truck will be replaced and end up in the shop as a "project" truck.

I believe Peter @ SBC told me once that the stock 1. 25" input on the NV4500 can take quite a beating. I would probably look into the 1 3/8" shaft if your approaching 600 but from some reliable sources, it seems the stock input can take probably just over 500, but not much more. Who knows, ask around.

 

[RT66DOC]

If you go for a rebuilt 4500 you'll have the fully splined mainshaft to hold 5th gear but the input shaft will still be 1. 25. Haisley and maybe others make a 1. 375 replacement mainshaft for the 4500 but last time I looked it was $850 so, to my mind, that puts the cost right up into 5600 territory.



Are you aware of the complete kits from places like Quad 4X4, Blumenthal, Std. Trans? Check here: http://www.quad4x4.com/ for a description of what all's in the kits. Looks to me like the $$$ numbers mentioned above will get you the whole enchilada - new 5600, flywheel, 13" SB clutch and all the miscellaneous stuff you'll need.



I vote for the 5600. I'm gonna guess it'll hold up to at least 350 HP - maybe even more.

 

[Woodenhead]

Thanks for the all the info fellas. I already called Dan at Quad4x4 yesterday after being recommended in a PM from another TDR member. Looks like he comes highly recommended.



I heard from several sources (some TDR members, some not) that just doing fully splined main shaft and updated nut is not always a perfect fix and some have still had 5th fall off again. It looks like Dan at Quad4x4 has a sound fix here .



I think since I have no plans on ever getting rid of the truck, I do plan on more hp in the future, I do tow on occasion, I certainly don't want any 5th gear problems in the future and I have the $$ available to do the conversion I'm going to go ahead and do it.



On Monday I have an appointment to get my 5th gear put back on and the nut welded. I know welding is not recommended but this is just a scabbed up fix to get me to Quad4x4 in Montana. Then the following week it's off to Quad4x4 for a new 5600.



Mike