Engine/Transmission (1994 - 1998) 5th gear mainshaft replacement

[Animal]

My dad broke the 5th gear mainshaft and needs to replace it. I've read you can remove & replace the mainshaft without removing the transmission but I'm having no luck. I've disassembled an old transmission (removed all gears) to tell him how to do it but can't remove the mainshaft from my old transmission. I live in Alaska and he's in Minnesota so I can't help other than how to do it if I can figure it out. What am I doing wrong?

 

[B.G. Smith]

From looking at a 99 FSM, (NV4500 5 speed) it looks like the input shaft has to be removed first and of course the transmission cover then the output shaft with gearing can be lifted out as an assembly. bg

 

[DTroy]

If it was a simple fifth gear replacement, leave the transmission in the truck if you want.



But if you need to replace the mainshaft, yank the transmission out.

 

[WDaniels]

Animal,

I just replaced everything in my transmission last summer. I got "Quad 4X4's" kit. He is out of Montana. I got the "silver" kit. He sells the instruction manual, the few tools you most likely don't have and has forgotten more about the NV4500 than most people know. He is a great vendor and a pleasure to work with. Give him a call, or get a hold of me by PM if you want more information.

WD

 

[Animal]

WDaniels,

I ordered the TorqueKing SI kit, they state you don't have to remove the transmission from the truck to change the 5th gear mainshaft. Also my dad talked to a tech and he stated you don't have to remove the transmission also and supplied him with instructions. He's now waiting on the mainshaft I order to give it a shot.



Thanks all, I'll let you know how it goes.

 

[SRadke]

If you're replacing the gear, nut, or both it can be done in the truck. If you're replacing the mainshaft the entire top half of the transmission must be disassembled and it WILL NOT happen without removing it from the truck.

-Scott

 

[Animal]

Thanks SRadke, I'll give the old man the bad news.