Engine/Transmission (1998.5 - 2002) NV4500 5th gear replacement

[Morphious]

Need some help from ya'll, lost 5th gear again tonight, and believe this time it's the actual gear. The reason I surmise this is when I had the 5th gear nut put on last year, the transmission shop told me that the gear was worn pretty good. I started noticing that the exhaust break would pop the truck out of 5th gear this winter, and tonight, just lost it totally coming down one of the big bridges. I've still got all the other gears. What I need help with is one, locating a very cheaply priced 5th gear, two what does it entail to install one, I haven't looked at the manual yet, will do that this evening. It's a 4x4, will I need to fully pull the transmission or can I get away with just a partial removal? I'm doing this by myself is why I ask. This wouldn't be that big a deal, but I lost the rear driveshaft in my jeep 2 weeks ago and don't have a backup vehicle.



Thanks,



Morph.

 

[SRadke]

I've always pulled the transmission but I think you could do it in place. Separte the transmission from the trans/transfer case adapter (that's the joint between the cast iron trans case and the aluminum adapter) and leave the adapter attached to the transfercase. You'll have to drive a couple small roll pins out of the fifth gear shift fork and I believe a snap ring to slide off the shift fork and fifth gear syncro. This will allow access to get the nut and gear off the mainshaft. You'll need a special wrench to get the nut off. it is a round nut with 4 notches in it. You could just use a hammer and punch but you'll need a wrench to torque it back down.



Get the nut off, slide the gear off, put the new gear on and torque down the nut. Reassemble the rest of the stuff in the opposite order you removed it. The service manual will walk you right through it.



I buy my parts from these guys and have nothingbad to say about their parts or service. Good luck.



-Scott

 

[Deezul1]

Untill you replace the main shaft with a fully splined one you will keep doing this repair over and over. I have Been there.