Engine/Transmission (1994 - 1998) NV4500 5th gear

[jw3500Ram]

I am new to TDR so I am going to apologize in advance for 1) asking a question about something that probably has been discussed before, 2) posting a "book", but I wanted to give as many details up front.

I have a 97 3500 4x4, NV4500 with SBC 13" clutch. It has had a problem with getting hung in 5th gear. When you come to a stop in 5th gear, the transmission will not come out of fifth gear. I know "who does that", apparently the mechanic that test drove my truck after aligning the front end last week. Then drove it back to the shop (not in 4wd low), slipping the clutch which is now destroyed. I have had the problem for over a year, I didn't realize it had the problem until a friend drove my truck and it happened to him (3 times in a row). Then I realized what the problem was and have been cautious with it since then. I didn't want to pull the transmission until I knew exactly what was wrong with it. I have heard many scenarios, bent shift fork, fifth gear nut debris, worn top cover, clutch, synchros, transmission is junk, on and on.

I was hoping it would last until spring so I could pull the transmission then, but that is out the window now. A friend and I have done all the work to the truck. Replaced the entire front suspension, front axle seals, clutches, pulled the P7100, KDP, front gasket, Front crank seal, and so on. I have a Dodge service manual and a good stock of tools but do not have the "shop tools" needed to rebuild the transmission.

I have ordered a new SBC 13125 OFEK and will be pulling the transmission this weekend. My questions are:
1) Does anybody know what I should be looking for in the transmission.
2) Is rebuilding the transmission something I can do myself without all of the recommended tools.

Thank you in advance for any comments or help.

 

[DonFitzwater]

NV4500's aren't a terribly complicated trans, however, what matters is your skill set. Have you ever torn into a manual trans? A phone call to Standard Transmission in Fort Worth, Tx may be worth your time.

 

[jw3500Ram]

No, I have never been inside a manual transmission. I have heard it is not difficult to rebuild. I can repair just about anything. I have rebuilt almost the entire truck, the only thing left is the transmission, transfer case and internal motor. I did have the fifth gear nut issue several years back and the transmission shop told me the only fix was to weld the fifth gear nut in place so that concerns me. I will probably end up ordering a complete rebuild kit or maybe even a reman unit.

 

[jw3500Ram]

I did buy a used top cover, complete with shift forks and rails a few months back from someone on Ebay. I bought to have a visual of the forks and rails and to compare the "worn" area of the top cover where the shifter sits. It was only 100 bucks and I thought it may be useful if my 5th gear fork was bent. The top cover was in better condition than the one on my truck. The seat the shifter sits in had half of the wear compared to the top cover on the transmission. I considered just replacing the top cover and reinstalling the transmission with the new clutch to see if it still had the fifth gear issue. The other operation of the transmission is good, no issues. I have changed the fluid at required service intervals. I thought if it didn't fix the problem at least it would give me some time to research my options. I may have to pull the transmission again but at least it would be back on the road.

 

[GAmes]

I did have the fifth gear nut issue several years back and the transmission shop told me the only fix was to weld the fifth gear nut in place so that concerns me. I will probably end up ordering a complete rebuild kit or maybe even a reman unit.

I hope you don't do business with them anymore. I second the suggestion to give Standard Transmission a call. They developed the fully splined mainshaft and can fix you up with whatever you need.

 

[jw3500Ram]

I sent 2 emails to standard transmission over a week ago with no reply yet. Looking at other options. Thanks for the suggestion.

 

[GAmes]

Why not call them? 800-783-8726

 

[jw3500Ram]

I called them yesterday. I am shipping the trans to them next week. Thanks for all of the info.

 

[MLee]

Jw;
Was the gear oil you used the preferred kind? not the "gL5" when the alignment guy drove your truck it stuck in 5th with him and he slipped the clutch to get it back to the shop? in 5th. gear. WOW. Maybe you should have checked with peter of South Bend to see why it was hanging in gear. (and got some Advice.)

 

[jw3500Ram]

I replaced the gear oil in the transmission about 8 months ago with the recommended oil from Dodge. I have talked with Standard Gear and the 5th gear problem is caused by the 5th gear synchro and sleeve. It's time for a rebuild. It would have only cost me 176.00$ and a few hours to pull the tail piece off. Since the 5th gear nut was welded in place the main shaft will need to be replaced.

 

[jw3500Ram]

I got the transmission back from Standard Transmission and Gear this week and will have it back in the truck this weekend. As well as new SBC clutch, new u joints, transfer case seals and fluid, new u joints, etc. I can't wait to get it back on the road.

 

[Cummins12V98]

Sounds like you are doing it right!