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Im just curious but when the NV4500 is available in the 03-04 trucks, did it ever come from the factory with an upgraded input shaft (the size of the NV5600) or an upgraded 5th gear to prevent it from coming off like the older ones?
Only the NV5600 for the 03/04 HO engine. I don't know if the standard output engine had anything different but I thought you could only get a standard output with an auto or in California.
If you got the SO and want a manual it came with a nv4500. 03 & 04 nv4500 were the same as what was in the 2nd gens. So it will need all the same upgrades.
I haven't heard of NV4500 5th gear failures on 3rd Gens but then maybe that's because there wasn't that many of them produced in the first place. . . most got the 6-speed.
'99 and up NV4500s had a revised fifth gear (locking) nut from the factory which greatly reduced the number of fifth gear failures. The main shaft, however, wasn't changed, so the revised nut was really just a band aid, but it seemed to help. *