Engine/Transmission (1998.5 - 2002) NV4500 synchro R&R???

[DLGonzo]

I'm going to drop my transmission to fix a leaky rear main, and a clutch disc. Third gear is getting a bit contrary, and reverse always has. I've got 230,000 miles and plan on keeping my truck so I'm sure my synchros could use the work. I've never broken into a manual transmission other than fixing my 5th gear nut, but I do almost all my work. How big of a headache is this going to be. I plan on getting the synchro kit from Quad4x4 with video. Feedback please.



Doug

 

[SRadke]

You can't get to the thrid gear syncro (or first, second, reverse) without removing the bearing from the rear of the mainshaft and you can't remove the bearing without destroying it. My advice is at 230k I'd buy the bearing and seal kit with the syncros and just do a total rebuild. That factory service manual does a fair job of walking you through this process, I have that section in a pdf I can email you if you like.



-Scott

 

[Ol'TrailDog]

I saw one site that had brass syncros instead of the fiber one for the NV4500. Not sure where it was but it was either Quad 4x4, Standard, or Blumenthal.

 

[DLGonzo]

Scott,



That pdf file would be great. All I have is the Hayens which has no rebuild detail. You can email to -- email address removed --. This is really going to be fun. Tha only other option is to drop cash for a reman, and I don't relly like that idea, but does anyone know a good place in the cental KY area???



Thanks guys

 

[DTroy]

If you buy a rebuild kit from Dan he will include an instruction video. I read the factory manual and Dan's procedure is easier and modified a tad. He does this stuff every day.



The rebuild isn't a hard job. Just make sure that your endplay is . 002-. 006"

Don't bother with the solid brass synchro rings.



The tools come with the big kit.

 

[SRadke]

I replaced 4 of my six syncros with brass and the shifting diffrence in those gears is negligeable. The two syncros that has a wear surface on each side I've not been able to find in solid brass but I'd sure like to if anyone makes them. That should let me get away from this synthetic fluid.



I'll get that pdf in the mail Doug.



-Scott

 

[DTroy]

I had wanted to do the same thing. I didn't want to have to use the overpriced fluid either. But after hearing how some people said that the shifting quality went down, I changed my mind.