NV4500 failure?

[sweetk30]

just a fyi pto units are same bolt pattern for small stuff. but specific gear to each unit they bolt to . so make sure the pto you have if for what you want tit to go on .

you can get the parts to redo it but half the time its cheeper to just buy a new one.

 

[rompinstompinmudmonkey]

I didn't know that. How do I tell if I have the right one? Just bolt it up And check to see if the gears mesh correctly? Or will the PTO gear have a part number I can cross reference?

 

[sweetk30]

a lot of homework .

if you know what it come off or that will be a start .

otherwise make / model / ser # / and possible brake down and get #'s off inside parts . then find a dealer for the brand . then hope parts still avalible . and at that point is it worth the $ to buy parts or new unit .

 

[rompinstompinmudmonkey]

I seem to have broken my NV4500 again. I probably only have 1000 miles on it since the input shaft was replaced. Not sure exactly what the deal is but its getting really frustrating!!

Just driving down the road in 5th gear, when I started to hear a clunk. I pressed in the clutch and it went away

Uh oh. I pulled off the road and went through the gears. Clunk, bang pop in every gear.

It only moves in 4th gear, and it seems like it wants to bind. Nothing in 1st, 2nd, 3rd 5th and a hell of a racket in reverse.

I've got no idea what let go, or why. I guess I'll pull the trans again and see what I'm working with.

 

[DEMON44]

Starting to seem like something may be shimmed wrong. Or bad parts from the last fix maybe?

A second failure so soon is very unusual for one of those.

 

[rompinstompinmudmonkey]

Yeah, I'm thinking I have some broken gears or a broken counter shaft. All the gears go through the counter shaft except 4th gear, and i have a problem with every gear but 4th.
I visually inspected all the parts last time before I reassembled and I didn't see anything that I was concerned about.

I haven't even pulled a trailer since the rebuild, so its not like I worked it really hard....

 

[DEMON44]

4th is direct. Does not use the countershaft for path of power.

So you have a countershaft failure of some sort.

 

[tRustyK5]

Which version do you have? The earlier version with the 6.34:1 first gear uses a two piece counter shaft, the later version with the 5.61:1 first gear uses a one piece counter shaft...

 

[rompinstompinmudmonkey]

Its a 96 dodge NV4500 so it has a 1 piece counter shaft

 

[Fordum]

Well........It did have a one piece shaft.....no telling how many piece shaft it is now.....

 

[rompinstompinmudmonkey]

Yeah, I'm afraid to see how much its going to cost for parts once I get it torn down. It may be cheaper just to replace the entire transmission

 

[rompinstompinmudmonkey]

Here is the pic of the broken input shaft from last fall.

And during the rebuild.

 

[DEMON44]

That's generally a shock load break. And you probably hurt the counter shaft when that input broke. Fractures that you can't see. That's a very possible scenario.

 

[rompinstompinmudmonkey]

Here's what I found today when I took the PTO covers off to inspect

Its kind of hard to take a pic, but for sure the input gear and countershaft are toast. I'll have to pull it and tear it down to see the rest.

 

[DEMON44]

That's definately collateral damage from the input shaft failure.

 

[rompinstompinmudmonkey]

I've got a line on a G56. I'm considering swapping that in.

I'm not sure on a few things though.

Does my starter need to be changed?
What about my slave cylinder? Does that or the hydraulic line to it need to be changed?
I know my clutch will have to be changed. South bend can put a 1 3/8" hub in my disc if I send it to them.
Will my 205 bolt to the G56? Will the spline engagement and clocking be correct? Or will I need a clocking ring?
Is a G56 more durable than an NV4500?

 

[DEMON44]

G65 and ZF6 are both superior to the nv4500. No question.

 

[DEMON44]

I don't have any concrete answers to the other concerns though.

Youd only have to change the starter if you changed the flywheel.

Slave and bolt up I just don't know.

 

[rompinstompinmudmonkey]

I just called south bend clutch and they said I need to swap the flywheel, starter, engine adapter, and slave cylinder also if I plan on swapping to a g56

 

[DEMON44]

Well there you go. They'd have a pretty good idea seeing that's what they do.

I know for sure you'll be happier with the 6 speed. Not just a little bit. A lot happier.