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NV4500 lockup! Can Any gurus tell me what happened here?

$400? Where are you shopping at, I'll take 3 at that price. Not happinging around here .If there's any NV4500 in a yard, it's $750 min, with many unknowns.
No, you cannot buy an NV4500 outright for $1500. It's more like $2000 when you include a core, my "core" was shot. I got all my parts for $1100, included the stupid special $25/qt oil. It's close, your not off base, but I kinda wanted to do it myself because I've never done one. Most main internals were gone, most places who deal with these start at $1250 plus a $350-700 core, plus shipping, plus oil. The local shops I called when I described what the damage wanted $2100-$2800 to bench build it. But parts availability and general goofyness of this trans is silly.
I was thinking of putting one in my K5, not anymore. Oh, you towed something bigger than a jet ski with it in 5th, i'm sorry, it wasn't designed for that. Oh, you had a leak and used 1qt of 75w oil because there was no finding the goofa$$ stupid special oil required and didn't feel like spending 3 nights extra camping in a parking lot while you wait to order it, I'm sorry, your syncros are now junk, oh when the syncros went, the kevlar they are made of, the pieces of which floating around in there just wrecked half of the hard parts in your trans.
You can find parts for the SM465 because it doesn't require special oil to go with the special metals (like those found inside the NV4500). China parts, which most of the SM465 parts you find today are as well, still do well bathed in regular 80w90oil in the Sm465. You don't find the super tight tolerances in the SM465 like you do in this thing. Put a china input shaft on your NV4500 is like rolling the dice. PLus there are 20times the SM465's in existance than NV4500's. In the 90's, when these things were primarily sold, manuals were heavily discouraged, and now in the 2000's, they are becoming extinct. GM already did away with them in trucks, Ford announced the end of manuals in F150's. Don't be surprised to see them go in the superduty's as well. Alot of shops around here don't even touch them because they are so rare these days.
My image of the NV4500 as the holy grail of manual transmissions is gone. THe OEM's tried too hard to make it shift like car and in doing that, have too many goofy aspects not found on transmissions from our era. It's a damn truck, it doesn't need to shift and sound like a corvette. More evidence of that stupidity is found in their experimentation with dual-mass flywheels. They had them on the GM400 series, couldn't amke it work, in 96, switched back to solid flywheel. When they introduced the GMT800's with a diesel in the early 2000's, they tried again the dual-mass flywheel. After warranting a good percentage of them, they started putting solid flywheels back on them. Why, do you ask they tried again with the dual mass BS after already failing at it, because they wanted it to act a little more like car, less vibes, a little easier and smoother shift. THey don't get it, it's truck, not a car. I'm so sick of these stupid soccer moms in their part time engineering job, oh, well, these need to shift smoother, tell the supplier to make some changes. It's a friken truck people, it's allowed to act like one! Well, the soccer moms working at GM got their way with the GMT900's, no more manuals, which is really a sad state of affairs.
The dodge folks have so many troubles with this trans because the cummins beats the pee out of it, cracked cases, can't keep a 5th gear on to save their lives, some guys drill the 5th gear clean thru the shaft and gear and put a roll pin thru it it's fallen off so many times, they just get sick of it. As soon as they touch thier injection pump to put out just a but more, troubles arise in the NV4500.
The SM465 in my K5 stays put. This POS is going back in my K2500 where it came from, and after this winter, if that trans lasts that long because the parts I have, some are from unknown origin, if it last that long, I will probably sell that truck.
This trans failed because of a failed pilot bearing, which caused the front input bearing to fail, with zero warning, not hard shifting as many people have tried to tell me would be a symtom of a bad pilot, no whining prior to the failure. All of sudden, a high pitched whine, and kaboom, and I'm sitting on the side of the road where this trans is not supposed to leave people, and lucky to be there only thru shear luck of available side of road and nothing in the way to get there within the few hundred feet of coast down I had, I could have been left in the middle of the road (with a trailer of goods mind you). I've tore out countless SM465's with near non-existant pilots. No sign of input bearing wear on those trans. When I rebuilt the engine in my C10, the 3sp saginaw tranny in there had a wrecked pilot, the input shaft where it mated the pilot was all tore up, the input bearing was perfect. I put a new shaft on, but that input bearing remains (50k mi since re-installation and still running), the tranny shop I checked with said, why bother, he'd never even heard of one of those 3sp saginaw's failing.
Anyhow, my rant is done. I will finish this job, mabey I will become less bitter about it once it's in and working right. I like doing things myself, but not when parts are expensive, very expensive, hard to find, and take days and weeks to get in.
 
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You could've got an SM465+bell out of the of the final years that they used them and swapped it in - the shifter is even in the same location as a 4500. Throw a US gear OD behind it and never worry about it again :wink1:
 
In the 90's, when these things were primarily sold, manuals were heavily discouraged, and now in the 2000's, they are becoming extinct. GM already did away with them in trucks, Ford annouced the end of manuals in F150's. Don't be surprised to see them go in the superduty's as well.

You can chalk that up to customer demand. More and more people want autos, and once it gets to the point where it is no longer profitable to design and build manuals for the few customers who want them, they go bye-bye.

I think mileage and emissions requirements also factor in - the PCM can't control how the driver shifts the manual, whereas with an auto the engine can be kept in the RPM range that is best for it, whether the driver likes it or not.

My guess is by 2010 no fullsize truck will be available with a stick :(
 
$400? Where are you shopping at, I'll take 3 at that price. Not happinging around here .If there's any NV4500 in a yard, it's $750 min, with many unknowns.
No, you cannot buy an NV4500 outright for $1500. It's more like $2000 when you include a core, my "core" was shot. I got all my parts for $1100, included the stupid special $25/qt oil. It's close, your not off base, but I kinda wanted to do it myself because I've never done one. Most main internals were gone, most places who deal with these start at $1250 plus a $350-700 core, plus shipping, plus oil. The local shops I called when I described what the damage wanted $2100-$2800 to bench build it. But parts availability and general goofyness of this trans is silly.

If you ask a ridiculously high price, you only need to sell a couple to make a big profit. Capitalism at work.

Chock one up to the educated consumer and sites like CK5 for educating people on the value of various parts ;)



I was thinking of putting one in my K5, not anymore. Oh, you towed something bigger than a jet ski with it in 5th, i'm sorry, it wasn't designed for that. Oh, you had a leak and used 1qt of 75w oil because there was no finding the goofa$$ stupid special oil required, I'm sorry, your syncros are now junk.
You can find parts for the SM465 because it doesn't require special oil to go with the special metals (like those found inside the NV4500). China parts do well bathed in regular 80w90oil in the Sm465. Put a china input shaft on your NV4500 is like rolling the dice. PLus there are 20times the SM465's in existance than NV4500's. In the 90's, when these things were primarily sold, manuals were heavily discouraged, and now in the 2000's, they are becoming extinct. GM already did away with them in trucks, Ford annouced the end of manuals in F150's. Don't be surprised to see them go in the superduty's as well. Alot of shops around here don't even touch them because they are so rare these days.
My image of the NV4500 as the holy grail of manual transmissions is gone. THe OEM's tried too hard to make it shift like car and in doing that, have too many goofy aspects not found on transmissions from our era. It's a damn truck, it doesn't need to shift and sound like a corvette. More evidence of that stupidity is found in their experimentation with dual-mass flywheels. They had them on the GM400 series, couldn't amke it work, in 96, switched back to soild flywhell. When they introduced the GMT800's, they also tried again the dual-mass flywhell. After warranting a good percentage of them, they started putting solid flywheels back on them. Why, do you ask they tried again with the dual mass BS, because they wanted it to act a little more like car, less vibes, a little easier and smoother shift. THey don't get it, it's truck, not a car. I'm so sick of these stupid soccer moms in their part time engineering job, oh, well, these need to shift smoother, tell the supplier to make some changes. It's a friken truck people, it's allowed to act like one!
The dodge folks have so many troubles with this trans because the cummins beats the pee out of it, cracked cases, can't keep a 5th gear on to save their lives, some guys drill the 5th gear clean thru the shaft and gear and put a roll pin thru it it's fallen off so many times, they just get sick of it.

Many comments on this stuff:

First, manuals are becoming a thing of the past because people don't want to shift their own gears anymore (you already mentioned this)

Second, I love the way the NV4500 shifts. It is WAY better to drive than the SM465.

Third, the fifth gear nut coming loose has already been addressed in this thread. Its an easy fix and doesn't cause any catastrophic failure, in the unlikely event it fails.



The SM465 in my K5 stays put. This POS is going back in my K2500 where it came from, and after this winter, if that trans lasts that long because the parts I have, some are from unknown origin, if it last that long, I will probably sell that truck.
This trans failed because of a failed pilot bearing, which cause the front input bearing to fail. With zero warning, not hard shifting as many people have tried to tell me would be a symtom of a bad pilot, no whining. All of sudden, a high pitched whine, and kaboom. I've tore out countless SM465's with near non-existant pilots. No sign of input bearing wear on those trans. When I rebuilt the engine in my C10, the 3sp saginaw tranny in there had a wrecked pilot, the input shaft was all tore up, input bearing was perfect. I put a new shaft on, but that input bearing remains (50k mi and still running), but the tranny shop I checked with said, why bother, he'd never even heard of one of those 3sp saginaw's failing.
Anyhow, my rant is done. I will finish this job, mabey I will become less bitter about it once it's in and working right. I like doing things myself, but not when parts are expensive, very expensive, hard to find, and take days and weeks to get in.

Wow. First, paragraphs are your friend ;)


As I mentioned above, the 4500 is great for a tow rig transmission (though a little closer ratio, say 6 speed trans, would be better). The 465 is as stout as it gets, you will be hard pressed to find any weak point on it.


My buggy runs the original 200K+ SM465 and the tow rig runs an NV 4500 with a scant 110K. Both have operated with zero failure, great reliability IMO.


'99 Dodge 2500 Cummins gets ~22 mpg empty, 13 mpg towing the trailer and buggy (14K lbs. or so).
 
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You can chalk that up to customer demand. More and more people want autos, and once it gets to the point where it is no longer profitable to design and build manuals for the few customers who want them, they go bye-bye.

I think mileage and emissions requirements also factor in - the PCM can't control how the driver shifts the manual, whereas with an auto the engine can be kept in the RPM range that is best for it, whether the driver likes it or not.

My guess is by 2010 no fullsize truck will be available with a stick :(

They can make PCM's that work with manuals that do just as well, and most of the time better in mileage, not quite sure on emissions. I've seen this data as I work in the auto industry. I've been in meetings where the stupid soccer mom tried to bash the manual and any reasoning for it, but she failed to present any real data pertaining to the particulars she was trying to talk about. They already do it for many vehicles sold here and abroad, but the manual version is not sold here. No, there's not as much control, but they can get close. The real problem, is the mentality in this country. No other country, aside from mabey canada, sells as many autos as we do. Europe still sells more manuals than autos. I blame that on the dumb dealers here, but that's a robust debate for anyone as to why this country is fixated on auto's.

38377k5 said:
Second, I love the way the NV4500 shifts. It is WAY better to drive than the SM465.
There is no question it shifts better. But at what cost. And I'm not talking just dollars here. I'm talkin' longevity and reliability and ease of service. The special alloy required to bond to the special kevlar syncro material. The special $25/qt oil to be compatible with the kevlar syncros, and to keep the temperatures down in 5th, the tight tolerances required for less noise and smoother shifts. Tighter tolerances means tighter tolerances, no mistakes, the second one batch of input shafts comes in .0001" off, your doomed, mabey not right away, but it's inevitable. All that add's up to less suppliers making the parts, which means, less availability and increased price for parts.

I'm just a little peeved right now. The cost of this is stupid. I rebuilt my 4.3l V6 engine in my C10 for less. The price I mention earlier doesn't include, a new clutch ($300), new GM hydraulic throwout bearing ($100), and vast amounts of my time.
Since I am a little pissed about it right now, perhaps I should wait to comment about it, but this needs to come out. This trans isn't as great as I think it's made out to be. Granted, my K2500 has 225k miles or so on it, mabey it was time, but I still say no, not that trans., not with the reputation it has and the life it has led (very mild occasional towing), and not most certainly not in the manner in which it went (no warning, stranded, that's a trait of an auto!). This shouldn't have happened and is the root of my animosity.
I'm sure I'll feel better about it in a few weeks.
Yeah, I know the 5th gear thing doesn't so much apply to the GM folks, but I mention it only to show how on the edge it was for it's application and the dodge folks know the limits.

I completely understand your point of view, you havn't had any trouble with your trans, I felt the same about, oh, a month and half ago. Don't get me wrong, I enjoy your feedback and comments and a good discussion. Mabey my expectations were off. I got over 350k from the SM465 before I put new bearings and a new shift fork in it. This NV4500, which I've owned since '98, is built up to be the same or better than the Sm465, yet my particular NV4500 led a much easier life than my SM465, and failed 35% faster. I shouldn't even say failed. The SM didn't fail, I was re-building the entire truck, and when removed I decided to go thru it with some new stuff, no hard parts.

Anyhow, like I said, perhaps I will feel differently once it's running again. I have already learned alot and that, is invaluable and worth the cost to me, although perhaps a little tough to swallow.
 
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Step away from the tranny and have a shot of something good...

They do make all brass synchro's for the NV4500, meaning you could go with 90W. I briefly considered it.

Every mechanical creation I've owned has had it's short comings, including the SM 465. Even the venerable sbc has it's 'weak spots'.

I looked at it this way, I wanted OD, manual, smooth shifting all in one package. I don't have 1400 lbs of tq, and I would rarely tow over 3000 lbs. It was still cheaper than a well built 700R-4, and still stronger.

Wait for the sticker shock to wear off a bit and you may mellow your opinion. I had the luxury of buying the parts i needed over 6 months or so, which made it easier to swallow. I'm still glad i did it, and although it has some known issues I still feel the NV4500 is a good light duty 5 speed. Like anything mechanical, they usually do well if kept within their design parameters.

I will be swapping from a pilot bearing to a pilot bushing though.

Rene
 
Thankfully, I am wise enough to know when to step away, and that happened about 3 hours ago (shortly after midnight EDT). Since then, I have had many Molson Canadian. :)
Perhaps the breaking straw and the cause of my rant was one of the, go figure, input bearing retainer bolts, broke. I was using a torque wrench, set at 20ft-lbs at specified, and before the wrench indicated the proper reading, the bolt broke. That put me in to 5 hours of, remove mainshaft, remove counter shaft, drill bolt out, tap, clean/degrease, and re-assemble to the point as I at before. How does a 20ft-lb bolt break? Once re-assembled to that point, I said, I need to be one step furthur, at which point the rear mainshaft bearing cup fell out of it's bathed $25/qt oil bath on the side and into a pile of metal shavings from the drilling. Then I stepped away. Yes, it has tainted me. It is a good trans, there is no doubt. My only hope, as sad as it may be at this time, is that it does't blow up within the first 20 miles I put on it!
 
LOL, I had my share of fun too. I dropped my input bearing when I was about to press it on the input shaft. It seemed fine, I cleaned it up had a good look at it, spun it a few times and then pressed it on. As soon as it was pressed on it felt 'rough'. I had a better look and eventually found one of the rollers had a nick...so I had to cut the bearing off, order another one and redo the whole process.

I had mine apart and together 4 or 5 times due to putting something together out of the correct sequence...:doah:

Rene
 
There is no question it shifts better. But at what cost. And I'm not talking just dollars here. I'm talkin' longevity and reliability and ease of service. The special alloy required to bond to the special kevlar syncro material. The special $25/qt oil to be compatible with the kevlar syncros, and to keep the temperatures down in 5th, the tight tolerances required for less noise and smoother shifts.

Out of curiosity, anyone know acceptable temps for a manual transmission? I kinda scoffed when my brother put a temp gauge in the '4500 but I've seen it as high as 220 pulling hard up I70 (~7K truck and 7K load). I imagine that's acceptable, especially given the synthetic fluid but its warmer than I would have guessed a manual trans would get.


I completely understand your point of view, you havn't had any trouble with your trans, I felt the same about, oh, a month and half ago. Don't get me wrong, I enjoy your feedback and comments and a good discussion. Mabey my expectations were off. I got over 350k from the SM465 before I put new bearings and a new shift fork in it.

Fingers crossed, I addressed the 5th gear problem with the last fluid change. Hopefully it lives a good, long life. After reading Rene's posts I'm probably going to add some extra fluid just to be safe.
 
I am not sure what the accetible range is, I do know the engineers at Dodge and GM had issues with the temps in the NV4500, and it is one of the issues the special oil addresses. The special oil maintains it's viscosity better at high tempsand extended time, other more mainstream oils started to break down, which further increases temps, and the downward spiral is in motion.
Now, when GM and Dodge do tests, it's extreme conditions. Desert 110degrees, in the heavist vehicle towing max load for a long time, then they take readings. But being that they have mentioned the temps, I imagine the NV4500 runs a bit on the higher side than most.
 
Well, she's completed.
All I need to do is mate it back to it's NP241, but I think I need to install a new input bearing on that as it seems loose, I think mabey when the mainshaft of the tranny started wobbling around it may have womped out that bearing.
But, mate it back to the NP241 and get it back into the truck.
Oh, adding to my costs, my flywheel wasn't saveable, the machinist said he would have to grind off too much to make it right. It had been ground 2 times already. So there's another $300. At least I didn't have a dual mass flywheel, those are $1000+ :eek1:

From this:
IMG_9531.JPG

to this:
IMG_9587.JPG

IMG_9589.JPG


I used the mopar packaged Syntorq as I have friends who work at chrysler (I used to work there), Chrylser dealers allow the employee parts discount at the counter (unlike GM employees), $18/qt. Still expensive, but beats $24qt at the GM dealer.
Hopefully she works ok! I don't think I'll have a chance to get it back in until a week from monday. We're leaving for a little labor day weekend at a friends, and I'll be out of town all next week for work.

Oh, and here's all my bad parts:
IMG_9590.JPG
 
Well, I applied myself late this afternoon, and put that thing back in the truck. Man do I hate wrestling 100's of pounds of limb smashing cast iron around underneath vehicles.

I just finished and took her for a spin. Seems to shift smooth, no vibes or noise, I think I did good! :woot: I run it for about 10 miles, and it seemd to do fine. Seems much tighter and less noise that before, but perhaps that just my imagination.

I suspect, like an engine, if there's anything put together wrong or meshing incorrectly, it will show up in the first 1000-2000miles for so. I'm glad it's done, my 4x4 is back and I am happy for now, I just hope it lasts.

I still wonder about the wiseness of all this. I spent way too much time on it, and money. But if I didn't do it myself, it would have cost probably about $1000 more+, and that would have put it in the part-out range and me buying a new truck. So I guess in a sense, it save me from spending thousands of dollars! :rotfl:

Anyhow, heres the breakdown with hours and cost (click on it):
NV4500Service.jpg

Thanks for all your input Rene and others. I'm sure I'll be happy with it once I know it's not going to blow up!

Now I can concentrate on rigging up a drive mechanism for that free lathe I was towing home when it blew up!

NV4500Service.jpg
 
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It is a good feeling when you take it out and it all works like it should. Glad to hear it did all work out, even though it's not cheap to do when the failure is as bad as yours (or mine)

Rene
 
Yeah, tell me about it. Standed me to boot. First time ever. This is not supposed to happen with this transmission, this is the exact thing I was aiming to avoid when I bought this truck back in '98 with 18k miles. Me to various salesmen at the time: "I don't want an automatic, I plan to keep this vehicle a long time, and I want longevity"
This truck doesn't get abused either, it's a road truck basically. Mild towing every now and again, I rigged a small plow off my front hitch, so I can plow my driveway, but it's not near what a real plow is. It's actually an ATV plow I extended slighty and welded up some mechaniusm to mount into my 2" receiver in the front.
I'm dying to find out what happened to it.

to bad this didnt happen 2 months ago i had an nv4500 in the for sale forum out of a 2000 chevy with low miles for only $500. :( could have help you out.
 

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