Dodge ram truck 3500 1996 Service Manual page 1439

B R — — — — ~ — NV4500 MANUAL TRANSMISSION 21 • 49
N V 4 5 0 0 MANUAL T R A N S M I S S I O N
INDEX
page
GENERAL INFORMATION
GEAR RATIOS 51
GENERAL INFORMATION 49
LUBRICANT LEVEL AND CAPACITY 51
SHIFT PATTERN 51
TRANSMISSION IDENTIFICATION . . . . . . . . . . . 51
DIAGNOSIS AND TESTING
CLUTCH PROBLEMS 52
COMMON PROBLEM CAUSES 51
HARD SHIFTING . . . . . . . . . . . . . . 51
LOW LUBRICANT LEVEL 52
NOISY OPERATION . . . . . . . . . . . . 52
SLIPS OUT OF GEAR . . . . . . . . . . . . . . . . 52
SER¥iCE PROCEDURES
SHIFT COVER COMPONENTS . . . . . . . . 52
G E N E R A L I N F O R M A T I O N
GENERAL INFORMATION
The NV4500 is a five-speed, constant mesh man­
ual transmission (Fig. 1). A l l gear ranges including
reverse are synchronized. Fifth gear is an overdrive
range with a ratio of 0.74:1. The transmission has a
cast iron gear case and aluminum shift cover.
Two versions of the NV4500 are used. A standard
duty version is used for 5.2L and 5.9L applications
and a heavy duty version for VIO/Cummins diesel
applications. Main differences are the larger diame­
ter input shaft, output shaft, and mainshaft fifth
gear in the heavy duty model. The different size
shafts and gear do not affect service. Overhaul pro­
cedures for the two versions are the same.
page
REMOVAL AND INSTALLATION
SHIFT COVER . .
59
SHIFT LEVER . 57
TRANSMISSION—2WD
54
TRANSMISSION—4WD . . . . . . . 55
DISASSEMBLY AND ASSEMBLY
EXTENSION/ADAPTER HOUSING 60
TRANSMISSION . . . . .
62
CLEANING AND INSPECTION
TRANSMISSION . . . . . 93
SPECIFICATIONS
TORQUE . 98
SPECIAL TOOLS
NV4500 MANUAL TRANSMISSION . . . . . . . . . . . 99
The NV4500 is a top loader style transmission. The
shift lever is located in the shift cover and operates
the shift forks and rails directly. The shift forks and
rails are all located within the aluminum cover
which is bolted to the top of the gear case.
A reverse gear inhibitor mechanism prevents
reverse gear engagement when shifting into forward
gear ranges. The inhibitor mechanism is located in
the shift cover.
Tapered roller bearings support the drive gear,
mainshaft and countershaft in the gear case. Pilot
roller bearings in the drive gear hub support the for­
ward end of the mainshaft. The mainshaft gears are
all supported on caged type roller bearings. Drive
gear thrust reaction is controlled by a needle type
thrust bearing. The bearing is located at the forward
end of the mainshaft.