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 Project CJ-7

 

Offroad Tire Info
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Tires for your Truck
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Offroad Tires
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All Terrain  Mud Terrain Tire Reviews & Information
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Super Swamper Bogger
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Mickey Thompson MTZ
Mickey Thompson MTX
Mickey Thompson Baja Claw
Mickey Thompson Baja Crusher
Competition Claw
Dunlop Mud Rover
Yokohama Geolandar
  
 

Jeep Project CJ-7

An ongoing Budgeted Rebuild/Build up of a Rock Crawling Machine.

Jeep Central
From Jeep History to Tech Specs and Projects.  This section is all about Jeeps.
Jeep Technical Info
Engines
Transmissions
Transfercases
Axles
Engine Swaps

Installing 23,000 Volt Offroad Lights

What are
HID Lights?

Onboard Air
Converting a York
AC Compressor
to Pump Air

Warn 9500i Winch Installation
 

HEI Ignition
Installation & Review


Jeep Dana 300 TeraLow - 4:1 Gearset for the Dana 300 Transfer Case

 

 

 
 

The NV4500 Manual Transmission

The NV4500 Transmission, Parts Diagram, Information, Installations and Reviews
  

 

Index Number Part Description
1 Speedo Drive Rotor
2 Mainshaft Overdrive Gear
3 Mainshaft Rear Bearing Cup
4 Mainshaft Reverse Washer
5 Reverse Mainshaft Gear
6 Reverse Mainshaft Sleeve
7 Needle Bearing
8 Reverse Gear Spacer
9 Retaining Ring
10 Reverse Clutch Gear
11 Mainshaft 1st & 2nd Bearing
12 Mainshaft 1st Speed Gear
13 Mainshaft
14 Clutch Gear
15 Mainshaft 1st & 2nd Snap Ring
16 Mainshaft Inner Synchro Ring
17 Mainshaft Center Synchro Ring
18 Mainshaft Outer Synchro Ring
19 Downshift Inhibitor Spring
22 Synchro Spring
23 Synchro Clutch Key
24 Synchro Block
25 2nd Speed Gear
26 3rd Gear Thrust Washer
27 3rd Gear Retaining Ring
28 Mainshaft 3rd Gear Bearing Spacer
29 3rd Speed Mainshaft Gear
30 Mainshaft 3rd Gear Bearing
31 Synchro Clutch Gear
32 Mainshaft Synchro Ring
34 Synchro Spring
35 Synchro Key
37 Maindrive Clutch Ring
38 Mainshaft Rear Thrust Bearing
39 Mainshaft Pilot Bearing
40 Maindrive Gear
41 5th Speed Synchro Sleeve
40 Maindrive Gear
41 Maindrive Bearing Cone
42 Countershaft Rear Bearing Cone
43 Countershaft Assembly
44 Countergear Key
45 3rd Counter Gear
46 Counter Drive Gear
47 Washer Selective
48 Countershaft Front Bearing Cone
49 Retaining Plate
50 Shim Selective Kit
52 Reverse Idler Gear Washer
53 Needle Bearing
54 Reverse Idler Gear
55 Spacer
56 Reverse Idler Gear Shift
57 Maindrive Retainer Assembly
58 Maindrive Oil Seal
59 Maindrive Bearing Cup
60 Countershaft Rear Bearing Cap
61 Countershaft Front Bearing Cup
62 PTO Cover
63 Case
64 Countershaft Rear Bearing Cup
65 Countershaft Rear Bearing Shim Kit
66 Countershaft Rear Thrust Washer
67 Needle Bearing
68 Countershaft 5th Bearing Spacer
69 Rear Countershaft Bearing Retaining Plate
70 Countershaft 5th Gear Clutch Hub
71 Countershaft 5th Clutch Sleeve
72 Countershaft 5th Synchro Ring
73 Countershaft 5th Clutch Ring
74 Snap Ring
75 5th Shifting Fork
76 5th Shifting Fork Shaft
77 Extension Housing
78 Vibration Dampener
79 Mainshaft Washer
80 Mainshaft Nut
81 Extension Housing Bearing
82 Snap Ring
83 Extension Housing Oil Seal
84 Propeller Shaft Yoke
85 Rear Output Spline Seal
87 Shift Lever Assembly
88 Shift Lever Cap
89 Seat Control Lever
90 Spring
91 Plug Expantion
92 Bolt
93 Dowel Pin
94 Bare Cover
95 Pin Interlock
96 Shift Fork Pin
97 3rd & 4th Shift Fork
98 Plunger Interlock
99 1st & 2nd Shift Rail
100 3rd & 4th Shift Rail
101 1st & 2nd Shift Fork
102 Spring Shift Finger Plunger
103 Plunger 1st & 2nd Bais Shift
104 Pin Spring
105 1st & 2nd Shift Lug
106 5th 5th Shift Lug
107 Reverse Shift Fork Pads
108 Reverse Shift Fork Pad Curved
109 3rd & 4th Shift Lug
110 Plunger Reverse Overdrive Fork
111 Reverse Inhibitor Bolt
112 Reverse Shift Inhibitor Assembly
113 Pin Reverse Inhibitor
114 Overdrive & Reverse Rail
115 Plunger Detent
116 Spring
117 Plug Shift Rail
118 Gasket Back Up Switch
119 Switch Back Up
120 Breather Assembly
121 Trunnion
122 Countershaft 5th Synchro Assembly
123 Mainshaft 1st & 2nd Synchro Assembly
124 Mainshaft 3rd & 4th Synchro

 


 


 
A cutaway view of the 2wd style NV4500 as found in GM applications. Image courtesy of GM Powertrain.

NV4500: General Information:

In 1992 Dodge and General Motors trucks started appearing in showrooms with one of the most versatile transmissions ever to be offered in a production truck: the New Venture Gear 4500. General Motors applications include it as an option in 3/4 and 1-ton full size trucks.  Dodge standard duty units come in trucks with the 5.2 and 5.9 liter engine, while Dodge HD versions are used with Cummins diesels and V10s.

This transmission is a fully synchronized (except reverse on GM models) five-speed gearbox with all of the strength and low-gear benefits (and then some) of the older granny four-speeds, with a 27-percent overdrive. The cast iron case is combined with massive gear sets in an almost compact 200lb package. This unit shifts with a smooth, short action and very distinct shift gates. We consider it the premium manual trans swap for 4x4 vehicles.

Gear Ratios:

Current production Dodge NV4500 and GM NV4500 share the same gear ratios. Early GM units (93-94) were built with a lower first gear ratio of 6.34 to 1.0. These low-geared GM boxes have since been discontinued and are generally much more difficult to obtain. We are able to provide new and remanufactured NV4500s with these early gearsets.

Beginning in 95, all GM units were built with the same gear ratios as the Dodge unit.

  GM 93-94 95/up GM; 93/up Dodge
First Gear 6.34 5.61
Second Gear 3.44 3.04
Third Gear 1.71 1.67
Fourth Gear 1.00 1.00
Fifth Gear 0.73 0.73
Reverse 6.34 5.61

Specifications

Dry weight: 195 lbs.
Oil capacity: 1 gallon
Rated GVW: 14,500 lbs.
Case material: cast iron
Synchronizers: Carbon fiber composite
Main/Counter shaft bearings: Timken tapered roller

Dimensions

NV4500 GM (6.34) GM (5.61) Dodge Dodge HD
Main case 12.375" 12.375" 12.375" 12.375"
4WD Adapter Housing 8.125 8.125 6.25 6.25
2WD Tailhousing 6" Tailhousing 6" Tailhousing 13" Tailhousing 13" Tailhousing
Yoke Fixed Yoke Fixed Yoke 30 spl Slip yoke 31 spl Slip yoke
Input shaft stickout 6.625 6.625 7.625 7.625
Input shaft spline 1.125" 10spl 1.125" 10spl 1.125" 10spl 1.250" 10spl
Pilot Dia .590" .590" .750" .750"

 

Bearing Retainer specification

 

Bellhousing T/O bearing
Index Dia. Snout Dia.
GM NV4500  1993-95 5.125" 1.373"
GM NV4500  1996 and up 5.60" none: Int Slave Cyl
Dodge NV4500 Standard Duty 5.60" 1.43"
Dodge NV4500 Heavy Duty 5.60" 1.75

Bellhousing Bolt Pattern:

  • GM 1993-1995  10.078 across the top, 10.394 across the bottom, 4.685 vertically
  • GM 1996 + up   10.078 across the top, 9.738 across the bottom, 6.043 vertically
  • Dodge (All)        10.078 across the top, 9.738 across the bottom, 6.043 vertically

Shifter Stub Specification

The NV4500 shifter will have a short stub sticking up from the top cover, There are 3 different methods by which a shifter extension handle attaches:

  • Dodge NV4500 1993-1999   A short, square stub sticks up
  • Dodge NV4500 1999-up        Threaded stub, 14mm x 1.5 pitch threads
  • GM NV4500 (All)                      Threaded stub, 12mm x 2.0 pitch threads 

Lubrication:
You MUST use the correct synthetic lubricant. The GM part no. for the correct oil is 12346190 (quart). The Dodge part number for the same oil is 4874459   Use of ANY other oil in the NV4500 will lead to failure and also voids any chance of a warranty claim.
 

NV4500 Conversions for Diesel, Gas, 2WD & 4WD
High Impact Transmission and Gear - Focused on building "Engineered Conversion Systems" for do-it-yourself installation. Free Consultation & Technical Support.

Jeep Transmissions Conversions: NV4500
Installing an NV4500 in your Jeep vehicle, the ultimate manual transmission.

Manual transmission parts, rebuild kits and overhaul kits for the NV4500 - A complete line of transmission parts, rebuild and overhaul kits to help you with manual transmission problems NV4500.

Installation Articles NV4500 Overdrive Transmission

Novak Conversions - New Venture 4500
The Novak Guide to the NV4500 Transmission

NV4500 Conversion in a Toyota Land Cruiser
Information and installation notes


Rebuilding an NV4500 Manual Transmission
A Four Wheeler Magazine article all about how they rebuilt an old NV4500 Manual Transmission.

NV4500 Transmissions, Adapters, NV4500 Conversion Kits - NV4500 Transmissions available in 2WD, 4WD, Gas or Diesel Applications from NV4500.com

Project Jeep Therapy: NV4500 Conversion
"One-ton dually, I think" he replied. My heart beat faster. "Only has a couple thousand miles on it"

NV4500 Specs from the 1994-2002 Dodge Ram

High-Impact NV4500 Conversion Packages

 
  

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