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27-0056 : Replacing Dodge Getrag 5 Speed with the NV4500 Dodge 2WD Kit (#27-0056)

Retail Price: $579.65


KIT CONSISTS OF:

No. Qty Part No. Description

1. 1 Kit 712585 DODGE NV4500 / GETRAG REP. 4WD

2. 1 Kit 716050D1 NV4500 SHIFTER HANDLE ASSY.

3. 1 Kit 716087 YOKE-1410 DODGE HD NV4500 2WD OUTPUT

INSTALLATION NOTES:

Between the years of 1989 to 1993, Dodge used a German made Getrag 5 speed transmission coupled to the Cummins diesel engine. These transmissions were used in both 2WD and 4WD vehicles. The availability of re-manufactured transmissions and replacement parts have been extremely difficult to locate. We have developed a bellhousing that will permit the use of the newer Heavy-Duty NV4500 transmission.

Many customers are aware that the NV4500 is currently coupled to the Cummins diesel. The logical reasoning might be to simply use a stock NV bellhousing from Chrysler. Although this may be true, as was our initial thought, these original Chrysler components for the NV4500 transmission proved to be extremely expensive. Not only would you need a new bellhousing, but you will also require new clutch components, a slave cylinder, and considerable labor.

The bellhousing we manufacture bolts to the Cummins 5.9 diesel and utilizes the stock slave cylinder, clutch arm, and release bearing. This bellhousing comes with a new pilot bushing for both the 2WD and 4WD applications.

TRANSMISSION MODIFICATIONS for 2WD and 4WD VEHICLES: Prior to assembly, modification will be required to the front portion of the NV4500 transmission. The bearing retainer must be removed from the front of the 5 speed and shortened to a length that is 4.297" long. This can be done by using a cut off wheel or engine lathe. By shortening the bearing retainer, this will prevent any interference with the hub on the clutch disc. The bellhousing should be test fitted up to the back of the Cummins block to check flywheel and clutch assembly clearance on the inside of the our bellhousing.

Floorboard modifications for the shifter lever will be required. Since there is a 4-1/2" difference in length between the Getrag and the NV4500, the hole in your floorboard will need to be located back roughly 4-1/2" for the handle location.


 New Venture 4500 (NV4500) Transmissions  

The New Venture Gear Corporation was developed when GM’s Muncie Transmission Division and Chrysler’s New Process Corporation joined forces to manufacture a full product line of manual transmissions. The NV4500 transmission was the highlight of this new venture. Featuring a granny low first gear coupled with a fifth gear overdrive, the stout NV4500 is truly the best of both worlds. 

First introduced in 1992, the NV4500 is a constant mesh helical geared, heavy duty 5 speed transmission. All forward gears are fully synchronized. The initial Dodge version offered a synchronized reverse. The transmission case is cast iron with an aluminum top cover. The case measures 12.375 inches and features dual PTO ports. The shifter handle typically allows for better accessibility over older granny 4 speeds as it is located further rearward at 9-1/2" from the face of the transmission.  

The 1992 & 1994 GM versions have a lower first gear of 6.34 and can be identified by a smaller front bolt pattern with a top to bottom measurement of 4.685". After 1995, the first gear and front bolt pattern reverted to the Dodge 5.61 first gear and the taller top to bottom 6.043" bolt hole configuration. The synchronized reverse was also added and the front bearing retainer was enlarged from 5.125" to 5.6" diameter. As a general rule, a GM NV4500 4WD transmission will always have a 32 spline rear output shaft with an 8-1/8" rear tailhousing. The input shaft is 6-5/8" 1-1/8" 10 spline with a .590" pilot tip. We have also seen a rare 1995 GM NV4500 which can be classified as a hybrid. The transmission has the lower 6.34 with the newer bolt pattern. 

Dodge 4wd NV4500 transmissions have always maintained the same gear ratios and bolt patterns throughout production; however, variations occur between diesel (and V10) versus gas models. Diesel NV4500 4WD transmissions always have a 29 spine rear output shaft with a 6-1/4"" rear tailhousing. The input shaft is 7-1/2" 1-1/4" 10 spline with a .75" pilot tip. The front bearing retainer index is 5.6" with a snout diameter of 1.75". 

Dodge Gas 4wd NV4500s initially were introduced with a 23 spline rear output shaft and a 6-1/4 tailhousing. The input shaft is 7-1/2", 1-1/8" 10 spline with a .75" pilot tip (we have seen very rare 1" 19 spline inputs in 1993 trucks). The front retainer is 5.6" with a 1.43" snout. In 2001, Dodge discontinued the 23 spline output shaft on the gas version NV4500, and all Dodge transmissions standardized to 29 spline.  

For most conversion applications, we like the Dodge gas version transmission with a GM input shaft. This allows the shortest transmission length for most applications. The GM input shaft from a 6.34:1 early transmission will not fit the Dodge transmissions. 

TRANSMISSION LUBRICATION: The NV4500 transmission uses approximately one gallon of synthetic oil. This oil is available at your local Dodge authorized dealer under Part No. 4874459 (quart), or your local GM authorized dealer under Part No. 12346190 (quart). Unlike regular petroleum oil that breaks down when it gets too hot, this synthetic oil is made up of different properties that do not break down. The transmissions are also equipped with synchronizer rings that are made of a fibrous material. The wrong fluid will cause the unit to develop “sticky” shifting. If the wrong fluid is used, more than likely you will have to have your transmission rebuilt.

 DO NOT SUBSTITUTE any other lubricant as internal damage will occur.  NOTE: Castrol Syntech is NOT the same as Castrol Syntorq. Castrol Oil Synthetic

 TORQUE SPECIFICATIONS: Top Shift Cover Bolt 200 Inch pounds. Adapter Housing 40 Foot pounds. Front Drive Gear Retainer 265 Inch pounds. Main Shaft Nut 4WD 275 Foot pounds.  P.T.O. Cover Bolts 30 Foot pounds.  Reverse Inhibitor Bracket 95 Inch pounds. Counter Shaft Brg. Ret. Plate 200 Inch pounds. Main Shaft Brg. Ret. Plate 200 Inch pounds.

 GASKETING SPECIFICATIONS: In order to install the new adapter housing, top cover, and bearing retainer, we recommend using Loctite 518 Gasket Eliminator. This sealant seems to work best. 

SPEEDOMETER: Most 4WD installations provide a speedometer drive gear on the back side of the transfer case. On 2WD transmission swaps, Dodge transmissions are the most desirable due to the mechanical speedometer drive. The later versions (1998 & newer transmissions) do not have any type of speedometer provisions. The GM 2WD NV4500 transmissions use an electronic speed sensor. These transmissions will not allow you to retain a cable speedometer drive.

BACKUP SWITCH:  All NV4500s are equipped with an electronic reverse backup switch. If your vehicle is equipped with some type of backup indicator light, it can be adapted very easily to the new NV4500 switch. The parts required to couple to this switch are PN300378 (1), PN300378 (2 req.), and PN300378-1 (2 req.). 

NV4500 rebuild kit:  If you find your own NV4500, but need to freshen it up with some new bearings seals and synchronizers, we offer PN715691. This kit supplies you with replacement parts for the normal wear items of the NV4500. 

Forward Speeds .... 5   

Dates Produced .... 1992 - 2005  

Manufacturer .... New Venture Gear  

Case Length .... 12.375  

Stock Adapter Length .... 6.25 Dodge & 8.125 GM 

Bellhousing Length ... 6.50 GM   

Over All Length .... Varies due to Adapters   

Case Material ... Cast Iron  

Input Shaft Spline .... 1-1/8 10 spline  & 1-1/4 10 spline Diesel 

Input Shaft Stickout Length .... 6.625 GM & 7.50 Dodge   

Pilot Diameter .... .590 GM or .750 Dodge   

Length .... 1.00    

Output Shaft Spline .... 4wd Model 23, 29 or 32     

1st Gear Ratio .... 5.61 or (6.34 GM 92-94) 

2nd Gear Ratio .... 3.04 or (3.44 GM 92-94)

3rd Gear Ratio .... 1.67 or ( 1.71 GM92-94) 

4th Gear Ratio .... 1.00  

5th Gear Ratio .... 0.73

Reverse Gear Ratio .... 5.04  or (6.24 GM 92-94)     

Transmission Weight .... 195Lbs 

Max Engine Torque .... 460    

Fluid Type .... Castrol Syntorq / Amsoil MTF   

Power Take Off Capable .... yes   

Gross Vehicle Weight Rated .... 15,000   

Input to Cluster Center Distance .... 4.291

INFORMATION ON TRANSMISSION IDENTIFICATION

 

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