NV4500 rebuild options

Heading down the highway the other day, cruising around 90 (not the usual) heard/felt a bang. Slowed to 60, felt another, then a few more on my way down the off ramp. Shifted to 4th, then while sliding to third it was grinding pretty good. Took it out of third then back in with no problems. Work was only 2 miles down the road so I limped it, city driving. Did the grinding thing a couple times going into 3rd or 2nd only.

Was banging mostly going over 20mph, felt like transfer case skipping teeth or a bad backfire but the odd shifting points me to the NV. No ideas on miles on it, bought it used and abused and put new bearings in it about 100k miles ago.

Blew my back out that day at work, go figure so I haven't been able to tear into it. So who makes good parts for these? I do work the truck hauling firewood/gravel/equipment etc and have a 351cw/ht60 on the shelf waiting to fall in....so I would like something that might hold up for another 100k anyhow.

On another note, money just isn't where I thought it should be so I am going to try and save the old clutch. It's a 13" valair ceramic that holds good. What are the limitations of the small input?

Not sure where you get hard parts. Probably used I would guess. Here is the rebuild kit I keep in my favorites on ebay.

Dodge NV4500 Transmission 4x4 Mainshaft 5th Gear Nut Rebuild Kit w/synchros | eBay

Where do you live? There was a place Missoula MT that had everything on the shelf. Can't remember the. And of the place though. It was about two years ago when I cracked 5th in have and damaged 4th, the counter gear and a shift fork lol. Carried a rebuild kit as well. I do have the guys number though, if you want/need it.


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Quad 4x4 is where I get all my nv4500 parts. Master rebuild kits down to individual parts.

I live in Mass. Not sure when I'll be able to get started, screwed my back up pretty good it seems.

Was trying to get an idea of what was good vs what is overpriced. I've seen full spline shaft rebuild kits for $350, just not sure of the quality. Similar kit at Quad is right around a grand....then you can get a whole rebuilt unit for 1100 elsewhere.

The Chinese syncros are brass I believe. I know you should stay away from them. I'm not sure if the bearings would cause you a problem or not. When I rebuilt mine, I called a company selling the kits on ebay to verify what parts were in the kit.

I like portland transmission in providence RI if you want a local place.

TB Trans out of washington is here I got all my rebuild parts from. Genuine NV sycnhros (Fiber lined). Guy is knowledgeable and best prices I have found.

I bought my parts from bearingkit.com have had no issues with them.

Well it appears to be the transfer case. Went to see if it had enough life to plow me out of this snowstorm, and it worked fine in low range. Took it through all the gears and it felt fine. Soon as I put it in high range, it started grinding trying to shift into gear at a stop. Clutch dragging a bit I guess?

Guessing the input or main shaft has issues...

You probably have a broken snap ring on the output shaft just pull the rear housing and you should see it I've seen it a few times, many times all thats needed is a new snap ring.

Finally pulled the transfer case today, snap rings were fine. Found a disintegrated thrust washer in-between the input and planetary. Surprisingly everything else looks pretty good, no chewed up teeth or anything. Easy fix.

This is on a 241DLD with almost 300k miles FWIW.