Hey guys, no problem here, just a report as helpful info. My original NV4500 was scratching in 3rd unless I shifted super slow and easy. It didn't do this when I bought it at 95K miles, but once it started (about 5K ago) it has gotten worse and worse. I am currently at the 119K mark.

I am working out of town, and didn't want excessive down time for a tranny shop to tear it down, find out what needs replacing, order the parts, and rebuild. So, I got to shopping rebuilt trannies. Most places I found wanted at least $1095 plus shipping and core charge for a rebuilt tranny. However, I found a place on ebay that was selling rebuilds that were supposedly overstocks from Chrysler. He said that Chrysler contracts out someone to rebuild trannies. These were supposed to be overstocks and they sell for $800, buy it now, and shipping was $75. No core charge either, and that is what was really attractive to me. I can keep my original to rebuild in my own time, and have a spare to go in at a moment's notice.

I also felt it was a good time to go with a good clutch, so I called Dan at Quad 4x4 and ordered the Con OFE. He recommended the flywheel be bored for the heavy duty pilot bearing, which I did. I also ordered the filter kit, cast iron tail shaft housing, castrol syntorq ($50/gal), plus some other odds & ends.

Rebuilt tranny inspection: I got the local mechanic, DeWayne, who has extensive knowledge of the NV4500's to remove the top cover for inspection of my rebuilt tranny. He also changed out the aluminum tail shaft housing with the cast iron piece. Upon inspection, he said all the synchros were new, and the rebuild looked like they did a good job. I could see some fibrous material on one of the synchros, so I am not sure if they are geniune New Venture synchros or aftermarket. The rebuilder also used the original design 5th gear nut that you stake into the keyway to prevent back-off. I had ordered the clamp-style latest design from Quad 4x4, but DeWayne said it would only be marginally better. He said I would probably never have a problem with it as well. I asked about welding, and he said he had done it a few times with a perfect history of holding. I may get flamed, but I told him to go ahead and weld it. He welded a short distance on the keyway side, and another short distance on the opposite side of the shaft. Hope it holds and doesn't cause problems. Here's a link to My Photos. Just look under NV4500:

http://pg.photos.yahoo.com/ph/walexa2002/my_photos

Installation: The installation went fine. The stock clutch was worn badly and needed replacing. The stock flywheel was in good shape as well as the pressure plate, but showed some clutch slippage. The needle bearing in the stock flywheel was in good condition. He did not drain the oil in my original NV4500, but had the shifter off the very top when I got there to pick up my truck. The oil in there was super black. I will know more when I get a chance to tear it down.

First test drive: This rebuilt tranny is harder to get into gear, but shifts fine. No grinding whatsoever. I am guessing that it just needs a little time to break-in? What has amazed me more than anything is the light clutch pedal effort. I am not sure exactly why, but pedal effort is probably half of what it was with the stock clutch. I am very impressed with the clutch and its feel. I have already bought some power products, just haven't had time to install them yet. Hope this helps someone out.

Waylan

 

When you had the heavy duty pilot bearing put in, do they just press it in or what?
thanks

 

I ordered the flywheel with the bearing already installed. I am guessing it is a press-fit, as it seemed secure in there. You can call Dan at quad4x4.com if you want to know for sure.

Waylan