QU10192 Rebuilder NV4500 Countershaft 1997-2007 Dodge and GM

QU10192 Rebuilder (2nd Design) Spec NV4500 5.04 Reverse Ratio Countershaft This is a very high quality replacement Countershaft being made for the Chrysler authorized re-builder to original equipment specs. Will replace original New Venture components with no loss of strength or function. Made in Korea.

See also QU10707 Aftermarket NV4500 Countershaft Assembly 5.04 Reverse Ratio

QU10192 and QU10707 NV4500HD One Piece Countershaft for 1997-2007 Manual Transmissions fit all 1997-2005 Dodge and 1997-2007 GM NV4500 series 5 speed manual transmissions. Reverse ration is 5.04-1. Front drive gear has 38 teeth, and the 3rd gear has 30 teeth. Your matching gear on the input shaft must have 22 teeth. This shaft can be identified by the full length of the reverse gear drive teeth which extends all the way to the rear bearing stop. We carry two countershaft choices for your NV4500 5 speed manual.

Need More Info? Use the handy Links below to access over 40 years of Dan's product and vehicle specific Tech Notes to easily get the information you need for your vehicle's repair, maintenance, or upgrade project!

Dan the Gear Man® Tech Notes:
Specs
Facts
For Conversion Applications
Causes of Gear Tooth Failure
Special Tools
Matching Parts
Applications

Tech Note 1: Specs
QU10192 and QU10707 replace OE gear QU10045 and are approximately 15" Long. The length of the 1st and Reverse gear drive teeth is 6". The groove at the back of the countershaft for the 5th gear clutch is over 0.100" wide. Countershaft End-Play should be set at 0.002"-0.006". The Gear Tooth Count is listed in the chart below:

Tech Note 2: Facts
Early (1992-1996) and Late (1997-2007) NV4500 Countershafts are not interchangeable. When first introduced, the NV4500 Transmission had a dual-plane reverse where the power transfer path from the counter shaft to the mainshaft reverse gear is offset. The front half of the 2-3/4" long reverse idler gear engages the countershaft, while the rear half drives the mainshaft reverse gear. Since there are no teeth on the counter shaft below the mainshaft reverse gear, that gear can be larger diameter and have more teeth (39). The 1992-1996 transmissions have a 6.34:1 reverse for 1992-1994 GM and 5.61:1 reverse for all Dodge and 1996 GM.

Effective with the 1997 model year, New Venture NV4500's use a single-plane reverse where the power transfer path from the countershaft to the mainshaft is inline. The full working width of the narrow, 1-1/2" wide reverse idler gear is inline with both the countershaft gear teeth and mainshaft reverse gear teeth. Since the countershaft drive teeth are now located directly under the mainshaft reverse gear, the mainshaft reverse gear diameter had to be reduced to the point it now has only 35 teeth. Less teeth means less gear reduction. All 1997 model year and newer NV4500 transmissions have a 5.04:1 Reverse.

The difference in the transmission case reverse idler gear pocket and mounting boss for the single and dual plan reverse means the countershaft, mainshaft reverse gear, reverse idler gear, and reverse idler shaft are NOT interchangeable between early and late cases

Tech Note 3: Conversion Applications
For conversion applications, QU10192 and QU10707 are compatible with any 22 tooth NV4500 Input Gear installed in a 1997 or newer transmission case. However, differences in Input Bearing Retainer and transmission to bellhousing bolt pattern dimensions preclude using a 1997 or newer transmission to directly replace a 1992-1995 GM transmission. Matching 22 tooth Input Shafts for QU10192 and QU10707 are:

Tech Note 4: Causes of Gear Tooth Failure
Typically, Countershaft gear tooth failures occur from one of three causes: low or improper oil, clutch pilot bearing failures (which cause misalignment of the input shaft), and excessive horsepower/torque (over 275hp/600 lb.-ft. of torque). Broken 3rd gear teeth are almost always caused by exceeding the demonstrated 600 lb.-ft. input strength limit of the NV4500.

There are claims that cryogenically treating NV4500 gears will increase gear strength as much as 30%. Unfortunately, there does not seem to be any peer-reviewed documentary evidence to support those claims. Cryogenically treating gears is primarily a cold-hardening process that changes the molecular structure of steel to decrease wear while retaining or increasing hardness. If properly done, it is probable the cryogenic treatment process does slightly increase the impact and fatigue resistance of NV4500 gears, but not enough to significantly increase the ability of an NV4500 transmission to reliably handle more than 600 lb.-ft. of input torque especially considering the maximum factory torque rating of the NV4500HD transmission is only 460 lb.-ft.

Tech Note 5: Special Tools
Need Torque Specs or Rebuild procedures? Order my 116 page, full color illustrated NV4500 Rebuild Manual. You will need some special tools to correctly service your NV4500 Transmission. The chart below lists our current NV4500 Special Tools for popular models.

Tech Note 6: Matching Parts
QU10140 Sealing Cap, Main Case Countershaft Front Bearing Bore
QK1102 Lock Ring Kit
QK1110 Thrust Washer Locating Pin Set
QU10141 Countershaft 5th Gear Bearing
QU10142 Timken High Performance Countershaft Front Bearing
QU10143 Timken High Performance Countershaft Front Bearing Cup
QU10144 Timken High Performance Countershaft Rear Bearing
QU10145 Timken High Performance Countershaft Rear Bearing Cup
QA10008 Countershaft Shim Kit
QU10008B Basic Countershaft Shim Kit
QK1010 Complete Small Parts Kit
QU10221 Basic Small Parts Kit
QU10031 OEM New Venture 5th Gear Clutch
QU10202 5th Gear Clutch
QU10304 Countershaft 5th Gear Thrustwasher
QU10079 Reverse Idler Gear
QU90020 NV4500 Manual Transmission Oil
TM1003 NV4500 Shop Manual
VSG1003DVD NV4500 Overhaul Video
QT1802 Countershaft Front Bearing Cup Installer
QT2004 Countershaft Front Bearing Installer
QT2005 Counter Shaft Rear Bearing Installer
QT2006 Countershaft Support
For Gearing, see Tech Notes 1, 3, and 4

Applications:
Chevy and GMC:
C1500, K1500, C2500, K2500, C3500, C3500HD, K3500 with NV4500 5 Speed: 1997, 1998, 1999
C2500, K2500, C3500, K3500 Standard and HD Pickup based models with NV4500 5 Speed: 2000, 2001, 2002, 2003, 2004, 2005, 2006
C3500HD 15,000 Lb. GCVW Cab and Chassis with NV4500 5 Speed: 2000, 2001, 2002
C2500, K2500 Silverado Classic and Sierra Classic with NV4500 5 Speed: 2007

Dodge and Ram:
Ram 2500, Ram 3500 with V10 and NV4500HD 5 Speed: 1997, 1998, 1999, 2000, 2001, 2002, 2003
Ram 2500, Ram 3500 with Cummins Diesel and NV4500HD 5 Speed: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004
Ram 2500, Ram 3500 with gas V8 and NV4500LD 5 Speed: 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005