QU10199 Replacement 1-1/4" x 10 Spline Dodge NV4500HD Input Shaft

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Dan the Gear Man® Tech Notes:
Specifications
Common Input Shaft Failures
NV4500HD
Input Shaft
Matching Parts
Matching Countershafts
Matching Popular Mainshafts
Matching Synchronizer Parts
Matching Bearings and Bearing Kits
NV4500 Tools
Applications

Tech Note 1: Specifications
QU10199 is a replacement, 22 tooth input shaft for Dodge NV4500HD transmissions. The matching Countershaft Gear must have 38 teeth. The shaft size is 1-1/4" x 10 spline. The tip for the pilot bearing is 3/4". Overall length is about 10". Approximate stick-out length from front face of transmission case to tip is 7-11/16". Combined Input Shaft and Mainshaft End-Play should be set at 0.002"-0.006".

Tech Note 2: Common Input Shaft Failures
The majority of NV4500 Input shaft failures are caused by one or more of the following:
#1. Failed clutch pilot bearing or bushing which chews up the input tip and can cause gear tooth breakage from misalignment between the engine and transmission.
#2. Running the transmission low on oil or with the wrong oil.
#3. Excessive horsepower which can cause either tooth breakage or the shaft to twist off.
#4. Bellhousing Index Hole off center and/or Bellhousing to block alignment pin(s) missing. A Cummins diesel bellhousing to transmission index hole that is more than 0.015" off center from the crankshaft centerline should be replaced. For V10 engines, maximum allowable runout is 0.010" which can be corrected by the use of offset dowels.

Tech Note 3: NV4500HD
The New Venture NV4500HD transmission was factory rated at 460 LB.-FT. of input torque. Except for the infamous fifth gear issue, NV4500HD performance and longevity is excellent with stock engines. The suitability of the NV4500HD for use behind modified, higher performance Cummins Diesel engines is debatable. Over a 15 year period, I worked on hundreds of NV4500HD transmissions out of trucks with everything from stock to highly modified competition Cummins Diesels. From what I saw, the failure rate of NV4500 transmissions increases dramatically when input torque exceeds 600 LB.-FT.. Yes, I know some guys run over engines with over 1,000 pounds of torque with no reported problems. I also know you can use bigger input shafts and cryogenically treat your gears which may help a little. The bottom line is this: If you increase your engine's power AND you use it, chances are you will experience a catastrophic transmission failure that would not have occurred with a stock or near stock engine.

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 4: Input Shaft
The New Venture NV4500 Input Shaft is designed to use three bearings. The input shaft is supported by a pressed-on Timken® high-performance Tapered Bearing Set. The back of the input shaft is bored for straight, caged roller bearing. The back face of the input shaft is ground flat for contacting the mainshaft to input thrust bearing. Another design feature of NV4500 input shafts is the 4th gear clutch ring is not an integral part of the input shaft, instead it is a slip fit to splines machined behind the input gear teeth. Incidentally, with the NV4500, 4th "gear" is simply a direct connection between the input shaft and output shaft with no power transfer through the countershaft.

Tech Note 5: Matching Parts
Other Matching Parts for QU10199 Input Shaft:
QU10049 or QU10702 4th Gear Clutch
QK1010 Complete Small Parts Kit
QU10221 Basic Small Parts Kit
QU10076 Rebuilder Spec 1-1/4" x 10 Spline NV4500HD Input Shaft
QU11238 Input Bearing Retainer
QU10126 Input Seal
QU10009 Mainshaft Shim Kit
QU10009B Basic Mainshaft Shim Kit
QU10558 Stock Type Needle Pilot Bearing for V10 and Cummins Diesel
QU51010 Heavy-Duty Ball Pilot Bearing for Cummins Diesel
QU10261 Upgrade 1-3/8" x 10 Spline NV4500HD Input Shaft
QU10541 Transmission Mount Support Plate for 4x4 Dodge Ram 5 Speed
QK1041 5 Speed Transmission Mount Kit for 1994-2002 Dodge Ram 2500, Ram 3500 4x4
QU90020 NV4500 Manual Transmission Oil
TM1003 NV4500 Shop Manual
V1003DVD NV4500 Overhaul Video
QT2005 Input Bearing Installer
QT1801 Input Bearing Cup Installer

Tech Note 6: Matching Countershafts
Matching Countershaft Part Numbers for QU10199 Input Gear are:

Tech Note 7: Matching Popular Mainshafts
Matching Popular Mainshaft Part Numbers for QU10199 Input Gear are:

Tech Note 8: Matching Synchronizer Parts
Matching NV4500 Synchronizer Parts for QU10199 Input Gear are:

Tech Note 9: Matching Bearings and Bearing Kits
Matching Bearings and Bearing Kits for QU10199 Input Shaft are:

Tech Note 10: NV4500 Tools
Need Torque Specs or Rebuild procedures? Order my 116 page, full color illustrated TM1003 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.

Applications
Dodge and Ram:
Ram 2500, Ram 3500 with V10 engine: 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Ram 2500, Ram 3500 with Cummins Diesel engine: 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004