NV5000 Manual Transmission Assembly for Dodge Ram 4x4s-Direct Replacement for NV4500

NV5000 5 Speed Manual Transmission Assembly is a Direct Replacement for NV4500HD Transmission in 1994-2004 Dodge Ram 2500 and Ram 3500 4x4 trucks with Cummins Diesel or V10 gas engines. Upgrade today to the all new, cast iron case, NV5000 5 speed heavy-duty manual transmission which is rated for 500 hp AND 500 lb-ft of torque. CURE 5th Gear Loss FOREVER! The NV5000 is NOT subject to the infamous 5th gear failure problem that plagued the NV4500 due to repositioning the 5th gear to inside the main case between the input shaft and mainshaft 3rd gear! The ZF built NV5000 will provide superior performance and reliability over your tired old NV4500. The NV5000 is manufactured in a cutting-edge ZF global facility, and it exemplifies advanced engineering and innovation. This new transmission meets the demanding needs of modern heavy-duty vehicles, providing unmatched performance, reliability, and longevity for Dodge/RAM heavy-duty pickups with either the Cummins Diesel or V-10 gas engines. Engineered with a focus on Diesel 4x4 configurations, the NV5000's design is ideal for high-stress situations like navigating tough terrains or hauling heavy loads. Its design ensures that it meets and exceeds the expectations of heavy-duty vehicle operators, offering a level of endurance and strength that is critical in such demanding applications. Specifically designed for Dodge and RAM 3/4 ton and 1-ton 4x4s, the smooth-shifting, quiet-running NV5000 is a direct bolt-in replacement for the original NV4500 diesel or the V10 4x4 models. It's an ideal option for vehicle owners who want to enhance their driving experience with the precision and control of a manual transmission.
Please see the notes below for answers to your most important questions!
Note: Will also fit 1989-1993 Dodge Ram 4x4 diesels by installing our QU5001 bellhousing and doing a slight modification to input retainer nose.

*Sold outright, no core charge, no core return required!  Ships truck freight only. Ships DRY! See Tech Note 2.

Dan the Gear Man® Tech Notes:
Specifications
Shipped Dry, NO Lubricant in Unit!
Construction
Gear Train
Manual Transmission Compatibility
Automatic Transmission Compatibility
Dyno Tested
High Horsepower and Torque Applications
Clutch Info
FAQ
Applications

Tech Note 1: NV5000 Specifications
Torque Rating: 500 lb.-ft.
Horsepower Rating: 500hp
Weight: 200 pounds
Subject to NV4500 Type 5th Gear Failures: No
Input Shaft Size: 1-1/4" x 10 Spline. Front tip that fits Pilot Bearing is same as NV4500
Output Shaft Spline: 29, same as G360, NV4500HD, and NV5600 4x4 transmissions
Forward Gear Ratios: 1st: 5.67, 2nd: 3.04, 3rd: 1.67, 4th: Direct (1:1), 5th: 0.76
Reverse Gear Ratio: 5.11
Synchronization: All forward gears. Reverse is not synchronized
Fluid Type: 75w80 GL-4 Synthetic
Fluid Capacity: 4.5 liters
Manufacturer: ZF
Manufactured In: China by ZF

Tech Note 2: Shipped Dry, NO Lubricant in Unit!
The NV5000 is shipped dry with NO oil in the unit. You MUST add 5 quarts (4.5 liters) of 75w80 FULL SYNTHETIC GL-4 rated manual transmission fluid. We recommend QU90086 RedLine MTL 75W80 GL-4 fluid, but you can use any other quality full synthetic 75w80 GL-4 rated manual transmission fluid. Operating your NV5000 transmission with no fluid or the wrong type will void the warranty!

Tech Note 3: Construction
The NV5000 transmission is meticulously constructed, from its robust front-bearing retainer, to the durable cast iron case and extension housing. These improvements address and resolve the cracking issues encountered with the NV4500, significantly enhancing the NV5000's longevity and dependability.

Tech Note 4: Gear Train
Furthermore, the top-loading NV5000's gear train is integrated into the main case, effectively eliminating the 5th gear problems that were a persistent challenge in the NV4500. This improvement means that all gears, including the reverse gear, are synchronized, providing a smoother and more reliable transmission experience.

Tech Note 5: Manual Transmission Compatibility
The NV5000 is designed for compatibility with the 1994-2004 RAM NV4500 bellhousings and all related clutch components, making it versatile and easy to integrate into existing systems (For 1994-1998, also order QU90074 Backup Wire Extension). It will also fit 1989-1993 W250 and W350 manual transmission 4x4s with the Cummins Diesel by adding QU5001 Bellhousing, QU10132 switch, QU10147 gasket, and QU90002 pigtail. to your order. For 1989-1993 trucks, the input bearing retainer nose will need to be slightly shortened (about 0.35") to allow clearance for the clutch hub.

Tech Note 6: Automatic Transmission Compatibility
The NV5000 can be used for auto to manual transmission conversions on most 1989-2018 RAM Diesel 4x4s. The NV5000 has a 29-spline output shaft. Since most RAM auto transmissions have a 23-spline output, you will also need to replace the transfer case input shaft or, if you have a 1989-1993 truck, use our TK11541 23 spline to 29 coupler. Auto to manual conversions require lots of other parts and may require wiring or programming changes that are outside our product offerings.

Tech Note 7: Dyno Tested
All NV5000s are Dyno Tested to ensure quality, performance, and function.

Tech Note 8: High Horsepower and Torque Applications
Like the NV4500, the NV5000 can, in many cases, be successfully used in applications with horsepower or torque ratings above the factory ratings of 500hp and 500 lb-ft of torque. How you drive will have a major influence on NV5000 durability in your higher power application. Due to the physical size limitations of the 18-3/4" case length needed to match the NV4500, it is not possible to make a "bullet proof" production manual transmission that will take all the torque of a built-up Cummins Diesel. While the design of the NV5000 is very robust, you will probably break something in it if you are sled pulling, drag racing, towing massive loads, or just have a very heavy foot on the accelerator. Gear tooth or shaft breakage from excessive power will not be covered under warranty! Be advised, there is no warranty coverage for applications with modified engines including those with power chips! For commerical use with stock engines, the warranty is 6 months/12,000 miles (whichever comes first) instead of the 12 months/unlimited mileage allowed for non-commercial use.

Tech Note 9: Clutch Info
The NV5000 is compatible with all stock and almost all aftermarket clutches used on 1989-2004 Dodge RAMs (see 1989-1993 or 1994-2004 Clutch Parts).  The 1989-2004 stock type QU51002 Clutch Release Bearing is the correct part to use with the NV5000. A new clutch release bearing and pilot bushing or bearing is recommended even if you are reusing your old clutch.
QU10555 Replacement stock type clutch pilot bushing for 1989-1993 (included with QU5001 Bellhousing Kit)
QU10558 Replacement stock type clutch pilot bearing for 1994-2004
QU51010 Heavy Duty Ball Type Pilot Bearing for 1989-2004 (requires machine shop modification to flywheel!)
QU10523 Clutch Fork for 1989-1993
QU10506 Clutch Fork or Lever Boot for 1989-1993
QK6016 Clutch Fork, Lever, Boot and Pivot Ball Kit for 1989-1993
QU10565 Clutch Fork 1994-2004

Tech Note 10: FAQ
Who is ZF?: German based ZF is one of the largest Tier 1 part manufacturers in the world. ZF supplies automotive, truck, agricultural, and industrial components to original equipment manufacturers from plants located around the world. https://www.zf.com/mobile/en/homepage/homepage.html

Why is the NV5000 made in China?: The NV5000 is manufactured in a ZF plant in China for MWT. Unlike the U.S. and Europe, Asia is still a major market for manual transmissions so the manufacturing capacity for complete manual transmissions is there and not here.

Do I need to send you my old transmission as a core?: No. We sell the NV5000 outright with no core charge and no core return required. It is your choice to keep, sell, or scrap your old transmission.

Are the rotating gears supported by bearings or bushings?: Bearings

Why is the Shift Pattern Different?: To eliminate the 5th gear nut issue, 5th gear was relocated to the front of the transmission which means it is shifted by a different fork than the NV4500 used.

Are any parts interchangeable between the NV5000 and NV4500?: No

Are special tool required to service the NV5000?: No

Will the factory 1994-2004 NV4500 Transmission Mount and Bolts fit the NV5000?: Yes

What type of testing has the NV5000 undergone? Over a two year period before the NV5000 was released for sale in late August of 2024, a number of units were put in the field for real world testing. Two were coupled to engines with 800 pounds of torque, another was in a hot-shot delivery truck and the rest were daily drivers. No failures or problems of any kind have been reported as of August 2024 with any of the test transmissions. It is still too early to say what the average life before rebuilding will be, but given ZF's long experience with manual transmissions we do expect the NV5000 to equal or exceed the average NV4500 service life.

What are the synchro rings made of?: Brass.

Is reverse gear synchronized? No. To prevent "grinding" the gears when shifting to reverse, it is recommended that the vehicle be fully stopped before shifting into reverse.

Do the Brass Synchro Rings work as good as the Carbon Fiber Lined Rings used in the NV4500? With the new generation full synthetic 75w80 GL-4 lubricants, the NV5000 should generally have a similar shaft effort as your old NV4500. Like all brass synchro rings, there will be small particles of brass worn from the teeth over time which does require more frequent oil changes compared to the NV4500.

What is the recommended oil change schedule? For normal driving, change the oil every 75,000-85,000 miles. For heavy pulling and/or use with engines boosted over stock ratings, change the oil every 40,000 to 45,000 miles.

Are the bearings preloaded like the Ford ZF5-42 or have end-play like the NV4500?: Neither. The shafts are supported by double-row ball bearings instead of tapered bearings.

Is there a build tag on the transmission?: Yes, it shows the serial number, ratios, and required oil type.

Will my backup light switch fit the NV5000?:  For 1994-2004 RAMs, you will reuse your old switch. The switch is in a different location, (for 1994-1998 trucks, we recommend you also order QU90074 Plug-In Extension Wire) but for 1999-2004 the factory wires will typically reach the new switch location. For 1989-1993 Dodge, your old switch will fit the NV5000, but the wire is too short to reach the new location, so for 1989-1993 Dodge trucks and all other applications, order QU10132 switch, QU10147 gasket, and QU90002 pigtail.

What about the shift lever?: A new bolt-on shift tower, lever, and knob are included with each new NV5000. The lever is the same length as 1998-2002 RAM NV4500 levers.

How does the shift lever connect to the shift stub?: Threads on. Has locknut to lock in position.

Can I Add A Filter or Cooler? No, the NV5000 does not have a place to mount a PTO like the NV4500 had. The bolt-on type filters and coolers all require a PTO mounting location to attach them to a transmission.

How long is the NV5000?: Same as the Dodge NV4500HD 4x4 transmission. 18-3/4" from front adapter plate to end of tailhousing. It is about 27" overall from input tip to end of output shaft.

Are parts available for the NV5000?: Yes, a complete line of replacement parts are available.

Why is the transmission shipped by truck freight instead of FedEx or UPS?: The transmission and shipping crate weigh well over 200 pounds. By both size and weight, they are too large to ship by FedEx or UPS package delivery services.

Is the NV5000 Available for 4x2 RAMs?: Not at this time.

Is the NV5000 Available for applications other than RAM Diesel 4x4s?: The design is very adaptable by changing the input and output parts and additional applications for GM and conversions are planned for future release. We do not have an availability date for other applications at this time.

Direct Fit Applications:
Dodge and RAM with Cummins Diesel or V10 and Manual Transmission:
W250, W350 (Also requires QU5001 Bellhousing and see Tech Note 5): 1989, 1990, 1991, 1992, 1993
RAM 2500, RAM 3500: 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004