QK1003 NV4500HD 4X4 Master Overhaul Kit with Tools for 94-04 Ram

QK1003 Master Overhaul Kit with Assembly Tools for 1994-2004 Dodge NV4500HD 4x4 Transmissions includes all the parts and special assembly tools normally required to restore your Heavy Duty Ram's worn out New Venture NV4500HD 4x4 5 speed manual transmission to like-new reliability. Kit includes 29 spline QA1045 heavy-duty full spline mainshaft, 22 tooth mainshaft 5th gear, mainshaft nut set, all bearings, all seals, all OE style synchro rings, mainshaft shims, countershaft shims, complete main case small parts kit, shift fork pads, RTV sealant and 2 types of threadlockers. QK1003 Master Overhaul Kit with assembly Tools ALSO includes the following assembly tools: mainshaft nut wrench, two bearing installers, two bearing cup installers, 14" driver handle, two shaft supports, 12 point metric impact socket for tailhousing bolts, and 8" punch for shift lug roll pin. Kit includes both USA made and import parts. Tools are USA made.

Also see QK1008 Master Kit without Tools

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:
Parts Included
Not a Press Fit
Mainshaft Nut Torque
Mainshaft Reference
Torque Ratings
Tool Applications
Matching Parts
Lubricants, Sealants, Threadlockers
Matching Mainshaft Gears
Applications

Tech Note 1: Parts Included
QK1003 Kit includes the following parts:
QA1045 Mainshaft Set (includes mainshaft, thrust washers, and nut set)
QU10067 Mainshaft 5th Gear
QU10123 4x4 Rear Output Seal
QU10126 Input Seal
QU10140 Cap/Seal Countershaft Front
TK10237 8 Piece Timken OE Spec Taper Bearing Set
TKA1180 8 Piece Needle Bearing Set for 1997-2004*
2 QU10018 1992-1996 Reverse Idler Gear Needle Bearing
QA1174 Complete Small Parts Kit for Main Case
QA10008 Complete Countershaft Shim Kit
QA10009 Complete Mainshaft Shim Kit
QK1095 Reverse Shift Fork Pad Kit 1997.5-2004
QU10164 Straight Reverse Fork Shift Pad 1997 (2)
QA1011 10 Piece OE Style Synchro Ring Kit
QT2001 1/2" Drive Mainshaft Nut Wrench
QT2004 Countershaft Front Bearing Installer
QT2005 Input Shaft and Countershaft Rear Bearing Installer (also installs Input Seal)
QT2006 Countershaft Support Tool
QT2008 1-2 Synchro Support
QT1801 Input Bearing Cup Installer (also used for outer rear wheel bearing cup)
QT1802 Countershaft Front Bearing Cup Installer (also installs rear output seal)
QT1101 14" Handle for Bearing Cup Installers
QT1020 12 Point Metric Impact Socket for Tailhousing Bolts
QT9300 8" Punch for 5th Gear Shift Lug
QU90006 3.35 oz Ultra Black RTV Sealant
S24200 6ml Medium Strength Blue Threadlocker
S24026 High Temperature Threadlocker for Mainshaft Nut

*If you have a 1994-1996 transmission, 2 QU10018 Reverse Idler Bearings are included in this kit. All other Kit parts are the same for 1994-2004 NV4500HD 4x4 transmissions.

Tech Note 2: Not a Press Fit
There is currently no available NV4500 mainshaft from any supplier that will have a press fit for the 3-4 synchro, mainshaft 5^th gear, or the rear output bearing. They are specifically designed and machined this way to speed assembly. The only shafts that had a press fit were the original equipment New Venture shafts and our Torque King shafts, both of which are long out of production and no longer available.

Tech Note 3: Mainshaft Nut Torque
The mainshaft nut torque is 270-280 Lb-ft. Secure the transmission to a sturdy work bench. Lock the transmission into 2nd and 4th gears.

Tech Note 4: Mainshaft Reference
For more information about NV4500 5th gear failures, see:
5th Gear Failures and Solutions
NV4500 Cast Iron Tailshaft Housings

We no longer make the Torque King® Mainshaft and Retrofit Kits as described in the 5th Gear Failures and Solutions, article which leaves full spline shafts the only choice currently available for Dodge NV4500HD transmissions. While full spline shafts do not actually cure the 5th gear issue, they do greatly reduce the chances of the nut backing off. QA1045 Kit is today's best option for preventing a 5th gear nut failure.

Tech Note 5: Torque Ratings
Ever since the Cummins Diesel was introduced in the 1989 Dodge Ram, people have been modifying the engines to crank out more horsepower. Unfortunately, all the manual transmissions used behind the Cummins Diesel (Getrag G360 (1989-1993), NV4500HD (1994-2004), NV5600 (1999-2005), and G56 (2005 to current) are only rated for around stock engine torque. When you increase your power output, you also increase the chance of having a major transmission failure. While some reasonably effective steps can be taken to increase the torque ratings of specific components, there is no practical way I know of to really make your Ram manual transmission "bullet proof" for big torque increases.

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 6: Tool Applications
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.

Tech Note 7: Matching Parts
QU10076 Rebuilder Spec 1-1/4" x 10 Spline Input Shaft
QU10199 Replacement 1-1/4" x 10 Spline Input Shaft
QU10261 Upgrade 1-3/8'x 10 Spline Input Shaft Kit
QU10018 Reverse Idler Bearing for 1994-1996 (order 2)
TK10519 Transmission to Transfer Case Gasket*
QU90020 NV4500 Manual Transmission Oil
TM1003 NV4500 Shop Manual
VSG1003DVD NV4500 Overhaul Video
QT2000 29 Spline Shaft Wrench
QT2036 Mainshaft Nut Wrench, 3/4" Drive
Dodge & Ram Shop Manuals

*Both the transmission output and transfer case input shafts are sealed. Dodge did not use a gasket or sealant between the NV4500HD transmission and NP241DLD or NP241DHD transfer cases on 1994-2004 Ram 2500, Ram 3500 4x4s. However, if you wish to use a gasket, TK10519 is the correct part to order.

Tech Note 8: Lubricants, Sealants, Threadlockers
Early production NV4500 Transmissions used an anaerobic sealant (QU90003) to seal between the main case and input bearing retainer, top cover, and rear housing. Mid-production units used anaerobic sealant just on the input retainer and RTV for everything else. Later production transmissions used black RTV Sealant (QU90006 or QU90005) for everything. Either type of sealant works fine (except the PTO covers ALWAYS should be sealed with RTV), but I prefer RTV for all components. Regardless of which sealant you use, make sure excess sealant does not block the lube access hole at the top of input retainer pilot that fits into the transmission case! Also, the threaded holes in the main case for the four retainer bolts and 12 PTO bolts are open ended, so you must use new bolts with factory applied threadlocker or apply Threadlocker (S24200) to your existing bolts to prevent oil seepage past the bolt threads. See my TM1003 NV4500 Shop Manual or VSG1003DVD NV4500 Overhaul Video for more information.

Lubricant and Chemical List for NV4500 Transmissions:
QU90020 NV4500 Manual Transmission Oil
QU90003 Anaerobic Sealant
QU90006 3.35 oz Ultra Black RTV Sealant
QU90005 0.5 oz Ultra Black RTV Sealant
S24200 6ml Medium Strength Blue Threadlocker
S9978 1 gram Medium Strength Blue Threadlocker
S9979 1 gram High Strength Red Threadlocker
S24026 High Temperature Threadlocker for Mainshaft Nut

Tech Note 9: Matching Mainshaft Gears

Applications
Dodge and Ram:
Ram 2500, Ram 3500 with 4x4 New Venture NV4500HD Transmission: 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004