nv4500 jumps out of 5th gear
 

Was driving down the road about a month ago and there was a load "clunk", still had all gears. I stopped looked for anything broken or unusual, nothing. Got back in,drove home no problems, up until this week. Truck made the "clunk" 2 times on Saturday, still had all gears, still found nothing broken. Sunday morning truck made the "clunk" and lost all gears. It took me a while to figure out that the transfer case had jumped into neutral. Put back into 2H and drove fine. Got home, adjusted transfer case linkage. Drove fine on Monday and this morning. On my way home from work this evening, "clunk" then a gear grinding noise in 5th, all other gears ok. Do you think it is the transmission or transfer case?

5th gear nut issue. Dodge has an updated nut for it, and I would start there.

5TH GEAR RETAINER NUT COMMON IN NV 4500 ........:ouch: TRANNY SHOULD BE OK ITS JUST BACKED OFF RIGHT NOW AND NOT ENGAGING...HATE TO ADMIT IT BUT I DROVE AROUND FOR MONTHS LIKE THAT LAST YEAR... 450-575 $ TOTAL WITH NEW RETAINER NUT UP-GRADE.......

:argh: thats what i was thinking. I must not be getting the nut tight enough, this will be the 3rd time of tightening it in 2 yrs. (new locking nut)

do you have the updated lock nut with retention screws in it???

Yeah, new nut from dodge

does this new nut from Dodge have retainer screws allen head screws (2 of them) that screw into the threads of the shaft???

not sure but will check when i get it apart.

the one with the brass in the set screw it is junk imo i put locktite on it and put the tourqe on that bitch in less than 150 mi it was back off,for the 3rd time ,so i got the new bottom shaft for the x2 revised 5th gear and it is fine it has two halves that are held in place by a collar that slides over them so they wont go no were held up so far

I've had the 5th gear nut come off, and replaced the driven gear and upgraded the nut, but my tranny will pop out of 5th gear (shifter actually jumps into neutral).. seems like this would be a good thread to look for that problem and maybe its the same problem Rexy is having.. to me it only happens on decel

on the shaft for the 5th gear nut their are grooves, i've found that when re-installing the nut after you have torqed the heck outta it with a hammer, take yourself a chissel or flat head and find the point on the nut that is in line with the grooves in the shaft. take the chissel and make an indention on the nut down into the grooves of the shaft. this should keep her from baking off on you. also, make sure that you check the springs and the and the little pieces they push out (forgot what to call them) on the clutch ring to make sure it's functioning properly.

I would suggest a full spline output shaft and a nut and gear.



RX7, this problem is the synchro on the fifth gear, its on the counter shaft and the assy is held on with a snap ring the synchro can be changed with tranny still in place just drop cross member and pull tailshaft housing off.The synchro runs around twenty to thirty dollars. Hope this helps.

Here is pictures of what the "clunk" noise is.

yep thats broken :ouch: Mine looked the same on the shaft splines (all rounded off).But never seen a gear break!! I can check to see if I can get a main shaft for you it will be monday or tuesday tho.

when i slide the 5th gear onto the splines on the shaft, i get a little bit of movement. Is this normal or are the splines wore out on the shaft.. I checked the donor 2wd trans. i got the 5th gear from and it has the same amount of movement. Any thoughts??

That movement is why the nut comes loose shaft is no good.

Thanks, it's kinda what I figured, I wish I would have known about it when I did the 5th gear nut though