i'm forced to believe they are 4.10's. in 5th at 3100 rpms im doin about 95-100. but i have lugged 5th gear, and i have towed heavy up steep grades in 5th. i dont beat the snot out of it but i do make it work n earn its keep

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yep all the other gears work as usual. it goes into 5th's place in the shift pattern, but no power transfer. how do i go about replacin the counter shaft? am i better off sendin my trans for a core n buyin a new one? i am fairly mechanically inclined and have a heated garage to work in. is this something i can do?

 

check the cone gear on the countershaft, it is on the back of the transmission the bigger gear on the lower shaft. just take the snapring off the lower shaft and check the internal splines on the gear. i had the same problem with my 96 and thought it was the famous nut but mine actually ripped the internal teeth on the cone gear. if thats the case, call Southern Gear Co. out of georgia. dodge wanted $400 for the gear and i got a new one shipped to me for less than 60 bucks from southern gear. their number is 1-800-289-7432. p.s. the splines will look ok from the outside but under the snap ring is a different story!

 

thanks for the info. i have the trans on the garage floor with the shift tower n inspection plate off n i cant see anything wrong with it... u wouldnt happen to have any pics of it would ya?

 

There is a full spline output shaft available for the Nv4500 it is a stronger gear to shaft engagement.The old shafts are only partially splined and weak.

 

my output shaft is fine. i've narrowed it down to somethin screwed up with the countershaft. is there anything this cummins wont break???

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this was exactly what the problem was. i pulled the snap ring off n pulled the gear and there are no teeth left inside it. the countershaft is fine but the gear is toast. i had the shift tower off the tranny lookin down inside thinkin this is not gonna be fun. thanks again man u saved me alot of hassle

 

this may help ya
NV4500 Transmission Exploded View

 

Your welcome. anything i can do to help with a problem i have seen makes me feel needed. im just glad to help. Southern Gear was the cheapest place i could find another gear. one of their techs told me that lugging in fifth would cause that.