Specifications

Fastener T ightening S pecificatio ns

Application
Backup Lamp Switch
Clutch housing cover bolts
Clutch Housing-to-Engine Studs (NV 4500)
Countershaft Retainer Plate-to Case Bolt
Lower PTO cover bolt (Oil Drain) (NV 4500)
Main Drive Gear Retainer-to-Case Bolt
Mainshaft Retainer Plate-to-Case Bolt
Oil Drain Plug (NV 3500)
Oil Fill Plug (NV 4500)
Oil Fill Plug (NV 3500)
Rear Oil Retainer-to-Case Bolt
Shift Housing Boot Screws
Shift Housing to Transmission Bolts
Shift Lever Cover-to-Case Bolts
Speed Sensor Bolt
Transmission-to-Clutch Housing Bolts (NV4500)
Transmission-to-Engine Studs (NV 3500)
Vibration Damper Mounting Nut (NV 4500) 4WD Models
Yoke Nut (NV 4500) RWD Models

N-m

Lb Ft

Lb in

28
10
31

21

__

23

35
37
31
35
60
41
60
54

26
27
23
26
44
30
46
40

89

2
10
23
22
100
47
100
441

17

18
89

16
74
35
74
325

Liters

Quarts

3.78

4.0

2.0

2.2

Lubrication S pecifications
Recommended
Application
Lubricant
New Venture Gear NV 4500 Manual Transmission
Castrol Syntorq
LT Transmission
Fluid
New Venture Gear NV 3500 Manual Transmission
Synch romesh
Transmission
Fluid GM
P/N 12345349

__

Diagnostic Information and Procedures

M a n u a l T ra n s m is s io n D ia g n o s is
1. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
2. Move the transmission rear extension housing up
and down.
If the plate is loose on the crossmember, tighten
the mounting bolts.
3. Replace the transmission rear mount if the rubber
is split or spongy.

C lu tc h S p in D o w n T im e
Check the clutch spin down time as follows:
1. Apply the parking brake. Block the vehicle wheels.
2. Shift the transmission into neutral.
3. Start the engine. Run the engine at idle speed.
4. Engage the clutch.
5. Disengage the clutch. Wait 9 seconds.
6. Shift the transmission into reverse.
7. If you hear a grinding noise, refer to Release
Bearing Noisy with Clutch Engaged in Clutch.

Repair Instructions
M a n u a l T ra n s m is s io n F lu id C h e c k
R em oval P rocedure
1. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
2. Clean all the dirt and all the oil from around the
fill plug.
3. Remove the oil fill plug.

102870

4. Ensure the transmission fluid level is even with

the bottom of the fill plug hole.
5. Install new transmission lubricant if required.
Refer to Lubrication Specifications.

N o tic e ; Refer to Fastener Notice

6. Install the oil fill plug.

Tighten
Tighten the oil fill plug to 41 N-m (30 lb ft).
7. Lower the vehicle.

Installation Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.

2. Clean all the dirt and all the oil from around the
fill plug.
3. Remove the oil fill plug.

4. Ensure the transmission fluid level is even with

the bottom of the fill plug hole.
5. Install new transmission lubricant if required.
Refer to Lubrication Specifications.

Notice: Refer to Fastener Notice in Cautions and

Notices.
6. Install the oil fill plug.
Tighten
Tighten the oil fill plug to 41 N-m (30 lb ft).
7. Lower the vehicle.

102870

F lu id R e p la c e m e n t (N V 3 5 0 0 )
R em oval P rocedure
Tools Required
J 36511 Oil Fill/Drain Plug Hex Bit (17 MM)

105611

important: Drain the transmission after a short period

of operation when the oil is warm. This allows any
existing fluid in the system to be expelled when the oil
is drained.
1. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
2. Support the vehicle with safety stands.
3. Clean all the dirt and all the oil from around the fill
plug and the oil drain plug.
4. Use the J 36511 in order to remove the oil
fill plug.
5. Catch the oil in a suitable container.
6. Use the J 36511 in order to remove the oil
drain plug.

Installatio n P rocedure
Tools Required
J 36511 Oil Fill/Drain Plug Hex Bit (17 MM)
1. Apply sealant to the oil drain plug threads. Use
Teflon GM P/N 1052080 or the equivalent.
Caution: Refer to Fastener Notice in Cautions and
Notices.
2. Use the J 36511 in order to install the oil
drain plug.
Tighten
Tighten the oil drain plug to 60 N-m (44 lb ft).

4730

3. Fill the transmission to the level of the fill plug

hole. Refer to Lubrication Specifications.

4. Apply sealant to the oil fill plug threads. Use

Teflon GM P/N 1052080 or the equivalent.

5. Use the J 36511 in order to install the oil fill plug.

Tighten
Tighten the oil fill plug to 60 N-m (44 lb ft).
6. Remove the safety stands.
7. Lower the vehicle.

F lu id R e p la c e m e n t (N V 4 5 0 0 )
R em oval P rocedure
Important: Drain the transmission after a short period
of operation when the oil is warm. This allows any
existing fluid in the system to be expeiied when the oil
is drained.
1. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
2. Support the vehicle with safety stands.
3. Clean all the dirt and all the oil from around the fill
plug and the oil drain plug.
4. Remove the oil fili plug.
5. Catch the oil in a suitable container.

102870

6. Remove the lower PTO cover bolt. The lower

PTO cover bolt is used as a oil drain plug.

102872

Installatio n P rocedure
Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Install the lower PTO cover bolt.
Tighten
Tighten the bolt to 37 N-m (27 lb ft).

2. Fill the transmission to the level of the fill plug

hole. Refer to Lubrication Specifications.

2327

3. Install the oil fill plug.

Tighten
Tighten the oil fill plug to 41 N-m (30 lb ft).
4. Remove the safety stands.
5. Lower the vehicle.

Shift Lever
R em oval P rocedure

1. Remove four screws and the shift boot trim plate

securing the shift tower boot to the floor panel
and the insulator.
Important: Do not disassemble the transmission shift

housing. Internal parts for the shift housing are not

available. Opening the shift housing will void the shift
housing warranty.
2. Remove the shift lever from the transmission shift
housing lever.
3. Remove the boot from the shift lever.

Installatio n Procedure
1. Install the boot to the shift lever.
2. Install the shift lever to the transmission shift
tower lever.
Notice: Refer to Fastener Notice in Cautions and

Notices.
3. Install the four screws securing the shift housing

boot to the floor panel and the insulator.

Tighten
Tighten the screws to 2 N-m (18 lb in).
4. Install the shift boot trim plate and screws.

V e h ic le S p e e d S e n s o r (N V 4 5 0 0 )
Rem oval Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
2. Support the vehicle with safety stands.
3. Disconnect the electrical connector from the
vehicle speed sensor assembly.
4. Place a suitable container under the transmission
in order to catch the fluid.

5. Remove the following parts:

5.1. One bolt
5.2. The vehicle speed sensor
5.3. The O-ring seal

Installation Procedure
1. Coat a new O-ring seal with a thin film of
transmission fluid. Use Castrol Syntorq GL-4
Transmission Fluid or the equivalent.
2. Install the following parts:
2.1. The O-ring on the vehicle speed sensor
assembly
2.2. The vehicle speed sensor assembly
N o t i c e : Refer to Fastener Notice in Cautions and
Notices.
2.3. One bolt

Tighten
Tighten the bolt to 22 N-m (16 lb ft).

3. Install the electrical connector on the vehicle

speed sensor assembly.
4. Remove the safety stands.
5. Lower the vehicle.
6. Check the transmission fluid level.

V e h ic le S p e e d S e n s o r (N V 3 5 0 0 )
Rem oval Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
2. Disconnect the electrical connector from the
vehicle speed sensor assembly.
3. Place a drain pan under the transmission in order
to catch the oil.

4. Remove the following parts:

The bolt
The vehicle speed sensor
The O-ring seal

Installation Procedure
1. Coat a new O-ring seal with a thin film of
transmission oil. Use Synchromesh Transmission
Fluid or the equivalent.
N o t i c e : Refer to Fastener Notice in Cautions and

Notices.
2. Install the following parts:
The O-ring on the vehicle speed sensor
assembly
The vehicle speed sensor assembly
The bolt
Tighten
Tighten the bolt to 22 N-m (16 lb ft).

3. Install the electrical connector on the vehicle

speed sensor assembly.
4. Lower the vehicle.

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B a c k u p L a m p S w itc h
R e p la c e m e n t (N V 3 5 0 0 )
Rem oval P rocedure
1. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
2. Support the vehicle with safety stands.
3. Disconnect the backup lamp switch electrical
connector.
4. Remove the backup lamp switch.

4778

Installation Procedure
Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Install the backup lamp switch.
The backup lamp switch has pre-applied thread
sealant on the threads.

2.
3.
4.
5.

Tighten
Tighten the backup lamp switch to
28 N-m (21 lb ft).
Connect the backup lamp switch electrical
connector.
Remove the safety stands.
Lower the vehicle.
Connect the battery negative cable assembly to
the battery negative terminal.
Tighten
Tighten the terminal bolt to 15 N-m (11 lb ft).

B a c k u p L a m p S w itc h
R e p la c e m e n t (N V 4 5 0 0 )
R em oval Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
2. Support the vehicle with safety stands.
3. Disconnect the backup lamp switch electrical
connector.

4. Remove the backup lamp switch.

102880
Installatio n P rocedure
N o t i c e : Refer to Fastener Notice in Cautions and

Notices.
1. Install the backup lamp switch. The backup lamp
switch has pre-applied thread sealant on the
threads.
Tighten
Tighten the backup lamp witch to 28 N-m (21 lb ft).

102880

2. Connect the backup lamp switch electrical

connector.
3. Remove the safety stands.
4. Lower the vehicle.

T ra n s m is s io n R e p la c e m e n t (N V 3 5 0 0 )
R em oval P rocedure
Tools Required
J 36221 Quick Connect Disengagement Tool
1. Shift the transmission into 3RD or
4TH speed gear.
2. Remove the shift lever and boot. Refer to Shift
Lever.
3. Raise the vehicle.
4. Drain the transmission oil. Refer to Fluid
Replacement (NV3500) or Fluid
Replacement (NV4500).
5. Remove the propeller shaft. Refer to one of the
following procedures in Propeller Shaft.
Propeller Shaft Replacement (Front Axle - All
Except NP8)
Propeller Shaft Replacement
(Front Axle - NP8)
Propeller Shaft Replacement (System
Balanced Assembly)
6. Remove the transfer case if the vehicle is
equipped with four wheel drive. Refer to one of the
following procedures in Transfer Case.
Transfer Case Replacement (Selectable Four
Wheel Drive)
Transfer Case Replacement (Auto Four Wheel
Drive )
Transfer Case Replacement (Manual Four
Wheel Drive)
7. Disconnect the wiring harness connector from the
vehicle speed sensor.

102878

8. Disconnect the wiring harness connector from the

backup lamp switch.
9. Disconnect the wiring harness retainers from the

transmission.

10. Use the J 36221. Depress the white plastic sleeve

on the quick connect in order to separate the
hydraulic clutch line from the concentric slave
cylinder quick connect.

11. Remove the clutch housing cover.

12. Remove the transmission rear mount.
13. Support the transmission. Use a suitable
safety stand.

14. Remove the frame crossmember. Refer to Rear

Bumper Brace Replacement in Frame and
Bumpers.

102889

15. Remove the transmission to the clutch housing

bolts and studs.
16. Pull the transmission straight back on the clutch
hub splines. Do not let the transmission hang
from the clutch plate and the clutch cover.
17. Remove the transmission from the vehicle.

102890

Installation Procedure
Important:
Do not force the transmission into the clutch.
Do not let the transmission hang from the clutch.
Leave the safety stand under the transmission
for support.
1. Install the transmission:
1.1. Put a thin coat of high-temperature grease
on the main drive gear splines.
1.2. Shift the transmission into 3RD or
4TH speed gear.
1.3. Rotate the transmission clockwise onto the
clutch hub splines.
Notice: Refer to Fastener Notice in Cautions and
Notices.
1.4. Install the bolts and the studs securing the
transmission to the engine.
Tighten
Tighten the bolts to 47 N-m (35 !b ft).
2. Install the frame crossmember. Refer to Rear
Bumper Brace Replacement in Frame and
Bumpers.
3. Install the transmission rear mount.
4. Remove the safety stand from beneath the
transmission.

102890

5. Install the hydraulic clutch line to the concentric

slave cylinder quick connect.
6. Install the wiring harness retainers to the
transmission.

102888

7. Install the electrical connector to the backup lamp

switch.

8. Install the electrical connector to the vehicle

speed sensor.
9. Install the transfer case if removed. Refer to one
of the following procedures in Transfer Case:
Transfer Case Replacement (Selectable Four
Wheel Drive)
Transfer Case Replacement (Auto Four Wheel
Drive )
Transfer Case Replacement (Manual Four
Wheel Drive)
10. Install the propeller shaft. Refer to one of the
following procedures in Propeller Shaft.
Propeller Shaft Replacement (Front Axle - All
Except NP8)
Propeller Shaft Replacement
(Front Axle - NP8)
Propeller Shaft Replacement (System
Balanced Assembly)
102878

11. Install the parking brake and controls, if removed.

Refer to Parking Brake Rep lacement in
Parking Brake.
12. Fill the transmission with new oil. Refer to Fluid
Replacement (NV3500) or Fluid

Replacement (NV4500).
13. Remove the safety stands.
14. Lower the vehicle.
15. Install the shift lever and the boot. Refer to Shift

Lever.

Transmission Replacement (NV4500 RWD)

Removal Procedure
Tools Required
J 36221 Clutch Line Disconnect Tool
1. Shift the transmission into 3RD or
4TH speed gear.
2. Remove the transmission shift lever and the boot.
Refer to Shift Lever.
3. Raise the vehicle.
4. Drain the transmission oil. Refer to Fluid

Replacement (NV4500).
5. Remove the propeller shaft. Refer to one of the
following procedures in Propeller Shaft.
Propeller Shaft Replacement (Front Axle - All

Except NP8)
Propeller Shaft Replacement

(Front Axle - NP8)

Propeller Shaft Replacement (System

Balanced Assembly)
6. Remove the parking brake and controls, if used.
Refer to Parking Brake Replacement in
Parking Brake.
7. Disconnect the wiring harness connector from the
backup lamp switch and from the vehicle speed
sensor.
8. Disconnect the wiring harness retainers from the
transmission.
9. Disconnect the hydraulic clutch line from the
concentric slave cylinder using the J 36221.

102888

10. Remove the transmission vent hose from the

transmission.
11. Remove the transmission rear mount.
12. Support the transmission.
13. Remove the frame crossmember. Refer to Rear
Bumper Brace Replacement in Frame and
Bumpers.
14. Remove the transmission to engine bolts.
15. Pull the transmission straight back on the clutch
hub splines. Do not let the transmission hang
from the clutch plate and clutch cover.

16. Remove the transmission from the vehicle.

Installation Procedure
Important:
Do not force the transmission into the clutch.
Do not let the transmission hang from the clutch.
Leave the safety stand under the transmission
for support.
1. Install the transmission.
1.1. Put a thin coat of high-temperature grease
on the main drive gear splines.
1.2. Shift the transmission into 3RD or
4TH speed gear.
1.3. Rotate the transmission clockwise onto the
clutch hub splines.
Notice: Refer to Fastener Notice in Cautions and
Notices.
1.4. Install the transmission to the engine bolts
and washers.

Tighten
Tighten the bolts to 100 N-m (74 lb ft).

2. Install the transmission to engine bolts.

Tighten
Tighten the studs to 31 N-m (23 lb ft).
3. Install the frame crossmember. Refer to Rear
Bumper Brace Replacement in Frame and
Bumpers.
4. Install the transmission rear mount.
5. Remove the safety stand from beneath the
transmission.
6. Install the transmission vent hose.

102891

7. Install the hydraulic clutch line to the concentric

slave cylinder quick connect.
8. Install the wiring harness retainers to the
transmission.
9. Connect the following electrical wiring harness
connectors:
The vehicle speed sensor
The backup lamp switch
10. Install the propeller shaft. Refer to one of the
following procedures in Propeller Shaft.
Propeller Shaft Replacement (Front Axle - All

Except NP8)
Propeller Shaft Replacement

(Front Axle - NP8)

Propeller Shaft Replacement (System
Balanced Assembly)
11. Install the parking brake and controls, if removed
Refer to Parking Brake Replacement in
Parking Brake.

12. Fill the transmission with new oil. Refer to Fluid

Replacement (NV3500) or Fluid
Replacement (NV4500).
13. Remove the safety stands.
14. Lower the vehicle.
15. Install the shift lever and the boot. Refer to Shift

Lever.

102888

Transmission Replacement (NV4500 4WD)

Removal Procedure
Tools Required
J 36221 Quick Connect Disengagement Tool
1. Shift the transmission into 3RD or
4TH speed gear.
2. Remove the shift lever. Refer to Shift Lever.
3. Drain the transmission oil. Refer to Fluid
Replacement (NV3500) or Fluid

Replacement (NV4500%
4. Remove the propeller shaft. Refer to one of the
following procedures in Propeller Shaft:
Propeller Shaft Replacement (Front Axle - All

Except NP8)

Propeller Shaft Replacement (Front

Axle - NP8)
102888

Propeller Shaft Replacement (System

Balanced Assembly)
5. Remove the transfer case. Refer to one of the
following procedures in Transfer Case:
Transfer Case Replacement (Selectable Four

Wheel Drive)
Transfer Case Replacement (Auto Four Wheel

Drive )
Transfer Case Replacement (Manual Four
Wheel Drive)
6. Remove the parking brake and controls, if used.
Refer to Parking Replacement in Parking Brake.
7. Disconnect the following electrical wiring harness
connectors:
The vehicle speed sensor
The backup lamp switch
8. Disconnect the wiring harness retainers from the
transmission.
9. Disconnect the hydraulic clutch line from the
concentric slave cylinder using the J 36221.
10. Remove the transmission vent hose.
11. Remove the transmission rear mount.
12. Support the transmission. Use a suitable
safety stand.
13. Remove the frame crossmember. Refer to Rear
Bumper Brace Replacement in Frame and
Bumpers.

102891

14. Remove the transmission to engine bolts.

15. Pull the transmission straight back on the clutch
hub splines. Do not let the transmission hang
from the clutch plate and clutch cover.
16. Remove the transmission from the vehicle.

105648

Installation Procedure
1. Install the clutch housing to the engine, if
removed.

Tighten
Tighten the studs to 100 N-m (74 lb ft).

Important:
Do not force the transmission into the clutch.
Do not let the transmission hang from the clutch.
Leave the safety stand under the transmission
for support.
2. Install the transmission.
2.1. Put a thin coat of high-temperature grease
on the main drive gear splines.
2.2. Shift the transmission into 3RD or
4TH speed gear.
2.3. Rotate the transmission clockwise onto the
clutch hub splines.
2.4. Install the transmission to the clutch
housing bolts and washers.

Tighten
Tighten the bolts to 31 N-m (23 lb ft).

Notice: Refer to Fastener Notice in Cautions and

Notices.
3. Install the frame crossmember. Refer to Rear
Bumper Brace Replacement in Frame and
Bumpers.
4. Install the transmission rear mount.

5. Remove the safety stand from beneath the

transmission.

105648

6. Install the transmission vent hose.

102891

7. Install the hydraulic clutch line to the concentric

slave cylinder quick connect.
8. Install the wiring harness retainers to the
transmission.
9. Connect the following electrical wiring harness
connectors:
The vehicle speed sensor
The backup lamp switch
10. Install the transfer case. Refer to one of the
following procedures in Transfer Case:
Transfer Case Replacement (Selectable Four

Wheel Drive)
Transfer Case Replacement (Auto Four Wheel
Drive )
Transfer Case Replacement (Manual Four
Wheel Drive)
11 . Install the propeller shaft. Refer to one of the
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following procedures in Propeller Shaft.

Propeller Shaft Replacement (Front Axle - All

Except NP8)
Propeller Shaft Replacement
(Front Axle - NP8)
Propeller Shaft Replacement (System
Balanced Assembly)
12. Install the parking brake and controls, if removed.
Refer to Parking Brake Replacement in
Parking Brake.

13. Fill the transmission with new oil. Refer to Fluid

Replacement (NV3500) or Fluid
Replacement (NV4500).
14. Remove the safety stands.
15. Lower the vehicle.
16. Install the shift lever to the transmission. Refer to

Shift Lever.

Description and Operation

Transmission Description and Operation
Identify transmissions by the number of forward gears
and the measured distance (in millimeters) between
centerlines of the mainshaft and the countershaft.

The New Venture Gear NV4500 (109 mm)

five speed manual transmission is available as
RP O MW3.
The transmission has the following features:
Synchronized shifting in all forward gears
The New Venture Gear NV3500 (85 mm) five speed
overdrive manual transmission is identified by the
RPO M50 for four wheel drive vehicles and RPO MG5
for rear wheel drive (RWD) vehicles.
The transmission has the following features:
Constant mesh helical gearing for reduced noise
A two-piece aluminum housing.
Synchronized shifting in all forward gears
A shift tower mounted shift lever.
Identify the transmissions by the number of forward
gears and the measured distance (in millimeters)
between centerlines of the mainshaft and the
countershaft.

Constant mesh helical gearing for reduced noise

Overspeed inhibitor from low to first speed gears
Dual cone low speed gear and 1ST speed
gear synchronizer
A shift tower mounted shift lever

Special Tools and Equipment

Illustration

Part Number Description

Illustration

Part Number Description

J 3880
Extension Housing Bearing
Installer

J 22828
Gear And Bearing Installer

102587

(D L

102580

J 8092
Universal Driver Handle

J 38805
Output Shaft Nut Socket

2015

102584

J 22834
Extension Housing Seal
Installer

J 23907
Slide Hammer
X

12375

4855

J 38856
Countershaft Bearing Cone
And Retainer Installer

J 26941
Output Shaft Oil Seal
Remover

102588

4862

J 39314
Vibration Damper Installer

(C D
102592

J 36502
Output Shaft Seal Installer

6
4884

Illustration

Part Number Description

J 36503
Extension Housing Seal
Installer

1342

J 36511
OilFill Plug Hex Bit (17 mm)

4869