New Venture Gear 4500 5-Speed

Fig. 18 Installing Overdrive Shift Lever Shaft Bushing:

Fig. 19 Installing Countershaft Front Bearing Cup:

Fig. 20 Installing Countershaft Rear Bearing:

1. Install overdrive shift lever shaft bushings using overdrive shift lever shaft bushing installer tool No. J-38803 or equivalent, Fig. 18.
2. Install overdrive shift lever and overdrive shift lever shaft.
3. Install overdrive shift lever retaining pin.
4. Install countershaft front bearing cup using countershaft bearing cone and retainer installer tool No. J-38856 or equivalent, Fig. 19.
5. Install countershaft assembly.
6. Install countershaft rear bearing using countershaft bearing and input shaft bearing installer tool No. J-22828 or equivalent, Fig. 20. Raise and support countershaft assembly while installing rear bearing to prevent damage to front bearing.
7. Install reverse idler gear, bearings, spacer and washers, then reverse idler gear shaft.
8. Install countershaft rear bearing cup, countershaft shims, bearing retainer plate and bearing retainer plate bolts. Torque bearing retainer plate bolts to 17 ft. lbs.

Fig. 21 Checking Countershaft Endplay:

Fig. 22 Installing Countershaft Bearing Cap:

Fig. 23 Checking Mainshaft Endplay:

9. Check countershaft endplay as follows:
a. Set dial indicator up on end of countershaft as shown in Fig. 21.
b. Use a screwdriver or equivalent to lift countershaft up and down to measure endplay. Endplay should be 0.002-0.006 inch. If endplay is not within specifications, adjust by selective shim under bearing retainer plate.
10. Install countershaft bearing cap using countershaft bearing cone and retainer installer tool No. J-38856 or equivalent, Fig. 22. Ensure outer lip is hit evenly until flush with case.
11. Install mainshaft assembly.
12. Install mainshaft rear bearing cup, shim, retainer plate and retainer plate bolts. Torque retainer plate bolts to 17 ft. lbs.
13. Check mainshaft endplay as follows:
a. Set dial indicator up on end of mainshaft as shown in Fig. 23.
b. Use a screwdriver or equivalent to lift mainshaft up and down to measure endplay. Endplay should be 0.002-0.006 inch. If endplay is not within specifications, adjust by selective shim under bearing retainer plate.
14. Install pin and countershaft thrust washer.
15. Install overdrive gear assembly onto overdrive shift rail.
16. Slide overdrive fork and gear assembly onto shift rail.
17. Install clutch gear retaining ring.
18. Support overdrive fork and drive overdrive shift rod pins downward from top of fork.
19. Install main drive gear bearing, main drive gear, main drive gear bearing retainer and main drive gear bearing retainer. Torque main drive gear bearing retainer bolts to 23 ft. lbs.
20. Install rear oil retainer and rear oil retainer bolts. Torque rear oil retainer bolts to 40 ft. lbs.
21. Install yoke assembly, spline seal, washer and nut. Torque nut to 325 ft. lbs.
22. Install shift lever cover and shift lever cover bolts. Torque shift lever cover bolts to 17 ft. lbs.
23. Install shift lever stub by pressing down cap and turning clockwise.