Page 1689 of 2889

MAINSHAFT AND GEARTRAIN
(1) Move 1-2 and 3-4 synchro sleeves into neutral.
(2) Remove drive gear thrust bearing from forward
end of mainshaft (Fig. 27).
(3) Remove fourth gear clutch gear and synchro
stop ring from mainshaft (Fig. 28).
(4) Roll gear case onto left side (Fig. 29).
(5) To remove mainshaft assembly (Fig. 29) lift
front end of mainshaft slightly.
NOTE: Handling mainshaft carfully because gears
are lose on the mainshaft.
(6) Grasp mainshaft rear splines, then turn spline
end of mainshaft counterclockwise to rotate shaft and
geartrain out of case. Tilt mainshaft outward and
removed from case.
Fig. 25 Pilot Bearing
1 - DRIVE GEAR
2 - MAINSHAFT PILOT BEARING
Fig. 26 Front Bearing Puller
1 - PULLER 6444
2 - RODS 6444-6
3 - JAWS 6447
4 - COLLAR 6444-8
5 - FLANGE 6444-1
6 - DRIVE GEAR
Fig. 27 Drive Gear Thrust Bearing
1 - MAINSHAFT
2 - DRIVE GEAR THRUST BEARING
Fig. 28 Fourth Gear Clutch Gear Stop Ring
1 - FOURTH GEAR SYNCHRO STOP RING
2 - FOURTH SPEED CLUTCH GEAR
21 - 54 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)
Page 1690 of 2889
REVERSE IDLER AND COUNTERSHAFT
(1) Remove countershaft rear bearing plate (Fig.
30).
(2) Remove countershaft end play shim and rear
bearing cup (Fig. 31).
(3) Remove reverse idler shaft (Fig. 32).(4) Rotate countershaft outward and push reverse
idler gear away from countershaft and toward front
of case (Fig. 33).
(5) Remove idler gear (Fig. 34).
Fig. 29 Mainshaft And Geartrain
1 - MAINSHAFT AND CASE
Fig. 30 Countershaft Rear Bearing Plate
1 - REAR BEARING PLATE
2 - COUNTERSHAFT
Fig. 31 Countershaft End Play Shim And Rear
Bearing Cup
1 - COUNTERSHAFT REAR BEARING CUP
2 - END PLAY SHIM
Fig. 32 Reverse Idler Shaft
1 - REVERSE IDLER SHAFT
BR/BEMANUAL - NV4500 21 - 55
MANUAL - NV4500 (Continued)
Page 1691 of 2889

(6) Keep reverse idler gear bearings and spacer
together for cleaning and inspection (Fig. 35). Insert
idler shaft through gear and bearings to keep them
in place.
(7) Remove idler gear thrust washers from gear
case. Install washers on idler shaft to keep them
together for cleaning and inspection.
(8) To remove countershaft rear bearing ,assemble
Puller Flange 6444-1 and Puller Rods 6444-4 (Fig.
36).
NOTE: Shaft cannot be removed from case until
rear bearing has been removed.(9) Position first Puller Jaw 6449 on bearing cone
(10) Seat puller flange in notch of puller jaw just
installed on bearing cone
(11) Install second Puller Jaw 6449 on bearing and
in notch of puller flange
(12) Slide Retaining Collar 6444-8 over puller jaws
to hold them in place
NOTE: Retaining collar has small lip on one end
and only fits one way over jaws.
(13) Install Puller 6444 on puller rods, then secure
puller to rods with retaining nuts
(14) Tighten puller bolt to remove bearing from
shaft. If bearing is exceptionally tight, tap end of
puller bolt with copper mallet to help loosen bearing.
Fig. 33 Idler Gear Moved Away From Countershaft
1 - REVERSE IDLER GEAR
2 - COUNTERSHAFT
Fig. 34 Reverse Idler Gear
1 - REVERSE IDLER GEAR
2 - DRIVE GEAR BORE
Fig. 35 Idler Gear Components
1 - BEARINGS
2 - REVERSE IDLER GEAR
Fig. 36 Countershaft Rear Bearing
1 - COLLAR 6444-8
2 - JAWS 6449
3 - PULLER 6444
4 - WRENCH
21 - 56 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)
Page 1692 of 2889

(15) Remove bearing puller tools then rotate coun-
tershaft out of gear case (Fig. 37).
(16) ToRemove countershaft front bearing, assem-
ble Puller Flange 6444-1 and Puller Bolts 6444-4
(Fig. 38).
(17) Position first Puller Jaw 6451 on bearing.
(18) Seat puller flange in notch of puller jaw.
(19) Install second Puller Jaw 6451 on bearing and
in notch of puller flange.
(20) Slide Retaining Collar 6444-8 over puller jaws
to hold them in place
NOTE: Retaining collar has small lip on one end
and only fits one way over jaws.
(21) Install puller bridge and bolt assembly 6444
on puller bolts and install retaining nuts
(22) Tighten puller bolt to remove bearing from
shaft. If bearing is exceptionally tight, tap end of
puller bolt with mallet to help loosen bearing.
(23) Remove bearing puller tools.GEAR CASE
(1) Remove countershaft front bearing cap with
mallet or hammer (Fig. 39).
Fig. 37 Countershaft And Case
1 - COUNTERSHAFT
Fig. 38 Countershaft Front Bearing
1 - JAWS 6451
2 - COLLAR 6444-8
3 - PULLER 6444
4 - FLANGE 6444-1
Fig. 39 Countershaft Front Bearing Cap
1 - HAMMER
2 - BEARING CAP
BR/BEMANUAL - NV4500 21 - 57
MANUAL - NV4500 (Continued)
Page 1693 of 2889

(2) Remove countershaft front bearing cup with
Remover 6454 and Handle C-4171 (Fig. 40).
(3) Remove roll pin that secures shift lug on shift
rail in case (Fig. 41). A small pin punch can be mod-
ified by putting a slight bend in it to drive pin com-
pletely out of shift rail (Fig. 41).(4) Remove shift lug rail.
MAINSHAFT
NOTE: Not all of the mainshaft gear and synchro
components are a one-way fit. Some gear and syn-
chro components can be installed backwards. Paint
or scriber gear and synchro components for instal-
lation reference. Then stack geartrain parts in order
of removal to avoid incorrect assembly.
(1) Remove drive gear thrust bearing from end of
mainshaft, if not previously removed.
(2) Remove 3-4 synchro hub, third gear stop ring
and third gear as an assembly (Fig. 42).
Fig. 40 Countershaft Front Bearing Cup
1 - REMOVER 6454
2 - HANDLE C-4171
Fig. 41 Shift Lug Roll Pin
1 - PUNCH
2 - 30É BEND
3 - PIN PUNCH MODIFICATION
4 - SHIFT LUG
5 - SHIFT RAIL
Fig. 42 Third Gear, Stop Ring, And 3-4 Hub
1 - THIRD GEAR
2 - THIRD GEAR STOP RING
3 - 3-4 SYNCHRO HUB
21 - 58 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)
Page 1694 of 2889
(3) Remove third gear bearing from mainshaft
(Fig. 43).
(4) Remove third gear bearing spacer (Fig. 44).
(5) Remove second gear thrust washer snap ring
from mainshaft (Fig. 44).(6) Remove second gear thrust washer (Fig. 45).
Note that washer is notched for locating pin.
(7) Remove thrust washer locating pin (Fig. 46).
Use needle nose pliers to remove pin.
Fig. 43 Third Gear Bearing
1 - THIRD GEAR NEEDLE BEARING
Fig. 44 Snap Ring And Third Gear Bearing Spacer
1 - SECOND GEAR THRUST WASHER
2 - THRUST WASHER SNAP RING
3 - THIRD GEAR BEARING SPACER
Fig. 45 Second Gear Thrust Washer
1 - SECOND GEAR
2 - THRUST WASHER
3 - SECOND GEAR BEARING
Fig. 46 Thrust Washer Locating Pin
1 - THRUST WASHER LOCATING PIN
BR/BEMANUAL - NV4500 21 - 59
MANUAL - NV4500 (Continued)
Page 1695 of 2889
(8) Remove second gear (Fig. 47).
(9) Remove second gear bearing (Fig. 48).
(10) Remove second gear clutch cone snap ring
(Fig. 49). Snap ring is seated in mainshaft synchro
hub groove.(11) Remove second gear clutch cone, synchro
clutch ring and synchro stop ring (Fig. 50).
Fig. 47 Second Gear
1 - SECOND GEAR
Fig. 48 Second Gear Bearing
1 - SECOND GEAR NEEDLE BEARING
Fig. 49 Second Gear Clutch Cone Snap Ring
1 - 1-2 SLEEVE
2 - SNAP RING
3 - SECOND GEAR CLUTCH CONE
Fig. 50 Second Gear Clutch Cone And Ring
1 - 1-2 SLEEVE AND HUB
2 - SYNCHRO STOP RING
3 - CLUTCH RING
4 - SECOND GEAR CLUTCH CONE
21 - 60 MANUAL - NV4500BR/BE
MANUAL - NV4500 (Continued)
Page 1696 of 2889
(12) Remove 1-2 synchro hub snap ring (Fig. 51).
(13) Remove 1-2 synchro sleeve, hub, struts and
springs as an assembly (Fig. 52). Note that tapered
side of sleeve also goes toward front. Do not disas-
semble synchro components unless worn or damaged.(14) Remove first gear synchro stop ring and
clutch ring (Fig. 53).
(15) Remove first gear clutch cone front snap ring
from mainshaft hub (Fig. 54).
Fig. 51 1-2 Sleeve And Hub Snap Ring
1 - 1-2 HUB SNAP RING
2 - 1-2 SLEEVE AND HUB
Fig. 52 1-2 Synchro Sleeve And Hub
1 - 1-2 SLEEVE AND HUB
Fig. 53 First Gear Stop And Clutch Ring
1 - FIRST GEAR CLUTCH RING
2 - FIRST GEAR STOP RING
Fig. 54 First Gear Clutch Gear Front Snap Ring
1 - FIRST SPEED CLUTCH GEAR
2 - CLUTCH GEAR SNAP RING (FRONT)
BR/BEMANUAL - NV4500 21 - 61
MANUAL - NV4500 (Continued)