QU10154 1992-1995.5 38 Tooth NV4500 Countershaft Front Gear is the big driven gear on the front of your early production Countershaft. QU10154 fits 1992-1995.5 5.61 ratio, New Venture NV4500 5 Speed Manual Transmissions with modular countershafts in 1992-95 Dodge and 1995 GM trucks. Your matching Main Drive Gear (Input Shaft) must have 22 teeth. QU10154 is driven by the input shaft, but it is also called the Countershaft Drive Gear or Countershaft 4th gear. Imported.
Dan the Gear Man® Tech Note 1:
QU10154 is a 38 tooth, keyed, press-fit gear that fits QU10090 Countershaft. The transmissions that use this gear will be early production NV4500 transmissions with 5.61:1 1st and reverse gear ratios. The matching input shaft MUST have 22 teeth. QU10154 Gear and QU10090 Countershaft can be replaced by QU10078 Countershaft assembly. QU10154 is NOT compatible with 1992-1994 20 tooth input, GM NV4500 transmissions with 6.34:1 low gear ratio.
Dan the Gear Man® Tech Note 2:
Five different 22 tooth input shafts match QU10154 Countershaft Gear depending upon the year, make and model.
|Year||Make||Engine||Part Number||Spline Size||Notes|
|1992-1993||Dodge||Gas||QU10054||1" x 19|
|1994-1995||Dodge||Gas V8||QU10046||1-1/8" x 10||NV4500LD|
|1994-1995||Dodge||V10 or Diesel||QU10199 or QU10076||1-1/4" x 10||NV4500HD|
|1994-1995||Dodge||Diesel||QU10261||1-3/8" x 10||Upgrade Part|
|1995||GM||All||QU10059 or QU10077||1-1/8" x 10|
Dan the Gear Man® Tech Note 3:
Typically, Countershaft gear tooth failures occur from one of three causes: low or improper oil, clutch pilot bearing failures (which cause misalignment of the input shaft), and excessive horsepower/torque (over 275hp/600 Lb-Ft of torque). Broken 3rd gear teeth are almost always caused by exceeding the demonstrated 600 Lb.Ft input strength limit of the NV4500.
There are claims that cryogenically treating NV4500 gears will increase gear strength as much as 30%. Unfortunately, there does not seem to be any peer-reviewed documentary evidence to support those claims. Cryogenically treating gears is primarily a cold-hardening process that changes the molecular structure of steel to decrease wear while retaining or increasing hardness. If properly done, it is probable the cryogenic treatment process does slightly increase the impact and fatigue resistance of NV4500 gears, but not enough to significantly increase the ability of an NV4500 transmission to reliably handle more than 600 Lb.-Ft. of input torque especially considering the maximum factory torque rating of the NV4500HD transmission is only 460 Lb.-Ft..
Dan the Gear Man® Tech Note 4:
Need Torque Specs or Rebuild procedures? Order my 116 page, full color illustrated NV4500 Rebuild Manual.
You will need some special tools to correctly service your NV4500 Transmission. The chart below lists our current NV4500 Special Tools for popular models.
TOOLS for SPECIFIC NV4500 MODELS
|5th Gear Nut
Torx® Cross Bolt
|Output Seal Installer||N/A||QT1801||N/A||QT2058
|Not Used||Not Used|
|Tailshaft Bushing Remover and Installer||Not Used||Not Used||Not Used||QT2044||Not Used||Not Used|
TOOLS For ALL NV4500 MODELS
Front Bearing Cup Installer
|QT1802||Use with QT1101 or QT1119 Driver Handle. Also can use flat side to install Dodge 4x4 Rear Output Seal|
|Countershaft Front Bearing Installer||QT2004||Can also use to press 3-4 Synchro Hub on original equipment mainshafts|
|Input Bearing & Countershaft Rear Bearing Installer||QT2005||Can also use to install Input Seal|
|Input Bearing Cup Installer||QT1801||Use with QT1100, QT1101, QT1116, or QT1119 Driver Handle.|
|Countershaft Support||QT2006||Use to support front of countersahft when installing countershaft rear bearing|
|1-2 Synchronizer Support||QT2008||Use to support 1-2 synchronizer hub during synchronizer assembly|
|10mm 1/2" Drive 12 Point Socket||QT1020||USA Made Impact Socket for Factory Tailshaft Housing Bolts|
|Long Shank Punch for Shift Lug||QT9300||3/16" x 8" Shank for 5th Gear Shift Lug Roll Pin|
Dan the Gear Man® Tech Note 5:
Matching Parts for QU10154 Countershaft Gear:
QU10090 Modular Countershaft
QU10078 One Piece Countershaft Assembly for 5.61 Ratio
QK1129 Drive Key Kit
QU10174 30 Tooth Countershaft 3rd Gear
QU90020 NV4500 Manual Transmission Oil
TM1003 NV4500 Shop Manual
V1003DVD NV4500 Overhaul Video
For Input Gears, see Tech Note 2
Chevy and GMC:
1995 C1500, K1500, C2500, K2500, C3500, C3500HD, K3500 with NV4500 5 Speed
Dodge and Ram:
1992-1993 D and W Series with Gas Engines and New Venture NV4500 5 Speed Manual Transmission
1994-1995 Ram 2500, Ram 3500 with Manual Transmission