Finally. And we're off! Unicorn 4500 complete rebuild.

[SquareRoot]

Well, it wasn't cheap but I only want to do this once. Premium Rebuild Kit from Torque King for my one year only 4500. The surrogate 4500 (bought used) I'm currently running is starting to sound like a rock crusher. Why is my spare a Unicorn you ask? Because it's a mid year unit (94) that has the old mounting bolt pattern but with the newer 95+ higher gears. Now I got both gear sets in the same case that fits my AA bell housing.

So prepare to follow along and see how this awesome transmission is put together.

 

[Juggernaut]

Did my 94 NV4500 in 2015. One of the easiest trannies I've ever built. The manual they have is Awesome. Hopefully you have the big flat nosed snap ring pliers and a good press. And make sure you have a flat, clean workspace when you go to putting those synchronizer sliders together. I had one of those little springs shoot out, like to never found it. They can be a little frustrating

 

[bluex]

The 4500 in my dually grinds going into 3rd an 4th so I'll definitely be watching this one! I've been thinking about rebuilding it myself rather than dropping 2k on it.

 

[Juggernaut]

If you're thinking about rebuilding this transmission, get this manual from Torque King. It is very well written with illustrations and step by step instructions. You will need a few specialty tools. Dial indicator, bearing pullers, and a press. There are 2 tapered roller bearings that need to be installed with the cup side out. They can be hammered on, but I believe it is to easy to damage the cage, and I don't recommend it. There's a race in a blind hole in the input shaft housing. Easiest way to get it out is to run a weld bead around the inside of the race, let it cool and the race will fall right out. Last is a large set of locking snap ring pliers. It can be done with standard snap ring pliers, I did it this way but it is a PITA! Spread them wide enough to get it out of the groove and work it off with flat screwdrivers

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