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chansey 01-06-2008 12:26 AM

NV5600 to FSO6406A 6 speed Fuller
2001 Dodge 3500, 112,000 mi, 5.9 Cummins, 4X 4, Long Bed with NV5600 6 speed transmission. Just went out again for the 3rd time. Failures were at 82,000, 97,000 and now at 112,000. Had regular dealer service. Use it to haul a 40' gooseneck and a Case 1155E loader tipping the scales at 25,000 lbs.

Parts are really hard to find. Last time I had to buy a core for $500 just to get parts for the rebuild by a heavy truck tranny shop. Problem seems to be in the 5-6 gear section with seized bearings.

Spoke with a rebuild shop in Ohio and they have started drilling lube holes in the case and bearing shell and claim they have not had any failures since they started. Anyone have experience with this procedure???

I am changing the NV5600 out for a Fuller FSO-6406A. It has a 660 HP rating with 6th OD at .78. These ratings are close to that of the NV5600.

This is not new or innovative. The Freightliner FL 70 has used the FS6406 6 speed since '93 and Ford has used Fuller's with Cummins on the F650 and F750 since 2003.

Since Fuller never has had a married transfer case, the transfer case would have to be divorced. Need to find the correct clutch set up that is used with the medium duty truck. Would need a #2 SAE flywheel housing and 1-3/4" clutch.

Parts are readily availabe for Fuller and never have to worry about synthetic oils--should be good for 500k miles or more.

Local trans shop has a NV5600 for $1000. Needs output shaft and bearing. Synchros and all gears look good. Mine will be available as soon as I complete the change-over. I suppose someone will want pictures and part numbers.

Bosshogg 01-06-2008 11:02 AM

I wonder if a double disc clutch can be had for the fuller behind a 5.9. Also, if you can get the adapter from the f-word, They are probably using an NV271 transfer case, and if so, that is one heck of a transfer case and some members have swapped them in place of their NV241's

chansey 01-20-2008 12:23 AM

NV5600 is Toast
Took the NV5600 tranny out of the truck yesterday. Knew clutch was going to be an issue when I splt the bell from the flywheel cover--chunks fell out. Only had about 10K mi on it. No disc material on flywheel side and very worn on cover side. Hadn't noticed slipping or noises.

I have a pile of junk for a tranny. The NV5600 has a broken output shaft and no bearings in any of the housings. 5-6 had been a little rough before she quit, just truck'n along a 65 and no load.

I took the first step to replacing the NV5600 with a Fuller. I picked up a SAE#2 flywheel cover (3921296) for $75. There are numerous 5.9 FW covers that will work. Need to get the 14" Cummins flywheel (Ace cat# AF392153) and 14" clutch. Starter is on drivers side. Will need to get a 28MT starter too.

There are numerous 5-6 & 7 speed Fuller and Spicer trannys that will work for this set-up. If I can get the info on the 2008 Ford Expedition, it is equipped with the Fuller FSO6406A (6 speed O/D) and connected to a transfer case. If I can find that adapter, the 4 X 4 will be just like the original. I hope I can remember to take photos and keep track of the part numbers. If you look at the gear ranges and OD, the Fuller FSO6406A is almost identical to the ranges found in the NV5600.


GOODBYE NV5600--hello Roadranger reliability

goosesgarage 01-20-2008 12:36 AM

sounds interesting i want to see when completed:popcorn:

Jakey's'01H.O. 01-20-2008 01:09 AM

just curious why youve had so many problems with these? what were you running for a gear oil? were you not using the clutch while under load?

Cummins5SPD 01-20-2008 02:24 AM

Id like to see some pics if you dont mind.
Too bad your so far away or Id buy that old tranny off you.

chansey 01-20-2008 02:35 AM

The truck has received regular dealer service. The oil it had in it was the Mopar transmission fluid P/N 4874464. Other than burnt black, the oil level was almost full when it failed.

If I had it to do over again--or knowing what I know now, I would make a dip stick for the PTO cover and extend it into the hood as well as tap the cover for a digital temp sensor. I would monitor both constantly. Heat kills the tranny.

Here are a few of the other issues I've had with the truck----while it was under warranty

2 transfer pumps
2 injection pumps
3 fuel sending units in the tank
steering/brake booster
Gooseneck trailer electrical hook-up

In spite of all this, I will keep the Cummins---been the F & C diesel model route and they were worse. Still have my parked and abandoned 1997 Chev 3500 that needs a transplant. Gave the 1996 F350 Ford away for $500 just so I wouldn't have to look at it. Neither made the 150K mark.

MMeier 01-20-2008 03:41 AM

I'd like to see pics also! Sick and tired of so called experts trying to build me a decent 5600!:$: Have my spare in garage now, lost 3rd and 4th in it a while back. Have to service current one soon, going to try the Torco RTF ( racing trans fluid) in it this time and see if it frees up the shifting somewhat. WTH is Rio Chama???

Chowderhead72 01-20-2008 03:56 AM

Um; 2008 excursion?

kaw19razor 01-20-2008 04:38 AM

My reverse gear Just ceized up on my nv4500... Lookin to swap in a different tranny. I was thinking about the 5600, but now that you mention a fuller... Do you have an idea of how much it is going to cost?

Valv 01-20-2008 09:18 AM

8 Attachment(s)
Check the new Sterling trucks, some have the new 6.7l with Fuller FS-6406A, some use the FULLER FS-5406A

chansey 01-20-2008 11:11 AM

NV5600 to Fuller
Ok, Rio Chama is a rural community in northern New Mexico half way between Espanola and Abiquiu on Hwy 84/285 (100 miles north of Albuq or 45 miles NW of Santa Fe). Have a 6 acre site with 300 feet of river frontage and have all my goodies on it.

As for total cost for a change out of the NV5600, it will depend on a number of things such as your location, parts sources and freight cost. Here in NM we only have a few "big" truck wreckers so parts are not easy to find and freight is a real problem.

The ideal change over package would be to find a medium duty truck with a 5.9 Cummins such as a Freightliner FL60 or FL70, Ford F550, 650, 750, F800, Sterling and others where you can purchase the entire package from starter, flywheel, flywheel cover, Fuller bell, clutch and tranny. A wrecker would much rather sell a package than pieces. I believe that all could be had for less than $3,000. I'm thinking that with the sources I have, I'll be in at $1,500. Don't overlook the 4BT's in bread trucks, UPS and others---the set-up is the same if they have the 5 or 6 speed Fuller.

Need to remember, if you have the 4 X 4, you will have to divorce the NP271 and have some additional support and driveline costs too. We need to find a source for that Fuller 4 X 4 adapter.

Completed mockup of 4 X 4 Adapter

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