You can always switch the guts to another case. It so happens that going up hills with a heavy load with the pedal to the metal is hard on input shafts/gears when in 5th gear. Unfortunately, there are no new overdrive input gear/shafts around. If you find an overdrive NP540/541/542 with ANY bolt pattern, if the gears are good, BUY IT!. The NP540 is the shortest heavy duty 5spd I know of. A 540 has a capacity of about 330 ft-lb and should be fine for any typical PW/M37 repower. The main difference between the 540 and 541/542 is, I believe, torque capacity.
In non overdrive configuration, 5th is 1.00, 4th 1.22, 3rd about 2.10, 1st and 2nd same as OD but there are many other ratio sets for the non overdrive versions. In overdrive configuration, the NP540 has the following ratios: 6.06 (1st and reverse), 3.31, 1.81, 1.00, 0.82. There may have been a very few in the old great big W300s. The NP540/541/542 were generally used in 1.5 ton to 2.5 ton trucks. Overdrive 540 was more of a close ratio withĪn. These are the ratios for the direct in 5th 540. In Reply to: New Process 540 transmission posted by BBNut on Novemat 19:35:41: Posted by Gary Robertson on Novemat 12:59:14: Re: New Process 540 transmission Re: New Process 540 transmission
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