With W46, W55, and W56 Transmissions

DISASSEMBLY OF TRANSMISSION

1. REMOVE RELEASE FORK AND BEARING
2. REMOVE BACK-UP LIGHT SWITCH, SPEEDOMETER DRIVEN GEAR (2WD)





3. REMOVE CLUTCH HOUSING FROM TRANSMISSION CASE
Remove nine bolts and clutch housing from transmission case.





4. REMOVE SHIFT LEVER RETAINER
(a) Remove the six bolts.
(b) Remove shift lever retainer and oil baffle plate.








5. REMOVE RESTRICT PIN








6. REMOVE EXTENSION HOUSING (2WD) OR TRANSFER ADAPTOR (4WD)
(a) Remove the shift lever housing set bolt.





(b) Remove the nine bolts.
(c) Using a plastic hammer, tap the extension housing (2WD) or the transfer adaptor (4WD).
(d) Disengage the shift and select lever from the shift head.
(e) Pull out the extension housing (2WD) or the transfer adaptor (4WD).





7. REMOVE FRONT BEARING RETAINER AND BEARING SNAP RINGS
(a) Remove seven bolts and front bearing retainer.





(b) Using a snap ring pliers, remove two bearing snap rings.





8. SEPARATE INTERMEDIATE PLATE FROM TRANSMISSION CASE
(a) Using a plastic hammer, carefully tap the transmission case.
(b) Pull the transmission case from the intermediate plate.





9. MOUNT INTERMEDIATE PLATE IN VISE
(a) Use two long clutch housing bolts, plate washers and suitable nuts as shown.

NOTICE: Install the plate washers in reverse of normal. Increase or decrease plate washers so that the bolt tip and the front tip surface of the nut are aligned.

(b) Mount the intermediate plate in a vise.





10. REMOVE LOCKING BALL AND SPRING
(a) Using SST, remove the four plugs.
SST 09313-30021





(b) Using a magnetic finger, remove the three springs and balls.





11. (4WD)
REMOVE SLEEVE YOKE
Using a SST, remove sleeve yoke from output shaft as shown.
SST 09950-20017





12.1 (4-Speed)
REMOVE SHIFT FORKS, SHIFT FORK SHAFTS AND REVERSE IDLER GEAR
(a) Pry out the lock washers of shift fork No.1 and remove the set bolts.





(b) Pry out the lock washers of shift fork No.2 and remove the set bolts.





(c) Using two screwdrivers and a hammer, tap out the snap ring of shift fork shaft No. 1.





(d) Using two screwdrivers and a hammer, tap out the snap ring of shift fork shaft No.2.





(e) Remove the reverse idler gear shaft stopper.






(f) Remove the reverse idler gear and shaft.





(g) Remove shift fork No.1 and shift fork shaft No.1.





(h) Using a magnetic finger, remove interlock pin No.1 and No.2.





(i) Remove shift fork No.2 and shift fork shaft No.2.





(j) Using magnetic finger, remove interlock pin No.3.





(k) Remove shift fork shaft No.3 with reverse shift arm.





12.-2 (5-Speed)
REMOVE SHIFT FORKS, SHIFT FORK SHAFTS AND REVERSE IDLER GEAR
(a) Pry out the lock washer of shift fork No.1 and remove the set bolt.





(b) Pry out the lock washer of shift fork No.2 and remove the set bolt.





(c) Using two screwdriver and a hammer, tap out the snap ring of shift fork shaft No. 1.





(d) Using two screwdrivers and a hammer, tap out the snap ring of shift fork shaft No.2.





(e) Remove the reverse idler gear shaft stopper.





(f) Remove the reverse idler gear and shaft.





(g) Remove shift fork No. 1 and shift fork shaft No. 1.





(h) Using a magnetic finger, remove interlock pin No.1 and No.2.





(i) Remove shift fork No.2 and shift fork shaft No.2.





(j) Using a magnetic finger, remove interlock pin No.3.





(k) Using a pin punch and a hammer, drive out fork shaft No.3 pin.





(l) Pull out shift fork shaft No.4.





(m) Remove shift fork No.3, shift fork shaft No.3 and reverse shift arm with the pin.





13. (2WD)
REMOVE SPEEDOMETER DRIVE GEAR
Pry out both ends of the clip and remove the drive gear.





14. (5-Speed)
MEASURE COUNTER FIFTH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the counter 5th gear thrust clearance.

Standard clearance:
0.10 - 0.41 mm (0.0039 - 0.0161 in.)
Maximum clearance:
0.46 mm (0.0181 in.)





15. (5-Speed)
REMOVE COUNTER REAR BEARING, SPACER, COUNTER FIFTH GEAR AND NEEDLE ROLLER BEARING
(a) Using snap ring pliers, remove the snap ring.





(b) Using SST, remove the rear bearing, spacer, 5th gear and bearing.
SST 09213-36020

NOTICE: Be careful not to catch the output shaft rear bearing roller on the counter 5th gear.

(c) Remove the spacer.





16. (5-Speed)
REMOVE HUB SLEEVE NO.3 ASSEMBLY
(a) Using two screwdrivers and a hammer, tap out the snap ring.





(b) Using SST, remove clutch hub No.3.
SST 09950-20017

NOTICE: Latch the claw of the SST onto the clutch hub not the shifting key retainer.





17. (5-Speed)
REMOVE OUTPUT SHAFT REAR BEARING AND FIFTH GEAR
(a) Using two screwdrivers and a hammer, tap out the snap ring.





(b) Using SST, remove the rear bearing and 5th gear.
SST 09312-20011(0931 3-00030, 09313-00040 09313-00050)





18. REMOVE REVERSE GEAR
(a) Using snap ring pliers, remove the snap ring.





(b) Using SST, remove the reverse gear.
SST 09950-20017





19. REMOVE CENTER BEARING RETAINER
(a) Using a torx socket wrench, unscrew the torx screws and remove the retainer.
(Torx socket wrench T40 09042-00020)





(b) Using snap ring pliers, remove the snap rings.





20. REMOVE OUTPUT SHAFT AND COUNTER GEAR AS A UNIT FROM INTERMEDIATE PLATE
(a) Remove the output shaft, input shaft and counter gear as a unit from the intermediate plate by pulling on the counter gear and tapping on the intermediate plate with a plastic hammer.
(b) Remove the input shaft from output shaft.





21. INSPECT BACK-UP LIGHT SWITCH
Check that there is continuity between terminals.





If operation is not as specified replace switch.