With W46, W55, and W56 Transmissions

1. REMOVE BACK-UP LIGHT SWITCH, SPEEDOMETER DRIVEN GEAR (2WD), SHIFT LEVER RETAINER AND RESTRICT PINS

2. REMOVE CLUTCH HOUSING FROM TRANSMISSION CASE

3. 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).

NOTE: Leave the gasket attached to the intermediate plate.

4. REMOVE FRONT BEARING RETAINER AND BEARING SNAP RINGS

5. 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.

NOTE: Leave the gasket attached to the intermediate plate.

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

CAUTION: 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.

7. 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.

8.-1 (4-Speed)
REMOVE SHIFT FORKS, SHIFT FORK SHAFTS AND REVERSE IDLER GEAR
(a) Pry out the lock washers of No. 1 and No. 2 shift forks, and remove the two set bolts.

(b) Using two screwdrivers and a hammer, tap out the two snap rings of No. 1 and No. 2 fork shafts.

(d) Remove the reverse idler gear and shaft.

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

(f) Using a magnetic finger, remove No. 1 and No. 2 interlock pins.

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

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

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

8.-2 (5-Speed)
REMOVE SHIFT FORKS, SHIFT FORK SHAFTS AND REVERSE IDLER GEAR
(a) Pry out the lock washers of No. 1 and No. 2 shift forks, and remove the two set bolts.

(b) Using two screwdrivers and a hammer, tap out the two snap rings of No. 1 and No. 2 fork shafts.

(d) Remove the reverse idler gear and shaft.

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

(f) Using a magnetic finger, remove No. 1 and No. 2 interlock pins.

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

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

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

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

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

9. (2WD)
REMOVE SPEEDOMETER DRIVE GEAR
Pry out both ends of the clip and remove the drive gear.

10. (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.)

11. (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

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

(c) Remove the spacer.

12. (5-Speed)
REMOVE NO. 3 HUB SLEEVE ASSEMBLY
(a) Using two screwdrivers and a hammer, tap out the snap ring.

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

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

13. (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

14. REMOVE REVERSE GEAR
(a) Using snap ring pliers, remove the snap ring.
(b) Using SST, remove the reverse gear.
SST 09950-20017

15. REMOVE CENTER BEARING RETAINER
(a) Using a torx socket wrench, unscrew the torx screws and remove the retainer.
(b) Using snap ring pliers, remove the snap ring.

16. 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.

17. MEASURE EACH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance of each gear.

Standard clearance:
0.10 - 0.25 mm (0.0039 - 0.0098 in.)
Maximum clearance:
0.30 mm (0.0118 in.)

18. REMOVE OUTPUT SHAFT CENTER BEARING AND FIRST GEAR ASSEMBLY
(a) Shift No. 1 hub sleeve onto the 2nd gear.
(b) Using a press, remove the center bearing, 1st gear, needle roller bearing, inner race and synchronizer ring.

19. REMOVE LOCKING BALL

20. REMOVE NO. 1 HUB SLEEVE ASSEMBLY, SECOND GEAR AND NEEDLE ROLLER BEARING
Using a press, remove the parts from the shaft as an assembly.

21. REMOVE NO. 2 HUB SLEEVE ASSEMBLY AND THIRD GEAR
(a) Using snap ring pliers, remove the snap ring.

(b) Using a press, remove No. 2 hub sleeve, synchronizer ring and 3rd gear.