W55, W56 Transmissions (2WD & 4WD)

NOTE: For measurements to be taken during disassembly, refer to Disassembly of Transmission. Service and Repair






INSPECTION OF COUNTER GEAR
1. MEASURE COUNTER FIFTH GEAR OIL CLEARANCE
(a) Install spacer, counter 5th gear and needle roller _ bearing to counter gear.
(b) Using a dial indicator, measure counter 5th gear oil clearance.
Standard clearance:
0.009 - 0.062 mm (0.0004 - 0.0024 in.)
Maximum clearance:
0.15 mm (0.0059 in.)
If the clearance exceeds the limit, replace the counter gear or needle roller bearing or counter 5th gear.





2. INSPECT COUNTER GEAR
Using a micrometer, measure the outer diameter of the counter shaft journal.
Minimum diameter:
Part A 26.835 mm (1.0564 in.)
Part B 29.81 mm (1.1736in.)





3. INSPECT SYNCHRONIZER RINGS
(a) Turn the ring and push it in to check the braking action.





(b) Measure the clearance between the synchronizer ring back and the gear spline end.
Standard clearance:
0.7 - 1.7 mm (0.028 - 0.067 in.)
Minimum diameter:
0.5 mm (0.020 in.)
If the clearance is less than the limit, replace the synchronizer ring.





4. MEASURE CLEARANCE OF SHIFT FORKS AND HUB SLEEVES
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the limit, replace the shift fork or hub sleeve.