W55, W56 Transmissions (2WD & 4WD)

INSPECTION OF OUTPUT SHAFT ASSEMBLY
1. 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.)





2. MEASURE EACH GEAR OIL CLEARANCE
Using a dial indicator, measure the oil clearance of each gear.
Standard clearance:
1st and 2nd gear
0.009 - 0.060 mm (0.0004 - 0.0024 in.)
3rd gear
0.060 - 0.103 mm (0.0024 - 0.0041 in.)
Maximum clearance:
1st and 2nd gear
0.15 mm (0.0059 in.)
3rd gear
0.20 mm (0.0079 in.)
If the clearance exceeds the limit, replace the gear, shaft or needle roller bearing.





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 clearance:
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.





5. INSPECT OUTPUT SHAFT AND INNER RACE
(a) Using calipers, measure the output shaft flange thickness.
Minimum thickness: 5.60 mm (0.2205 in.)





(b) Using calipers, measure the inner race flange thick- ness.
Minimum thickness: 4.76 mm (0.1874 in.)





(c) Using micrometer, measure the outer diameter of the output shaft journal.
Minimum diameter:
2nd gear 42.835 mm (1.6841 in.)
3rd gear 37.80 mm (1.4882 in.)





(d) Using micrometer, measure the outer diameter of the inner race.
Minimum diameter: 42.855 mm (1.6872 in.)





(e) Using a dial indicator, check the shaft runout.
Maximum runout: 0.06 mm (0.0024 in.)