With W55, and W56 Transmissions

1. INSTALL OUTPUT SHAFT TO INTERMEDIATE PLATE

(a) Before installing the output shaft, use SST to remove the counter gear center bearing outer race.
SST 09608-35014 (09608-06020, 09608-06090)
HINT: Install the outer race after installing the counter gear.

(b) Install the output shaft into the intermediate plate by pulling on the output shaft and tapping on the intermediate plate.

2. INSTALL INPUT SHAFT AND COUNTER GEAR
(a) Apply gear oil to the needle roller bearing.
(b) Install needle roller bearing to the input shaft.

(d) Using SST, install the counter gear center bearing outer race.
SST 09316-60010 (09316-00010)
HINT: Be careful not to damage the bearing rollers.

3. INSTALL BEARING RETAINER
(a) Using snap ring pliers, install the bearing snap ring.
HINT: Be sure the snap ring is flush with the intermediate plate surface.

(b) Using a torx socket wrench, tighten the screws. (Torx socket wrench T40 09042-00020)
Torque: 130 kg-cm (9 ft-lb, 13 N-m)

4. INSTALL REVERSE GEAR
Using SST, install the reverse gear.
SST 09312-20011(09313-00010, 09313-00030, 09313-00040, 09313-00050)

5. INSTALL SNAP RING
(a) Select a snap ring that will allow minimum axial play.

(b) Using a snap ring pliers, install snap ring.

6. INSTALL FIFTH GEAR AND OUTPUT SHAFT REAR BEARING
Using SST, install the 5th gear and rear bearing.
SST 09312-20011 (09313-00010, 09313-00030, 09313-00040, 09313-00050)

7. INSTALL SNAP RING
(a) Select a snap ring that will allow minimum axial play.

(b) Using a screwdriver and a hammer, install snap ring.

8. INSTALL CLUTCH HUB NO.3
Using SST, drive in clutch hub No.3. SST 09316-60010 (09316-00010, 09316-00070)
HINT: When installing the clutch hub, support the countershaft in front with a 3-5 Ib hammer or equivalent.

9. INSTALL SNAP RING
(a) Select a snap ring that will allow minimum axial play.

(b) Using a screwdriver and a hammer, install snap ring.

10. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE ROLLER BEARING AND COUNTER FIFTH GEAR
(a) Install the bearing spacer.
(b) Apply gear oil to the needle roller bearings.
(c) Assemble the counter 5th gear, synchronizer ring and needle roller bearings.

(d) Install the 5th gear assembly with the synchronizer ring slots aligned with the shifting keys.

11. INSTALL SPACER AND BEARING
(a) Install the spacer.
(b) Install the bearing with the ball shield toward the rear.
(c) Using a hammer and socket wrench, drive in the bearing.
HINT: When driving in the bearing, support the countershaft in front with a 3-5 lb hammer or equivalent.

12. INSTALL SNAP RING
(a) Select a snap ring that will allow minimum axial play.

(b) Using a snap ring pliers, install snap ring.

13. (2WD)
INSTALL SPEEDOMETER DRIVE GEAR
(a) Put a clip on the output shaft and install the drive gear clip into the slot.
(b) Slide the drive gear with clip and fit the clip into the holes.

14. MEASURE COUNTER FIFTH GEAR THRUST CLEARANCE
Using a feeler gauge, measure counter 5th gear thrust clearance.
Standard clearance:
0.10 - 0.41 mm (0.0039 - 0.0161 in.)

15. INSTALL SHIFT FORKS, SHIFT FORK SHAFTS AND REVERSE IDLER GEAR
(a) Install the reverse idler gear and shaft.
(b) Install shift fork No.3, shift fork shaft No.3 and reverse shift arm.
(1) Coat the pin with MP grease and insert it into the reverse shift head hole.

(2) Insert shift fork shaft No.3 through shift fork No.3 and the reverse shift arm.
(3) Align shift fork No.3 with the hub sleeve No.3 groove, put the reverse shift arm into the pivot of bearing retainer and align the reverse shift arm shoe with the reverse idler gear groove. Install shift fork shaft No.3 to the intermediate plate.

(c) Install shift fork shaft No.4.
(1) Push the pin, which was inserted into the reverse shift arm hole, into the groove of shift fork shaft No.3.

(2) Install shift fork shaft No.4 to the intermediate plate over the reverse shift arm.

(d) Using a pin punch and a hammer, drive in the slotted spring pin until it is flush with the fork.

(e) Appply MP grease to interlock pin No.3 and install the pin into the intermediate plate hole.

(f) Install shift fork No.2 and shift fork shaft No.2.
(1) Apply MP grease to interlock No.2 pin and install the pin into the shaft hole.

(2) Place shift fork No.2 into the groove of hub sleeve No.2.
(3) Install shift fork shaft No.2 to the shift fork through the intermediate plate.

(g) Install the snap ring of shift fork shaft No.2.

(h) Appply MP grease to interlock pin No.1 and install the pin into the intermediate plate.

(i) Install shift fork No.1 and shift fork shaft No.1.
(1) Install shift fork No.1 into the groove of hub sleeve No.1.
(2) Insert shift fork shaft No.1 to the shift fork through the intermediate plate.

(j) Install the snap ring of shift fork shaft No. 1.

(k) Install the shift fork No.1 and No.2 set bolts with lock washers.
Torque: 125 kg-cm (9 ft-lb, 12 N-m)

(l) Using pliers, stake the bolts with lock washers.

16. INSTALL LOCKING BALL AND SPRING
(a) Install the balls and springs into each hole.

(b) Apply liquid sealer to the plug threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(c) Using SST, tighten the four plugs.
SST 09313-30021
Torque: 250 kg-cm (18 ft-lb, 25 N-m)

17. INSTALL REVERSE IDLER GEAR SHAFT STOPPER
Install the reverse idler gear shaft stopper and tighten the bolt.
Torque: 250 kg-cm (18 ft-lb, 25 N-m)

18. DISMOUNT INTERMEDIATE PLATE FROM VISE
(a) Dismount the intermediate plate from the vise.
(b) Remove the bolts, nuts, plate washers and gasket.

19. (4WD)
INSTALL SLEEVE YORK
Using SST, install sleeve york to the output shaft.
SST 09950-20017

20. INSTALL TRANSMISSION CASE TO INTERMEDIATE PLATE
(a) Apply seal packing to the transmission case as shown.
Seal packing: Part No. 08826-00090, THREE BOND 1281 or equivalent

(b) Align each bearing outer race and each shift fork shaft end with the case holes.
(c) Using a plastic hammer, tap on the case to install it.

21. INSTALL BEARING SNAP RINGS
Using snap ring pliers, install the two snap rings.

22. INSTALL FRONT BEARING RETAINER
(a) Apply seal packing to the retainer as shown, and install it to the transmission case.
Seal packing: Part No. 08826-00090, THREE BOND 1281 or equivalent

(b) Apply liquid sealer to the bolt threads.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(c) Install and torque the bolts.
Torque: 250 kg-cm (18 ft-lb, 25 N-m)

23. INSTALL EXTENSION HOUSING (2WD) OR TRANSFER ADAPTOR (4WD)
(a) Insert shift and select lever into the extension housing (2WD) or the transfer adaptor (4WD).

(b) Apply seal packing to the extension housing (2WD) or the transfer adaptor (4WD).
Seal packing: Part No. 08826-00090, THREE BOND 1281 or equivalent

(d) Install shift lever housing to shift and select lever shaft, push in the extension housing (2WD) or the transfer adaptor (4WD).
(e) Install and torque the bolt.
Torque: 400 kg-cm (29 ft-lb, 39 N-m)

(f) Install nine bolts to the extension housing (2WD) or the transfer adaptor (4WD).
(g) Torque the bolts.
Torque: 375 kg-cm (27 ft-lb, 37 N-m)

24. AFTER INSTALLING EXTENSION HOUSING (2WD) OR TRANSFER ADAPTOR (4WD), CHECK FOLLOWING ITEMS:
(a) Check to see that input shaft and output shaft rotate smoothly.
(b) Check to see that shifting can be made smoothly to all positions.

25. INSTALL RESTRICT PINS
(a) Install the restrict pins together with a gasket.
HINT: (4-Speed)
Install the screw plug on the reverse gear side.
(5-Speed)
Install the black pin on the reverse gear/5th gear side.
(b) Torque the restrict pins.
Torque: 410 kg.cm (30 ft-lb, 40 N-m)

26. INSTALL CLUTCH HOUSING
(a) Install the clutch housing.
(b) Install and torque the bolts.
Torque: 375 kg-cm (27 ft-lb, 37 N-m)

27. INSTALL SHIFT LEVER RETAINER
(a) Install the shift lever retainer with a oil baffle.
(b) Install and torque the six bolts.
Torque: 185 kg-cm (13 ft-lb, 18 N-m)

28. (2WD)
INSTALL SPEEDOMETER DRIVEN GEAR
(a) Install the speedometer driven gear.
(b) Install the bolt with lock plate.
(c) Torque the bolt.
Torque: 130 kg-cm (9 ft-lb, 13 N-m)
29. INSTALL BACK-UP LIGHT SWITCH
Install and torque the back-up light switch.
Torque: 410 kg-cm (30 ft-lb, 40 N-m)
30. INSTALL RELEASE FORK AND BEARING