Reverse Idler Gear

Reverse Idler Gear









Disassembly

1. Remove the clip.





2. Remove the thrust washer.





3. Remove the needle bearing.





4. Remove the reverse idler gear.





5. Remove the friction damper.





6. Remove the reverse synchronizer assembly.





7. Remove the reverse idler gear washer.





8. Remove the reverse idler gear.





9. Remove the reverse idler gear washer.





Assembly

1. Install the reverse idler gear washer.





2. Install the reverse idler gear.





3. Install the reverse idler gear washer.





4. Install the reverse synchronizer assembly.
- Reverse clutch hub inspection.
- Inspect the clutch hub sleeve and hub operation. Install new components as necessary.

- Inspect the gear teeth for damage, wear, and cracks. Install new components as necessary.

- Measure the clearance between the hub sleeve and shift forks. If it exceeds the maximum specification replace the hub sleeve and shift fork as a set.

Reverse Clutch Hub Sleeve and Shift Fork Clearance







- Reverse synchronizer ring inspection.
- Inspect the synchronizer teeth for damage, wear and cracks. Install new components as necessary.

- Inspect the tapered surface for wear or cracks. Install new components as necessary.

- NOTE: Set the synchronizer ring squarely on the gear and measure around the circumference.
Measure the clearance between the synchronizer ring and the flank surface on the gear. If it is less than minimum specification, replace the synchronizer ring.

Reverse Synchronizer Ring Clearance











5. Install the friction damper onto the reverse idler gear.





6. NOTE: The reverse idler gear is not serviced separately. A kit consisting of the output shaft reverse gear, the countershaft reverse gear and the reverse idler gear is available for service. All 3 gears in the kit must be installed. The replacement gears are not compatible with the existing gears.

Install the reverse idler gear.

- Reverse idler gear inspection.
- Inspect the synchronizer cones for wear. Install new components as necessary.

- Inspect the gear teeth for damage, wear and cracks. Install new components as necessary.

- Inspect the synchronizer ring matching teeth for damage or wear. Install new components as necessary.





7. Install the needle bearing.





8. Install the thrust washer.





9. Install the clip.





10. Measure the reverse idler gear component dimension.

Reverse Thrust Washer Thickness






- If the reverse idler gear component dimension is not within specification, install a thrust washer of the correct thickness.