REVERSE IDLER GEAR COMPONENT ASSEMBLY

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1. Assemble the reverse idler gear component in the order shown in the figure.

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1

Reverse gear shaft

2

Thrust washer

3

Reverse idler gear

4

Clutch hub sleeve

(See Clutch Hub Sleeve Assembly Note.)

5

Thrust washer

6

Reverse synchronizer key spring

7

Synchronizer ring

8

Reverse idler gear

9

Friction damper

10

Needle bearing

11

Shim

(See Shim Assembly Note.)

12

Clip

Clutch Hub Sleeve Assembly Note

1. Assemble the clutch hub sleeve to the reverse idler gear.

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Note

• The clutch hub sleeve can be assembled to only the specified position due to the shape of its spline. Therefore, it is necessary to find the position where the clutch hub sleeve can be assembled smoothly while gradually rotating the clutch hub sleeve in the rotation direction.

Shim Assembly Note

1. Measure distance A shown in the figure from the thrust washer to the needle bearing.

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2. Select a shim of the appropriate thickness referring to the measured values in the table.

Distance A measured value

Appropriate shim thickness (mm {in})

Equal to or more (mm {in})

Less than (mm {in})

56.495 {2.2242}

56.525 {2.2254}

3.150 {0.1240}

56.525 {2.2254}

56.575 {2.2274}

3.100 {0.1220}

56.575 {2.2274}

56.625 {2.2293}

3.050 {0.1201}

56.625 {2.2293}

56.675 {2.2313}

3.000 {0.1181}

56.675 {2.2313}

56.725 {2.2333}

2.950 {0.1161}

56.725 {2.2333}

56.775 {2.2352}

2.900 {0.1142}

56.775 {2.2352}

56.800 {2.2362}

2.850 {0.1122}

Distance A measured value	Appropriate shim thickness (mm {in})
56.495 {2.2242}	56.525 {2.2254}	3.150 {0.1240}
56.525 {2.2254}	56.575 {2.2274}	3.100 {0.1220}
56.575 {2.2274}	56.625 {2.2293}	3.050 {0.1201}
56.625 {2.2293}	56.675 {2.2313}	3.000 {0.1181}
56.675 {2.2313}	56.725 {2.2333}	2.950 {0.1161}
56.725 {2.2333}	56.775 {2.2352}	2.900 {0.1142}
56.775 {2.2352}	56.800 {2.2362}	2.850 {0.1122}

3. Align the notch of the shim with the projection of the friction damper, and assemble the selected shim.

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1	Reverse gear shaft
2	Thrust washer
3	Reverse idler gear
4	Clutch hub sleeve (See Clutch Hub Sleeve Assembly Note.)
5	Thrust washer
6	Reverse synchronizer key spring
7	Synchronizer ring
8	Reverse idler gear
9	Friction damper
10	Needle bearing
11	Shim (See Shim Assembly Note.)
12	Clip

Distance A measured value		Appropriate shim thickness (mm {in})
Equal to or more (mm {in})	Less than (mm {in})	Appropriate shim thickness (mm {in})
56.495 {2.2242}	56.525 {2.2254}	3.150 {0.1240}
56.525 {2.2254}	56.575 {2.2274}	3.100 {0.1220}
56.575 {2.2274}	56.625 {2.2293}	3.050 {0.1201}
56.625 {2.2293}	56.675 {2.2313}	3.000 {0.1181}
56.675 {2.2313}	56.725 {2.2333}	2.950 {0.1161}
56.725 {2.2333}	56.775 {2.2352}	2.900 {0.1142}
56.775 {2.2352}	56.800 {2.2362}	2.850 {0.1122}