Reverse Gear

Fig. 102:

1. Install the reverse shift fork and synchronizer as an assembly onto the reverse shift rail and the output shaft. Verify that the raised square shoulder and snap-ring on the synchro face the case.
2. Using a suitable punch and hammer, install the roll-pin securing the reverse shift fork to the reverse shift rail. The correct size punch is 6 mm (7/32 inch).

Fig. 103:

3. Install the reverse gear bearing sleeve onto the output shaft. It may be necessary to use Installer 6446 to install the sleeve.

Fig. 104:

4. Install reverse gear, reverse gear synchronizer cone, reverse gear outer blocker ring, and reverse rear bearing.

Fig. 105:

5. Install the output shaft ball bearing assembly and reverse thrust washer onto the output shaft. Note that the raised shoulder on the thrust washer faces away from the reverse gear.
6. Install a new output shaft nut onto the output shaft.
7. Using Wrench 8226 on the output shaft nut and Socket 6993 to hold the output shaft, tighten the output shaft nut. Torque the nut to 339 Nm (250 ft. lbs.).
8. Using a suitable punch with an approximately 9 mm (5/16 inch) diameter ball end, stake the nut into the slot in the output shaft.
9. Use a suitable shop press, press the countershaft reverse gear into the sleeve.
10. Using Installer C-4652 and Handle C-4171, install the reverse countershaft rear bearing onto the countershaft reverse gear assembly.
11. Install the reverse idler gear rear bearing, bearing spacer, front bearing, and front thrust washer onto the idler gear shaft.

Fig. 106:

12. Install idler and reverse countershaft gears together.
13. Install the reverse idler thrust washer from the reverse idler.

Fig. 107:

14. Install the crossover cam rollers and pin.