Reverse Gear and 5TH Gear
DISASSEMBLY
1. Bearing snap ring
- Use a pair of snap ring pliers to remove the bearing snap ring.
2. Ball bearing
Set the bearing remover to the bearing and the mainshaft end to remove the bearing.
Bearing remover: J-37217
Puller: J-37487
3. Bearing snap ring
4. Speedometer drive gear
5. Clip
6. Retainer snap ring
7. Retaining ring
8. Thrust plate
9. Thrust washer and lock ball
10. Reverse gear snap ring
- Use a pair of snap ring pliers to remove the snap ring.
11. Bearing snap ring
12. Ball bearing
13. Counter 5th gear
- Engage the Rev-5th synchronizer with the 5th gear.
- Attach the bearing remover to the counter gear shaft.
- Pull the reverse shaft toward you and hold it.
- Use the bearing remover to remove the ball bearing and the counter 5th gear together with the reverse idler gear assembly.
14. Reverse shaft assembly
15. Reverse idler gear
16. Thrust washer
17. Shaft pin
18. Counter reverse gear
19. 5th gear
20. 5th block ring
21. Needle bearing
22. Mainshaft nut
- Engage the 3rd-4th synchronizer with the 3rd gear.
- Engage the 1st-2nd synchronizer with the 1st gear.
- Attach the holding fixture to the mainshaft and the counter gear.
Holding fixture: J-37224
Base: J-3289-20
- Use the mainshaft nut wrench to remove the mainshaft nut.
Wrench: J-37219
23. Rev-5th synchronizer assembly
24. Reverse ring ('91), Blocker ring ('92)
25. Reverse gear
- Use screw drivers between the reverse gear and bearing plate to remove the Rev-5th synchronizer assembly together with reverse ring and gear.
26. Needle bearing
27. Bearing plate and screw
- Use the torx bit wrench to remove the bearing plate screw from the intermediate plate.
Torx bit wrench: J-37225 (T45).
28. Bearing snap ring
29. Intermediate plate
- Use the snap ring pliers (2) to remove the mainshaft bearing snap ring (1).
- Push the intermediate plate toward the rear of the transmission to remove it.
INSPECTION AND REPAIR
Refer to "TOP GEAR SHAFT, MAIN GEAR SHAFT, AND COUNTER GEAR" for inspection and repair. Top Gear Shaft, Main Gear Shaft, and Counter Gear
REASSEMBLY
29. Intermediate plate
- Mesh the counter gear with the mainshaft assembly.
- Install the holding fixture to the mainshaft and the counter gear.
Holding fixture: J-37224
Holding fixture base: J-3289-20
- Place the holding fixture (with the mainshaft and the counter shaft) in a vise.
- Install the intermediate plate.
28. Bearing snap ring
27. Bearing plate and screw
- Apply recommended thread locking agents or its equivalent to each of the bearing plate screw threads.
- Tighten the screws to the specified torque.
- Torx bit wrench: J-37225 (T45)
Bearing plate screw torque: 15 N-m (11 lb-ft)
26. Needle bearing
25. Reverse gear
24. Reverse ring ('91), Blocker ring ('92)
23. Rev-5th synchronizer assembly
1. Turn the clutch hub face (1) toward the sleeve small groove (2) on the outer circumference.
2. Check that the inserts (3) fit snugly into the block ring insert grooves.
3. Check that the insert springs (4) are fitted to the inserts as shown in the illustration.
4. Check that the clutch hub (6) and the sleeve (7) slide smoothly.
5. Install the synchronizer assembly to the mainshaft.
The clutch hub face (with the heavy boss) must be facing the reverse gear side.
22. Mainshaft nut
1. Mesh the 1st-2nd synchronizer with both the 1st and 3rd gears (double engagement).
This will prevent the mainshaft from turning.
2. Install the mainshaft hub nut.
3. Use the mainshaft nut wrench to tighten the mainshaft nut to the specified torque.
Wrench: J-37219
Mainshaft nut torque: 127 N-m (94 lb-ft)
4. Use a punch to stake the mainshaft nut.
21. Needle bearing
20. 5th block ring
19. 5th gear
18. Counter reverse gear
- Apply engine oil to the counter reverse gear and the reverse gear.
- Install the counter reverse gear to the counter gear.
Note the projection at either side of the counter revers gear.
The larger projection must be facing the intermediate plate.
17. Shaft pin
16. Thrust washer
15. Reverse idler gear
14. Reverse shaft assembly
13. Counter 5th gear
- Set the counter 5th gear to the reverse idler shaft slot.
- Install the reverse idler shaft together with the counter 5th gear to the transmission.
12. Ball bearing
11. Bearing snap ring
Bearing Snap Ring Availability - MUA Transmission:
- Select the snap ring which will provide the minimum clearance between the ball bearing and the snap ring.
There are six snap ring sizes available.
The snap rings are color-coded to indicate their thickness.
Ball bearing and snap ring clearance
Standard: 0 - 0.15 mm (0 - 0.0059 in.)
- Use a pair of snap ring pliers to install the snap ring to the mainshaft.
The snap ring must be fully inserted into the counter 5th gear snap ring groove.
10. Reverse gear snap ring
Reverse Gear Snap Ring Availability - MUA Transmission:
- Select the snap ring which will provide the minimum clearance between the intermediate plate and the snap ring.
There are three snap ring sizes available.
The snap rings are color-coded to indicate their thickness.
Intermediate plate and snap ring clearance
Standard: 0 - 0.15 mm (0 - 0.0059 in.)
- Use a pair of snap ring pliers to install the snap ring to the mainshaft.
The snap ring must be fully inserted into the counter 5th gear snap ring groove.
9. Thrust washer and lock ball
Thrust Washer Availability - MUA Transmission:
- Use a thickness gauge to measure the clearance between the 5th gear and the thrust washer.
If required, replace the existing thrust washer with a new thrust washer to bring the clearance to specification.
There are four thrust washer sizes available.
The thrust washers are color-coded to indicate their thickness.
5th gear and thrust washer clearance
Standard: 0.10 - 0.25 mm (0.004 - 0.0010 in.)
- Apply grease to the thrust washer and the lock ball.
- Install the thrust washer and the lock ball.
8. Thrust plate
7. Retaining ring
6. Retaining snap ring
5. Clip
4. Speedometer drive gear
3. Bearing snap ring
2. Ball bearing
- Use the installer to install the ball bearing to the mainshaft.
Installer: J-37223
1. Bearing snap ring