Reverse Idler Shaft and Gears
Disassembly and AssemblyDISASSEMBLY
1. Remove reverse idler gear adjusting shim.
2. Remove reverse idler gear (rear), reverse coupling sleeve and insert spring simultaneously.
3. Remove reverse idler gear needle bearing.
4. Remove thrust needle bearing.
5. Remove reverse baulk ring.
6. Remove reverse idler gear (front).
7. Remove reverse idler gear needle bearing.
8. Remove thrust needle bearing.
9. Pull off locking pin from reverse idler shaft.
INSPECTION AFTER DISASSEMBLY
Reverse Idler Shaft and Gears
Check parts listed below. If necessary, replace them with new ones.
^ Damage, peeling, dent, uneven wear, bending, and other nonstandard conditions of the shaft.
^ Excessive wear, damage, peeling, and other non-standard conditions of the gears.
Synchronizer
Check parts listed below. If necessary, replace them with new ones.
^ Damage and unusual wear on contact surfaces of coupling sleeve, synchronizer hub, and insert spring.
^ Coupling sleeve and synchronizer hub must move smoothly.
^ If any crack, damage, or excessive wear is found on cam face of baulk ring or working face of insert, replace it.
Baulk Ring Clearance
Press baulk ring against cone, and measure clearance between baulk ring and cone. If measurement is below limit value, replace it with a new one.
Clearance
Standard: 0.95 - 1.4 mm (0.0374 - 0.055 inch)
Limit value: 0.7 mm (0.028 inch)
Bearing
Check parts listed below. If necessary, replace them with new ones.
^ Damage and rough rotation of bearing.
ASSEMBLY
Assembly is in the reverse order of disassembly.
CAUTION:
^ Install with orientation of insert spring as shown.