Reverse Idler Shaft and Gears

REVERSE IDLER SHAFT AND GEARS

Disassembly and Assembly
DISASSEMBLY
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 items. 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 items. 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, 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 items. If necessary, replace them with new ones.
^ Damage and rough rotation of bearing.

ASSEMBLY
Paying attention, assemble in reverse order of disassembly.





CAUTION: Be careful with orientation of insert spring.