Reverse Idler Shaft and Gears

REVERSE IDLER SHAFT AND GEARS

Disassembly and Assembly
DISASSEMBLY
1. Remove the reverse idler gear adjusting shim.
2. Remove the reverse idler gear (rear), reverse coupling sleeve and insert spring simultaneously.
3. Remove the reverse idler gear needle bearing.
4. Remove the thrust needle bearing.
5. Remove the reverse baulk ring.
6. Remove the reverse idler gear (front).
7. Remove the reverse idler gear needle bearing.
8. Remove the thrust needle bearing.
9. Pull off the locking pin from the reverse idler shaft.

INSPECTION AFTER DISASSEMBLY
Reverse Idler Shaft and Gears





Check the items listed. If necessary, replace them with new ones. Damage, peeling, dent, uneven wear and bending of the reverse idler shaft.
^ Excessive wear, damage and peeling, of the reverse idler gears.

Synchronizer





Check the items listed. If necessary, replace them with new ones.
^ Damage and excessive wear on contact surfaces of coupling sleeve, synchronizer hub, and insert spring.
^ Coupling sleeve and synchronizer hub must move smoothly as shown.





^ If any crack, damage, or excessive wear is found on the cam face of the baulk ring or working face of the insert as shown, replace it.

Baulk ring clearance





^ Press the baulk ring against the cone, and measure the clearance between the baulk ring and cone as shown. If the measurement is below the specified limit, replace it with a new one.
Baulk ring to gear clearance
Standard: 0.95 - 1.4 mm (0.0374 - 0.055 inch)
Limit value: 0.7 mm (0.028 inch)

Bearing





Check the item listed. If necessary, replace it with a new one.
^ Damage and rough rotation of the bearing.

ASSEMBLY





Assembly is in the reverse order of disassembly.

CAUTION: Install the insert spring with the orientation as shown.