Reverse Gear

Reverse gear

To dismantle





1. Set up the reverse gear in 87 90 487 Sleeve, differential bearing.
2. Carefully tap the reverse gear out of its support using a drift.

Important: Ensure that the washer is not compressed by the shaft.

3. Lift off the bearing support, bearing washer, reverse gear pinion, synchromesh sleeve, baulk ring, wire ring, reverse gear wheel and needle bearing from the reverse gear.





4. Check the condition of all parts as regards wear. Replace damaged or defective parts. Measure the wear on the synchromesh by fitting it in place. Measure with a feeler gauge in three places and calculate an average of the readings. If the dimension is less than 0.5 mm the synchromesh must be replaced.

To assemble





Grease all components with synthetic manual gearbox oil before fitting, refer to Summary of lubricants and sealants.

1. Place the reverse shaft in a 17 mm sleeve so that the lower support washer does not become detached from the shaft.
2. Fit the needle bearing and reverse gear wheel to the shaft.
3. Fit the baulk ring. Check that the wire ring is fitted to the baulk ring.
4. Fit the synchromesh sleeve.
5. Fit the reverse pinion with integrated synchromesh hub.





Important: The 3 recesses in the synchromesh hub should fit over the 3 lugs on the baulk ring.

6. Fit the bearing washer. Check that the washer's tag is between the lugs on the reverse shaft support.

Note: Always use a new reverse shaft support to ensure a press fit.





7. Sparingly apply Cylindrical fastening, Loctite 648 in the shaft hole on the rear axle support. Always use a new rear axle support to ensure a press fit.
8. Press on the reverse shaft support as illustrated (the holes should be aligned). Use a 17 mm sleeve and press on fully.

Important: The bolt hole for the rear axle support must be on the opposite side to the shaft oil hole.

9. Secure the reverse shaft by screwing it in the clutch housing.

Tightening torque 24 Nm (18 ft. lbs.)

10. Check that the reverse gear is correctly assembled by measuring using a feeler gauge. Measure between the upper pinion and the thrust washer at the reverse shaft support. Play should be 0.10 - 0.20 mm.





11. Try shifting the reverse gear by pushing the synchromesh sleeve up and down.