Reverse Idler Gear Shaft

DISASSEMBLY





1. Put reverse idler gear shaft in a large deepwell socket. Use a socket large enough so that the rim of the socket rests on reverse gear and not on idler shaft washer.

NOTICE: When tapping out the reverse idler gear shaft, make sure the shaft washer does not separate from shaft.

2. Carefully tap reverse idler gear shaft out of shaft support bracket.





3. Remove shaft support bracket and discard.
4. Remove reverse idler gear washer, reverse idler gear, reverse synchronizer sleeve, reverse gear blocking ring w/spring, reverse gear, and reverse gear bearing.
5. Check condition of gears and synchronizer. Measure clearance between blocking ring and reverse idler gear in four places.
Clearance: The minimum blocking ring clearance for reverse gear synchronizer: 0.5 mm (0.020 inch)

ASSEMBLY





IMPORTANT: Lubricate all rotating parts and bearings with manual transaxle fluid (P/N 21018899) during assembly.

IMPORTANT: The reverse synchronizer sleeve can only be placed on the reverse idler gear when the tall teeth on the sleeve are aligned with the deep tooth gaps in the gear.

1. Install reverse synchronizer sleeve to reverse idler gear. The chamfered edge of sleeve goes down (towards reverse idler gear).





2. Install reverse gear blocking ring with spring on reverse idler gear and synchronizer sleeve. Align blocking ring lugs with gaps in gear.





3. Install reverse gear on reverse gear blocking ring.





4. Install reverse gear bearing on reverse idler shaft and install shaft through reverse and reverse idler gears.





5. Install reverse gear washer.

NOTICE: The reverse idler gear shaft lubrication hole (located on opposite end of shaft from bracket) must be on opposite side of shaft from reverse idler shaft support bracket hole when installing bracket.

NOTICE: Always use a new reverse idler gear shaft bracket.

IMPORTANT: The tab on the reverse idler gear washer must fit between the lugs on the bottom of the shaft support bracket.

6. Install new shaft support bracket with a press as shown. Make sure hole in bracket aligns with shaft hole. Use a 17 mm socket to press on bracket.





7. Measure clearance between reverse gear and reverse gear washer.
Clearance:
Standard: 0.10 mm - 0.20 mm (0.004 inch - 0.008 inch)
8. Move synchronizer sleeve up and down to check for proper operation.