Reverse Idler Gear
A: REMOVAL1. Remove the manual transmission assembly from vehicle.
2. Remove back-up light switch and neutral position switch.
3. Remove transfer case with extension case assembly.
4. Remove transmission case.
5. Remove drive pinion shaft assembly.
6. Remove main shaft assembly.
7. Remove differential assembly.
8. Remove shifter forks and rods.
9. Pull out straight pin, and remove idler gear shaft, reverse idler gear and washer.
10. Remove reverse shifter lever.
B: INSTALLATION
1. Install reverse shifter lever, reverse idler gear and reverse idler gear shaft, and secure with straight pin.
NOTE: Be sure to install reverse idler shaft from the rear side.
2. Install reverse arm fork spring, ball and interlock plunger (5.56 x 9.6) to reverse fork rod arm. Insert reverse fork rod into hole in reverse fork rod arm, and hold it with outer snap ring using ST.
CAUTION: Apply grease to plunger to prevent it from falling.
ST 399411700 ACCENT BALL INSTALLER
3. Position ball (7.1438), spring and gasket in the reverse shifter rod hole on the left side transmission case, and tighten checking ball plug.
CAUTION: Replace gasket with a new one.
4. Inspect and adjust clearance between reverse idler gear and transmission case wall.
5. Install shifter forks and rods.
6. Install differential assembly.
7. Install main shaft assembly.
8. Install drive pinion shaft assembly.
9. Install transmission case.
10. Install transfer case with extension case assembly.
11. Install back-up light switch and neutral position switch.
12. Install the manual transmission assembly from vehicle.
C: INSPECTION
1. Move the reverse shifter rod toward the reverse side. Inspect clearance between reverse idler gear and transmission case wall.
If out of specification, select the appropriate reverse shifter lever and adjust.
Clearance A: 6.0 - 7.5 mm (0.236 - 0.295 inch)
2. After installing a suitable reverse shifter lever, shift into neutral. Inspect clearance between reverse idler gear and transmission case wall. If out of specification, select the appropriate washer and adjust.
Clearance: 0 - 0.5 mm (0 - 0.020 inch)
3. Check the reverse idler gear and shaft for damage. Replace if damaged.
D: ADJUSTMENT
1. Select the appropriate reverse shifter lever from the table below, and adjust until the gap between the reverse idler gear and transmission case wall is within specification.
Clearance A: 6.0 - 7.5 mm (0.236 - 0.295 inch)
2. Select the appropriate washer from the table below, and adjust until the gap between the reverse idler gear and transmission case wall is within specification.
Clearance: 0 - 0.5 mm (0 - 0.020 inch)