Reverse Idler Gear

Reverse Idler Gear

REMOVAL
1) Remove the manual transmission assembly from the vehicle.
2) Prepare the transmission for overhaul.
3) Remove the oil pipe, neutral position switch, back-up light switch and harness.
4) Remove the extension case.
5) Remove the transfer driven gear.
6) Remove the center differential.
7) Remove the oil pump.
8) Remove the transmission case.
9) Remove the reverse idler gear assembly.

INSTALLATION
1) Select the reverse fork rod.
2) Install the reverse idler gear assembly.
3) Install the transmission case.
4) Install the oil pump.
5) Install the center differential.
6) Install the transfer driven gear.
7) Install the extension case.
8) Install the oil pipe, neutral position switch, backup light switch and harness.
9) Install the manual transmission assembly to the vehicle.

DISASSEMBLY

NOTE: Sleeves and reverse gears meet at a specified position. Before disassembly, mark the meeting position of the sleeve and hub.

1) Remove the spring pin.





2) Remove the snap ring and washer.





3) Remove the counter high & low washer and reverse idler gear.





4) Remove the knock pin and reverse idler gear needle bearing.





5) Remove the collar.
6) Remove the reverse sleeve.





7) Remove the outer baulk ring, reverse synchro cone and inner baulk ring from the reverse sleeve.





8) Remove reverse idler gear No. 2.





9) Remove the counter high & low washer and needle bearing.





10) Remove the knock pin.





11) Remove the snap ring and friction plate from reverse gear.





12) Remove the sub gear and spring.





ASSEMBLY
1) Attach the sub gear and spring.

NOTE:
^ Turn the white marking on the hook section towards the sub gear side, and attach the spring.
^ Point the stamp (marking A) towards the outside, and install the sub gear.





^ While paying attention to the direction of the sub gear attachment hole, attach the spring and sub gear.





2) Install the friction plate and snap ring.

NOTE: Confirm that the friction plate is installed in the proper direction.





3) Apply adequate gear oil to the shaft, needle bearing and reverse drive gear inner surface.
4) Install the knock pin.





5) Install the counter high & low washer and needle bearing.

NOTE: Point the groove towards the reverse idler gear, and attach the washer.





6) Install the reverse idler gear No. 2.





7) Attach the shifting insert key to the appropriate location of the reverse sleeve.

NOTE: The angle of each shifting insert key is 120°.





8) Attach the reverse sleeve to the reverse idler gear No. 2.

NOTE: Confirm that the reverse sleeve is installed in the proper direction.





9) Apply adequate gear oil to the collar, needle bearing and reverse drive gear inner surface.
10) Install the outer baulk ring, reverse synchro cone and inner baulk ring.





11) Install the collar and needle bearing, then the knock pin.





12) Match the protrusion of the reverse synchro cone to the hole on the reverse idler gear, and install the reverse idler gear.





13) Point the groove towards the reverse idler gear, and attach the counter high & low washer and the washer.
14) Using the ST, install the snap ring.
ST 18672AA000 GUIDE CLIP





15) Inspect and adjust the clearance between the snap ring and the washer.
16) Install the spring pin.

NOTE: Use new spring pins.

INSPECTION
Disassembled parts should be washed with unleaded gasoline first, then inspected carefully.
1) Bearing
Replace the bearings in the following cases.
^ If there is wear, rusting or damage of the bearings.
^ If the bearing does not rotate smoothly or an abnormal noise is emitted when turning.
^ When bearing has other defects.
2) Bushing (each gear)
If the sliding surface is damaged or excessively worn, replace the bushing.
3) Gear
Replace gears in the following cases.
^ When gear teeth surface is damaged or excessively worn.
^ If the contact area of the baulk ring is damaged.
^ If the inner face of the gear is worn.
4) Baulk ring, synchro cone
If there is wear, rusting or damage at the baulk ring, replace the baulk ring and synchro cone.
5) Shifting insert key
Replace the shifting insert key if deformed, excessively worn or defective in any way.





6) Check clearance between the snap ring and washer.





If the clearance is out of the specification, select a snap ring from the following table.





After replacing the snap ring, inspect the clearance.