Reverse Idler Gear
Reverse Idler GearREMOVAL
1) Remove the manual transmission assembly from the vehicle.
2) Remove the back-up light switch and the neutral position switch.
3) Remove the transfer case together with the extension case assembly.
4) Remove the transmission case.
5) Remove the drive pinion shaft assembly.
6) Remove the main shaft assembly for single-range.
7) Remove the front differential assembly.
8) Remove the shifter forks and rods.
9) Pull out the straight pin, and remove the reverse idler gear shaft, washer, reverse idler gear and washer.
10) Remove the reverse shifter lever.
INSTALLATION
1) Install the reverse shifter lever, washer, reverse idler gear, washer and reverse idler gear shaft, and secure them with the straight pin.
NOTE:
^ Be sure to install the reverse idler gear shaft from rear side.
^ Use a new straight pin.
2) Check and adjust clearance between the reverse idler gear and the timing case wall surface.
3) Install the shifter forks and rods.
4) Install the front differential assembly.
5) Install the main shaft assembly for single-range.
6) Install the drive pinion shaft assembly.
7) Install the transmission case.
8) Install the transfer case together with the extension case assembly.
9) Install the back-up light switch and the neutral position switch.
10) Install the manual transmission assembly to the vehicle.
INSPECTION
1) Move the reverse shifter rod toward the reverse side. Check the clearance between the reverse idler gear and the transmission case wall surface. If out of specification, select the appropriate reverse shifter lever and adjust.
Clearance A:
6.0 - 7.5 mm (0.236 - 0.295 in)
2) After installing a suitable reverse shifter lever, shift into neutral. Check the clearance between the reverse idler gear and the transmission case wall surfaces.
If out of specification, select the appropriate washer and adjust.
Clearance:
0 - 0.5 mm (0 - 0.020 in)
3) Check the reverse idler gear and shaft for damage. Replace if it is damaged.
ADJUSTMENT
1) Select the appropriate reverse shifter lever from the table below, and adjust until the clearance between the reverse idler gear and transmission case wall is within specification.
Clearance A:
6.0 - 7.5 mm (0.236 - 0.295 in)
2) Select the appropriate washer from the table below, and adjust until the clearance between the reverse idler gear and transmission case wall is within specification.
Clearance:
0 - 0.5 mm (0 - 0.020 in)
