Reverse Idler Gear

Reverse Idler Gear

REMOVAL

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) Shift into 4th.
9) Remove the snap ring.





10) Remove the reverse idler gear shaft securing bolt.





11) Press out the reverse idler gear shaft from the backside of the transmission to remove.

NOTE:
Support the reverse idler gear assembly with hands to avoid collapsing.





12) Remove the reverse idler gear.
13) Remove the reverse idler gear bushing.





INSTALLATION

1) Install the reverse idler gear bushing with the cutout portion of the reverse idler gear bushing facing the front of the transmission.





2) Assembling reverse idler gear assembly
(1) Install the reverse coupling sleeve to the reverse idler gear No. 2.

NOTE:
^ Install the reverse coupling sleeve in the correct direction.
^ Make sure that the oval-shaped cutout portion inside the reverse coupling sleeve matches the center of the reverse idler gear No. 2 groove.





(2) Install the shifting insert.

NOTE:
Press in the ball part to install.





(3) Install the baulk ring and reverse idler gear.





(4) Install the needle bearing and reverse idler gear collar.





(5) Install the thrust bearing and washer.

NOTE:
Install the thrust bearing in the correct direction.





3) Install the assembled reverse idler gear assembly to the transmission case and hold it with hands.
4) Install the reverse idler gear shaft.

NOTE:
^ Install with the cutout portion of the reverse idler gear shaft facing the RH side of the transmission case.
^ Make sure that the groove of the reverse idler gear shaft comes out of the reverse idler gear bushing.





5) Install the reverse idler gear shaft securing bolt.

Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)





6) Install the snap ring.





7) Select the reverse idler gear bushing.
8) Remove the reverse idler gear assembly and replace with the selected bushing.
9) Install the reverse idler gear assembly, oil case guide and reverse idler gear shaft.

NOTE:
^ Install with the cutout portion of the reverse idler gear shaft facing the RH side of the transmission case.
^ Make sure that the groove of the reverse idler gear shaft comes out of the reverse idler gear bushing.
^ Insert the cutout portion of the reverse idler gear bushing into the oil case guide.





10) Install the reverse idler gear shaft securing bolt.

NOTE:
Use a new gasket.

Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)





11) Install the snap ring.





12) Check the reverse shifter fork.
13) Install the front differential assembly.
14) Install the main shaft assembly for single range.
15) Install the drive pinion shaft assembly.
16) Install the transmission case.
17) Install the transfer case together with the extension case assembly.
18) Install the back-up light switch and the neutral position switch.
19) Install the manual transmission assembly to the vehicle.

DISASSEMBLY

REVERSE IDLER GEAR ASSY

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





2) Remove the sub gear and spring.





ASSEMBLY

REVERSE IDLER GEAR ASSY

1) Attach the sub gear and spring.

NOTE:
Point the stamp (marking A) towards the outside, and install the sub gear.





2) Install the friction plate and snap ring.

NOTE:
Make sure the friction plate is installed in the proper direction.





INSPECTION

1) Check the clearance between the reverse idler gear bushing and reverse idler gear washer. If out of specification, select the appropriate reverse idler gear bushing and adjust.

Clearance (a):
0.1 - 0.3 mm (0.004 - 0.012 in)





2) Check the reverse idler gear and shaft for damage. Replace if it is damaged.
3) Apply gear oil to the cone of the gear and while press-fitting the synchronizer ring, check there is no rotation in the circumferential direction.





4) Coupling sleeve and synchronizer hub
^ Check the slipping condition of the coupling sleeve.
^ Check the splines on the coupling sleeve and reverse idler gear for wear.
5) Shifting insert
Replace the shifting insert if there is deformation, excessive wear on the ball section or any defectiveness.





ADJUSTMENT

1) Select the appropriate reverse idler gear bushing from the table below, and adjust until the clearance between the reverse idler gear and reverse idler gear washer is within specification.

Clearance (a):
0.1 - 0.3 mm (0.004 - 0.012 in)