Counter Gear and Reverse Idler Gear

DISASSEMBLY
REMOVE HUB SLEEVE NO. 3, SHIFTING KEY AND SPRING FROM SYNCHRONIZER RING
a. Remove the synchronizer ring assembly from the hub sleeve No. 3.





b. Turn the reverse synchronizer pull ring.





c. Remove the reverse synchronizer ring and 5th synchronizer ring from the synchronizer pull ring and cone ring.





d. Turn the reverse synchronizer pull ring, separate the pull ring and cone ring.
e. Push the shifting key and spring, and remove the 3 shifting keys and springs from the reverse synchronizer ring.

INSPECTION





1. INSPECT 5TH GEAR RADIAL CLEARANCE
a. Install the spacer, counter 5th gear and needle roller bearings.
b. Using a dial indicator, measure the counter 5th gear radial clearance.
Standard clearance: 0.015 - 0.068 mm (0.0006 - 0.0027 inch)
Maximum clearance: 0.160 mm (0.0063 inch)
If the clearance exceeds the maximum, replace the gear bearing or shaft.





2. INSPECT COUNTER GEAR
Using a micrometer, measure the outer diameter of the counter gear journal.
Minimum diameter: 27.860 mm (1.0968 inch)
If the outer diameter is less than the minimum, replace the counter gear.
3. INSPECT 5TH SYNCHRONIZER RING
a. Check for wear or damage.





b. Install the synchronizer pull ring, cone ring and outer ring to the gear spline piece No. 5.





c. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
If it does not lock, replace the synchronizer ring.





4. INSPECT SHIFT FORK AND HUB SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 inch)
If the clearance exceeds the maximum, replace the shift fork or hub sleeve.





5. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE
Using a dial indicator, measure the reverse idler gear radial clearance.
Standard clearance: 0.040 - 0.082 mm (0.0016 - 0.0032 inch)
Maximum clearance: 0.130 mm (0.0051 inch)
If the clearance exceeds the maximum, replace the reverse idler gear or reverse idler gear shaft.





6. INSPECT REVERSE IDLER GEAR AND SHIFT ARM CLEARANCE
Using a feeler gauge, measure the clearance between the reverse idler gear and shift arm.
Standard clearance: 0.05 - 0.35 mm (0.0020 - 0.0138 inch)
Maximum clearance: 0.50 mm (0.0197 inch)
If the clearance exceeds the maximum, replace the shift arm or reverse idler gear.

REPLACEMENT
IF NECESSARY, REPLACE COUNTER GEAR FRONT BEARING





a. Using a snap ring expander, remove the snap ring.





b. Using SST and a press, remove the bearing.
SST 09950-00020
c. Replace the side race.





d. Using a socket wrench and press, install a new bearing and side race.








e. Select a snap ring that allows the minimum axial play.





f. Using a snap ring expander, install the snap ring.

REASSEMBLY
INSTALL SYNCHRONIZER RING ASSEMBLY TO HUB SLEEVE NO. 3
a. Put the key spring into the hole of the shifting key.
b. Push the 3 shifting keys with the 3 key springs to the reverse synchronizer ring.





c. Install the synchronizer cone ring to the reverse synchronizer pull ring and turn the pull ring.





d. Install the 5th synchronizer ring.
e. Install the reverse synchronizer ring.





f. Turn the reverse synchronizer pull ring.





g. While pushing the 3 shifting keys, install the synchronizer ring assembly to the hub sleeve No. 3.