Reverse Idler Gear: Service and Repair

NOTE: For removal and installation procedures refer to "Manual Transmission/Transaxle, Service and Repair."





DISASSEMBLY
Remove No.3 hub sleeve, shifting key and spring from synchronizer ring.
a. Remove the synchronizer ring assembly from the No.3 hub sleeve.





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 and separate the pull ring and cone ring.





e. Remove the 3 shifting keys and key springs by carefully levering up the shifting key spring with one screwdriver and levering the shifting key away from the reverse synchronizer ring with another screwdriver.

INSPECTION
1. Inspect counter 5th gear radial clearance.
a. Install the spacer, counter 5th gear and needle roller bearing to the counter gear.





b. Using a dial indicator, measure the counter 5th gear radial clearance. If the clearance exceeds the maximum, replace the counter gear, needle roller bearing or counter 5th gear.
Standard clearance: 0.009-0.060 mm (0.0004-0.0024 inch)
Maximum clearance: 0.150 mm (0.0059 inch)





2. Inspect counter gear.
Using a micrometer, measure the outer diameter of the counter shaft journal.
- If the outer race is less than the minimum, replace the counter gear.
- If the clearance exceeds the maximum, replace the gear or shaft.
Minimum diameter:
Part A: 26.975 mm (1.0620 inch)
Part B: 29.950 mm (1.1791 inch)





3. Inspect reverse idler gear radial clearance.
Using a dial indicator, measure the reverse idler Or radial clearance.
Standard clearance: 0.041-0.074 mm (0.0016-0.0029 inch)
Maximum clearance: 0.194 mm (0.0076 inch)





4. Inspect reverse idler gear and shift arm shoe clearance.
Using a feeler gauge, measure the clearance between the reverse idler gear and shift arm shoe. If the clearance exceeds the maximum, replace the shift arm shoe or reverse idler gear.
Standard clearance: 0.20-0.41 mm (0.0079-0.0161 inch)
Maximum clearance: 0.90 mm (0.0354 inch)





5. Inspect 5th gear synchronizer ring.
a. Check for wear or damage.
b. Install the synchronizer pull ring, cone ring and outer ring to the 5th gear.





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.





6. Inspect shift fork and hub sleeve clearance.
Using a feeler gauge, measure the clearance between the hub sleeves and shift forks. If the clearance exceeds the maximum, replace shift fork or hub sleeve.
Maximum clearance: 1.0 mm (0.039 inch)
7. Replace bearing as necessary.

ASSEMBLY
1. Install the synchronizer assembly to the No.3 hub sleeve.





a. Push the synchronizer key spring, install the shifting key and key spring to the reverse synchronizer ring.
b. using a screwdriver, push the 3 key springs into the synchronizer ring spring gaps.





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