Reverse Gear

NOTE: Component identifier numbers used in the following illustrations relate to specific steps in the procedures below.




Disassembly
1. Place the reverse gear in a screw vice with protective jaw faces.
2. Mark with a marking pen the reverse gear's position in the shaft support.




3. Carefully tap out the reverse gear shaft from the reverse gear support.

NOTE: Hold on to the shaft and make sure that no parts disappear.




4. Lift out the bearing support, reverse gear pinion, sleeve, baulk ring, wire coil, reverse gear wheel and needle bearing from the reverse gear shaft.
5. Check the condition of all parts as regards wear.
- Replace damaged or defective parts.
- Check the wear on the synchromesh by putting it in its correct place.
- Measure with a feeler gauge in three places and calculate a mean value.
- If the mean value is less than 0.5 mm, the synchromesh should be replaced.





Disassembly

NOTE: Lightly oil all parts with suitable 10W30 engine oil prior to installing.

1. Place the reverse gear shaft in a screw vice with protective jaw faces.
2. Install the needle bearing and reverse gear wheel on the shaft.
3. Install the baulk ring.
- Check that the wire coil is installed on the synchromesh.
4. Install the synchromesh sleeve.
- The high heels of the sleeve should fit into the deep teeth gaps in the baulk ring.
- The high teeth in the sleeve should be installed facing downwards.




5. Install the reverse gear pinion and its integrated synchromesh hub.

NOTE: The three notches in the synchromesh hub should fit over the three holes in the baulk ring.




6. Insert the bearing washer.
- Check that the washer's tap is between the heels of the reverse gear shaft support.
7. Press the reverse gear shaft support on to the shaft in accordance with previous marking.
- Use a 17 mm sleeve and a 9 mm sleeve as supports and press until it reaches the bottom.

NOTE:
- The screw holes of the reverse gear support should be in line with the shaft's lubrications holes.
- As a test, install a screw in the shaft, through the shaft support, to check that the shaft's hole is in line with the shaft support's hole.

8. Check that the reverse gear is correctly assembled by measuring with a feeler gauge.
- Measure between the upper pinion and the axial bearing washer at the reverse gear shaft support.
- The play should be 0.10-0.20 mm.
9. Try to engage reverse gear by pressing the sleeve up and down.