Page 2017 of 4179

REVERSE IDLER SHAFT AND GEARS
MT-85
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REVERSE IDLER SHAFT AND GEARSPFP:32281
Assembly and Disassembly (RS5F51A)ECS008C8
DISASSEMBLY
1. Remove reverse idler gear adjusting shim.
2. Remove reverse idler gear (rear), reverse coupling sleeve and reverse insert spring simultaneously.
3. Remove reverse idler gear needle bearing.
4. Remove thrust needle bearing.
5. Remove reverse baulk ring.
6. Remove reverse idler gear (front).
7. Remove reverse idler gear needle bearing.
8. Remove thrust needle bearing.
9. Remove retaining pin from reverse idler shaft.
CAUTION:
Do not reuse retaining pin.
INSPECTION AFTER DISASSEMBLY
Reverse Idler Shaft and Gears
Check items below. If necessary, replace them with new ones.
Damage, peeling, dent, uneven wear, bending, and other non-
standard conditions of the shaft.
Excessive wear, damage, peeling, and other non-standard con-
ditions of the gears.
Synchronizer
Check items below. If necessary, replace them with new ones.
Damage and unusual wear on contact surfaces of reverse cou-
pling sleeve, reverse synchronizer hub, and reverse insert
spring.
Reverse coupling sleeve and reverse synchronizer hub must
move smoothly.
If any crack, damage, or excessive wear is found on cam face of
reverse baulk ring or working face of insert, replace it.
SCIA0953J
SMT637A
SMT867D
Page 2018 of 4179

MT-86
REVERSE IDLER SHAFT AND GEARS
Baulk ring clearance
Push baulk ring on the cone, and measure the clearance
between baulk ring and cone. If the measurement is below limit,
replace it with a new one.
Bearing
Check items below. If necessary, replace them with new ones.
Damage and rough rotation of bearing.
ASSEMBLY
Paying attention to the following work, assemble in reverse order of disassembly.
CAUTION:
Be careful with orientation of reverse insert spring.
Assembly and Disassembly (RS6F51A)ECS008C9
DISASSEMBLY
1. Remove reverse idler gear adjusting shim.
2. Remove reverse idler gear (rear), reverse coupling sleeve and reverse insert spring simultaneously.
3. Remove reverse idler gear needle bearing.
4. Remove thrust needle bearing.
5. Remove reverse baulk ring.
6. Remove reverse idler gear (front).
7. Remove reverse idler gear needle bearing.
8. Remove thrust needle bearing.
9. Remove retaining pin from reverse idler shaft.
CAUTION:
Do not reuse retaining pin.Clearance
Standard value : 0.95 - 1.4 mm (0.037 - 0.055 in)
Limit value : 0.7 mm (0.028 in)
SMT140
SCIA0954E
Page 2019 of 4179

REVERSE IDLER SHAFT AND GEARS
MT-87
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INSPECTION AFTER DISASSEMBLY
Reverse Idler Shaft and Gears
Check items below. If necessary, replace them with new ones.
Damage, peeling, dent, uneven wear, bending, and other non-
standard conditions of the shaft.
Excessive wear, damage, peeling, and other non-standard con-
ditions of the gears.
Synchronizer
Check items below. If necessary, replace them with new ones.
Damage and unusual wear on contact surfaces of reverse cou-
pling sleeve, reverse synchronizer hub, and reverse insert
spring.
Reverse coupling sleeve and reverse synchronizer hub must
move smoothly.
If any crack, damage, or excessive wear is found on cam face of
reverse baulk ring or working face of insert, replace it.
Baulk ring clearance
Push baulk ring on the cone, and measure the clearance
between baulk ring and cone. If the measurement is below limit,
replace it with a new one.
Bearing
Check items below. If necessary, replace them with new ones.
Damage and rough rotation of bearing.
ASSEMBLY
Paying attention to the following work, assemble in reverse order of disassembly.
SCIA0953J
SMT637A
SMT867D
Clearance
Standard value : 0.95 - 1.4 mm (0.037 - 0.055 in)
Limit value : 0.7 mm (0.028 in)
SMT140
Page 2020 of 4179
MT-88
REVERSE IDLER SHAFT AND GEARS
CAUTION:
Be careful with orientation of reverse insert spring.
SCIA0954E
Page 2021 of 4179

FINAL DRIVE
MT-89
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FINAL DRIVEPFP:38411
Assembly and Disassembly (RS5F51A)ECS008CA
PRE-INSPECTION
Check the clearance between side gear and differential case as
follows.
1. Clean final drive assembly sufficiently to prevent side gear thrust
washer, differential case, side gear, and other parts from sticking
by gear oil.
2. Upright differential case so that side gear to be measured faces upward.
3. Place the drift below and a dial gauge onto side gear. Move side
gear up and down, and measure the clearance.
CAUTION:
There should be no resistance and gears should rotate
freely.
4. If not within specification, adjust the clearance by changing side
gear thrust washer thickness.
5. Turn differential case upside down, and measure the clearance
between side gear and differential case on the other side in the
same way.
DISASSEMBLY
1. Remove final gear mounting bolts, and then separate the final gear from differential case.
2. Remove differential side bearing (clutch housing side) using the
drift and pullers.
3. Remove differential side bearing (transaxle case side) using the
drift and pullers.
PCIB0806E
Clearance between side gear and differential case
: 0.1 - 0.2 mm (0.004 - 0.008 in)
SMT611A
SCIA0906E
SCIA0907E
Page 2022 of 4179

MT-90
FINAL DRIVE
4. Remove retaining pin from differential case, and then remove
pinion mate shaft using a pin punch.
5. Rotate pinion mate gears, and remove pinion mate gears, pinion
mate thrust washers, side gears, and side gear thrust washers
from differential case.
INSPECTION AFTER DISASSEMBLY
Gear, Washer, Shaft and Case
Check side gears, side gear thrust washers, pinion mate shaft,
pinion mate gears, pinion mate thrust washers and differential
case. If necessary, replace with a new one.
Bearing
Check for bearing damage and rough rotation. If necessary,
replace with a new one.
CAUTION:
When replacing tapered roller bearing, replace outer and inner
races as a set.
ASSEMBLY
1. Apply gear oil to sliding area of differential case, each gear, and thrust washer.
2. Install side gear thrust washers and side gears into differential
case.
3. While rotating pinion mate thrust washers and pinion mate
gears, aligning them diagonally, install them into differential
case.
SCIA0908E
MTK0135D
SPD715
SMT839
Page 2023 of 4179

FINAL DRIVE
MT-91
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4. Insert pinion mate shaft into differential case.
CAUTION:
Be sure not to damage pinion mate thrust washers.
5. Measure end play of side gears following the procedure below.
Then select side gear thrust washer.
a. Upright the differential case so that its side gear to be measured
faces upward.
b. Place the drift below and a dial gauge onto side gears.
c. Move side gears up and down to measure end play, and select
thrust washer so that it satisfies the standard value. Refer to MT-
101, "DIFFERENTIAL SIDE GEAR THRUST WASHER" .
CAUTION:
There should be no resistance and gears should rotate
freely.
Place differential case upside down. Be sure to measure
end play for opposite side-gears likewise.
Only one thrust washer can be selected.
6. Install a new retaining pin into pinion mate shaft using a pin
punch.
CAUTION:
Do not reuse retaining pin.
7. Press in differential side bearing (transaxle case side) to differ-
ential case using the drifts.
MTK0132D
PCIB0806E
End play standard value
: 0.1 - 0.2 mm (0.004 - 0.008 in)
SMT611A
SCIA0908E
SCIA0910E
Page 2024 of 4179

MT-92
FINAL DRIVE
8. Press in differential side bearing (clutch housing side) to differ-
ential case using the drifts.
9. Install final gear into differential case, and tighten final gear
mounting bolts to the specified torque. Refer to MT-23, "
FINAL
DRIVE COMPONENTS" .
Assembly and Disassembly (RS6F51A)ECS008CB
PRE-INSPECTION
Check the clearance between side gear and differential case as
follows.
1. Clean final drive assembly sufficiently to prevent side gear thrust
washer, differential case, side gear, and other parts from sticking
by gear oil.
2. Upright differential case so that side gear to be measured faces upward.
3. Place the drift below and a dial gauge onto side gear. Move side
gear up and down, and measure the clearance.
CAUTION:
There should be no resistance and gears should rotate
freely.
4. If not within specification, adjust the clearance by changing side
gear thrust washer thickness.
5. Turn differential case upside down, and measure the clearance
between side gear and differential case on the other side in the
same way.
DISASSEMBLY
1. Remove final gear mounting bolts, and then separate the final gear from differential case.
SCIA0911E
SCIA0912E
PCIB0806E
Clearance between side gear and differential case
: 0.1 - 0.2 mm (0.004 - 0.008 in)
SMT611A