Gear Assembly

How to Assemble the Lower Reverse Idler Gear Assembly

Special Instructions

The new reverse idler shaft uses a snap ring in place of the capscrew.

Special Tools

• Torque Wrench 100 lb. ft. capacity Previous Design Current Design

Slotted Thrust Washer Inner Race Snap Ring

Notched Thrust Washer

Capscrew Washer Bearing Reverse Idler Shaft

Reverse Idler Gear Slotted Thrust Washer Inner Race Snap Ring

Notched Thrust Washer

Washer

Snap Ring Bearing Reverse Idler Shaft

Reverse Idler Gear

5

Procedure -

1. Position the reverse idler bearing and inner race into the reverse idler gear.

2. Hold the reverse idler gear and flat thrust washer in place in the main case, and insert the idler shaft, threaded end to the front, through the rear case bore and into the gear. Do not insert the reverse idler shaft into the main case support boss yet.

3. Position the slotted thrust washer in front of the gear with a slot facing up. Note the word FRONT on the slotted washer, and make sure it faces the front of the transmission. Continue to feed the idler shaft forward through this washer and into the hole in the case boss.

4. Slide the reverse idler shaft into the support boss bore, and with a soft bar and driver, drive the reverse idler shaft fully into position.

5. Secure the shaft in position according to one of the procedures below:

Note: For Nut Fastener Design: Inspect the nylon locking insert in the nut, and replace the nut if it is excessively worn. After inspecting and/or replacing the nut, install the nut and washer on shaft front. Tighten the nut to 67-75 lb. ft. (90 to 101 N•m) of torque.

Note: For Capscrew Fastener Design: Apply Eaton®Fuller® thread sealant #71205 or equivalent to the capscrew threads, and install the capscrew and washer. Tighten the capscrew to 67-75 lb. ft. (90 to 101 N•m) of torque.

Note: For Snap-ring design: Install the washer and snap ring on idler shaft using socket. Place snap-ring over front of reverse idler shaft seal, snapping into place by using a large socket. Tap lightly into place.