Reverse gear
Reverse gear |
1. |
Set up the reverse gear in
87 90 487 Sleeve, differential bearing
.
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2. |
Carefully tap the reverse gear out of its support using a drift.
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3. |
Lift off the bearing support, bearing washer, reverse gear pinion, synchromesh sleeve, baulk ring, wire ring, reverse gear wheel and needle bearing from the reverse gear.
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4. |
Check the condition of all parts as regards wear. Replace damaged or defective parts. Measure the wear on the synchromesh by fitting it in place. Measure with a feeler gauge in three places and calculate an average of the readings. If the dimension is less than 0.5 mm the synchromesh must be replaced.
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To assemble |
Grease all components with synthetic manual gearbox oil before fitting, refer to Summary of lubricants and sealants .
1. |
Place the reverse shaft in a 17 mm sleeve so that the lower support washer does not become detached from the shaft.
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2. |
Fit the needle bearing and reverse gear wheel to the shaft.
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3. |
Fit the baulk ring. Check that the wire ring is fitted to the baulk ring.
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4. |
Fit the synchromesh sleeve.
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5. |
Fit the reverse pinion with integrated synchromesh hub.
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6. |
Fit the bearing washer. Check that the washer's tag is between the lugs on the reverse shaft support.
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7. |
Sparingly apply
Cylindrical fastening, Loctite 648
in the shaft hole on the rear axle support. Always use a new rear axle support to ensure a press fit.
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8. |
Press on the reverse shaft support as illustrated (the holes should be aligned). Use a 17 mm sleeve and press on fully.
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9. |
Secure the reverse shaft by screwing it in the clutch housing.
Tightening torque 24 Nm (18 lbf ft) |
11. |
Try shifting the reverse gear by pushing the synchromesh sleeve up and down.
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