Reverse Idler Gear Assemble

WARNING: This page is about a different car, the 2010 Pontiac G5 and 2010 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: View Of Reverse Synchronizer Sleeve

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IMPORTANT: The reverse synchronizer sleeve can only be placed on the reverse gear when the tall teeth on the sleeve are aligned with the deep tooth gaps in the gear.

IMPORTANT: Lubricate all rotating parts and bearings with manual transaxle lubricant P/N 21018899 during assembly.

Install the reverse synchronizer sleeve to reverse gear. The chamfered edge of the sleeve goes down, towards reverse gear.

Fig 2: Aligning Blocking Ring Lugs

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Install the reverse gear blocking ring (3) with the leaf springs and spring ring (2) on the reverse gear (4), thrust washer (5), and synchronizer sleeve (1). Align the blocking ring lugs with gaps in the gear.

Fig 3: Installing Reverse Idler Gear

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Install the reverse idler gear on the reverse gear blocking ring.

Fig 4: Identifying Reverse Idler Gear Thrust Bearing & Shaft

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Install the reverse idler gear thrust bearing on the reverse idler shaft and install the shaft through the reverse idler and reverse gears.

Fig 5: Installing Shaft Support Bracket

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Install the reverse gear washer.

IMPORTANT: The reverse idler gear shaft lubrications hole, located on the opposite end of the shaft from the bracket, must be on the opposite side of the shaft from the reverse idler shaft support bracket hole when installing the bracket.

IMPORTANT: Always use a new reverse idler gear shaft bracket.

IMPORTANT: The tab on the reverse gear washer must fit between the lugs on the bottom of the shaft support bracket.

Install the NEW reverse idler shaft support bracket with a press as shown. Make sure the bolt hole in the bracket aligns with the threaded shaft hole. Use a 17 mm socket to press on the bracket.

Fig 6: Identifying Dimple On Reverse Idler Shaft Bracket

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Use center punch and dimple on the reverse idler shaft bracket next to the reverse idler shaft.

Fig 7: Measuring Clearance Between Reverse Gear & Reverse Gear Washer

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Measure the clearance between the reverse gear and reverse gear washer. If excessive, verify the reverse idler shaft washer has not moved during the installation of the reverse idler shaft bracket. Ensure the reverse idler thrust needle bearing is not out of position.
Specification: The clearance should be 0.1-0.2 mm (0.004-0.008 in).

Move the synchronizer sleeve up and down to check for proper operation.