Reverse Idler Gear: Assembly

WARNING: This page is about a different car, the 2011 Mercury Milan and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

Install the reverse idler gear washer.

Fig 1: Locating Reverse Idler Gear Washer
Courtesy of FORD MOTOR CO.
Install the reverse idler gear.

Fig 2: Locating Reverse Idler Gear
Courtesy of FORD MOTOR CO.
Install the reverse idler gear washer.

Fig 3: Locating Reverse Idler Gear Washer
Courtesy of FORD MOTOR CO.

Install the reverse synchronizer assembly.

Reverse clutch hub inspection.

Inspect the clutch hub sleeve and hub operation. Install new components as necessary.
Inspect the gear teeth for damage, wear, and cracks. Install new components as necessary.
Measure the clearance between the hub sleeve and shift forks. If it exceeds the maximum specification replace the hub sleeve and shift fork as a set.

REVERSE CLUTCH HUB SLEEVE AND SHIFT FORK CLEARANCE

Standard	Maximum
0.10 mm-0.40 mm (0.003-0.015 in)	0.90 mm (0.035 in)

Reverse synchronizer ring inspection.

Inspect the synchronizer teeth for damage, wear and cracks. Install new components as necessary.
Inspect the tapered surface for wear or cracks. Install new components as necessary.

NOTE:

Set the synchronizer ring squarely on the gear and measure around the circumference.

Measure the clearance between the synchronizer ring and the flank surface on the gear. If it is less than minimum specification, replace the synchronizer ring.

REVERSE SYNCHRONIZER RING CLEARANCE

Standard	Minimum
1.50 mm (0.059 in)	0.80 mm (0.031 in)

Fig 4: Locating Gear Flank Surface

Courtesy of FORD MOTOR CO.

Install the friction damper onto the reverse idler gear.

Fig 5: Locating Friction Damper
Courtesy of FORD MOTOR CO.

NOTE: The reverse idler gear is not serviced separately. A kit consisting of the output shaft reverse gear, the countershaft reverse gear and the reverse idler gear is available for service. All 3 gears in the kit must be installed. The replacement gears are not compatible with the existing gears.

Fig 6: Locating Reverse Idler Gear

Courtesy of FORD MOTOR CO.

Install the reverse idler gear.
- Reverse idler gear inspection.
- Inspect the synchronizer cones for wear. Install new components as necessary.
- Inspect the gear teeth for damage, wear and cracks. Install new components as necessary.
- Inspect the synchronizer ring matching teeth for damage or wear. Install new components as necessary.
Install the needle bearing.

Fig 7: Locating Needle Bearing
Courtesy of FORD MOTOR CO.
Install the thrust washer.

Fig 8: Locating Thrust Washer
Courtesy of FORD MOTOR CO.
Install the clip.

Fig 9: Locating Clip
Courtesy of FORD MOTOR CO.

Measure the reverse idler gear component dimension.

REVERSE THRUST WASHER THICKNESS

mm	Inch
2.04	0.080
2.09	0.082
2.14	0.084
2.19	0.086
2.24	0.088
2.29	0.090
2.34	0.092
2.39	0.094

If the reverse idler gear component dimension is not within specification, install a thrust washer of the correct thickness.

Fig 10: Measuring Reverse Idler Gear Component Dimension

Courtesy of FORD MOTOR CO.