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Reverse Idler Gear: Assembly

WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the reverse idler gear washer.
    Fig 1: Locating Reverse Idler Gear Washer
    G06276060Courtesy of FORD MOTOR CO.
  2. Install the reverse idler gear.
    Fig 2: Locating Reverse Idler Gear
    G06276062Courtesy of FORD MOTOR CO.
  3. Install the reverse idler gear washer.
    Fig 3: Locating Reverse Idler Gear Washer
    G06276063Courtesy of FORD MOTOR CO.
  4. 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 SPECIFICATION TABLE

      Standard Maximum
      0.10-0.40 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.
      • 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.
        NOTE: Set the synchronizer ring squarely on the gear and measure around the circumference.
      REVERSE SYNCHRONIZER RING CLEARANCE SPECIFICATION TABLE

      Standard Minimum
      1.50 mm (0.059 in) 0.80 mm (0.031 in)
    Fig 4: Locating Synchronizer Ring
    G06276057Courtesy of FORD MOTOR CO.
  5. Install the friction damper onto the reverse idler gear.
    Fig 5: Locating Reverse Idler Gear
    G06276056Courtesy of FORD MOTOR CO.
  6. 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.
    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
    G06276055Courtesy of FORD MOTOR CO.
  7. Install the needle bearing.
    Fig 7: Locating Needle Bearing
    G06276054Courtesy of FORD MOTOR CO.
  8. Install the thrust washer.
    Fig 8: Locating Thrust Washer
    G06276053Courtesy of FORD MOTOR CO.
  9. Install the clip.
    Fig 9: Locating Clip
    G06276069Courtesy of FORD MOTOR CO.
  10. Measure the reverse idler gear component dimension.
    REVERSE THRUST WASHER THICKNESS SPECIFICATION TABLE

    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
    G06276070Courtesy of FORD MOTOR CO.
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