Operation CHARM: Car repair manuals for everyone.
Manuals through 2025 now available!

Our trusted friends have launched a new website named LEMON, which has newer manuals. It also contains all the CHARM manuals.

LEMON is the spiritual successor to CHARM, I recommend you try it!

Link: lemon-manuals.la or lemon-manuals.org.ua

(Some people have issue connecting. LEMON is investigating. For now, use Firefox or change your DNS server)

Or, hide this message: temporarily or permanently

Disassembly

1. Remove thrust bearing washer from front end of output shaft.

2. Mark third-fourth synchronizer hub and sleeve for assembly reference, then remove blocking ring, sleeve, and hub as assembly.

3. Remove third-fourth synchronizer insert springs and remove inserts, then remove sleeves from hubs.

4. Remove third gear from shaft, then remove snap ring retaining second gear on shaft and remove tabbed second gear thrust washer and second gear.

5. Using tool J-29721 and adapters 293-39 or equivalent, remove output shaft rear bearing.

6. Remove first gear thrust washer, first gear roll pin, first gear, and blocking ring.

7. Mark alignment of first-second gear synchronizer sleeve and output shaft hub for assembly reference, then remove insert spring and inserts from first-reverse sliding gear and remove gear from output shaft hub. Do not try to remove the first-second-reverse hub from the output shaft as the hub and shaft are assembled and machined as a matched set during manufacture to insure concentricity.