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

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Input Shaft





INSPECTION
1. Measure the clearance between 3rd gear and 2nd gear.





2. If the clearance exceeds the maximum specified, check the contact surface of 3rd gear, 2nd gear and clutch hub (3rd/4th). Replace worn and damaged parts.
3. Measure the clearance between 4th gear and 5th gears.





4. If the clearance exceeds the maximum, check the contact surfaces of 4th gear, 5th gear, clutch hub (3rd/4th), and clutch hub (5th). Replace worn and damaged parts.

DISASSEMBLY
1. Remove the 5th clutch hub assembly, 5th synchronizer ring, and 5th gear using the SST.





2. Remove 3rd/4th clutch hub assembly, 3rd synchro nizer ring, and 3rd gear using the SST.

REASSEMBLY





1. Install a new bearing using the SST.





2. Install the 5th synchronizer ring, 5th gear, and a new bearing using the SST