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

Part 1

OUTPUT SHAFT

DISASSEMBLY AND ASSEMBLY

Disassembly Steps 1-36:




Required Special Tools:





DISASSEMBLY SERVICE POINTS
<> BALL BEARING REMOVAL





1. Using special tool MD998917, support the ball bearing, and then set them on the press.
2. Push down on the output shaft with the press, and remove the ball bearing.

<> REVERSE GEAR BEARING SLEEVE REMOVAL





1. Using special tool MD998801, support the reverse gear, and then set them on the press.
2. Push down on the output shaft with the press and remove the reverse gear bearing sleeve.

<> 5TH SPEED-REVERSE SYNCHRONIZER HUB REMOVAL





1. Using special tool MD998801, support the 4th speed gear, and then set them on the press.
2. Push down on the output shaft with the press and remove the 5th speed-reverse synchronizer hub.

<> 3RD SPEED GEAR REMOVAL





1. Using special tool MD998917, support the 2nd speed gear, and then set them on the press.
2. Push down on the output shaft with the press and remove the 3rd speed gear.

<> 2ND SPEED GEAR SLEEVE REMOVAL





1. Using special tool MD998917, support the 1st speed gear, and then set them on the press.
2. Push down on the output shaft with the press and remove the 2nd speed gear sleeve.

<> 1ST SPEED GEAR SLEEVE REMOVAL





1. Using special tool MD998801, support the 1st speed gear sleeve, and then set them on the press.
2. Push down on the output shaft with the press and remove the 1st speed gear sleeve.

<> ROLLER BEARING INNER RACE REMOVAL





1. Using special tool MD998917, support the roller bearing inner race, and then set them on the press.
2. Push down on the output shaft with the press and remove the roller bearing inner race.