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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Basic Inspection



BASIC INSPECTION
1. Clean all disassembled parts, and check for wear, damage, or any other faults, then repair or replace as necessary.







2. When disassembling, check inside of gearbox for water. If any water is found, carefully check boot for damage, input shaft dust seal, adjusting screw and boot clips for poor sealing. If faulty, replace with new parts.













SERVICE LIMIT
Make a measurement as shown. If it exceeds the specified service limit, adjust or replace.

NOTE: When making a measurement, vise gearbox by using ST 926200000 STAND. Never vise gearbox by inserting aluminum plates, etc. between vise and gearbox.



RACK SHAFT PLAY IN RADIAL DIRECTION #1:




RACK SHAFT PLAY IN RADIAL DIRECTION #2:





RACK SHAFT PLAY




INPUT SHAFT PLAY #1:




INPUT SHAFT PLAY #2:





INPUT SHAFT PLAY








TURNING RESISTANCE OF GEARBOX
Using ST, measure gearbox turning resistance.
GST 926230000 SPANNER