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)

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Inspection

Wash all the disassembled parts clean, and examine them for wear, damage, or other defects. Repair or replace defective parts as necessary.
1. Drive gear and drive pinion
(1) If abnormal tooth contact is evident, find out the cause and adjust to give correct tooth contact at assembly. Replace the gear if excessively worn or incapable of adjustment.
(2) If crack, score, or seizure is evident, replace as a set. Slight damage of tooth can be corrected by oil stone or the like.

2. Bearing
- Replace if seizure, peeling, wear, rust, dragging during rotation, abnormal noise or other defect is evident.

3. Oil seal
- Replace if deformed or damaged, and at every disassembling.

4. Differential carrier
- Replace if the bearing bores are worn or damaged.

5. Differential case
- Replace if its sliding surfaces are worn or cracked.

6. Companion flange
- Replace if the oil seal lip contacting surfaces have flaws.