assembling and testing manual transmission

COMPETENCY BASED LEARNING MATERIALCOMPETENCY BASED LEARNING MATERIALCOMPETENCY BASED LEARNING MATERIALCOMPETENCY BASED LEARNING MATERIAL

Sector:

AUTOMOTIVE

Qualification:

Automotive Servicing NC II

Unit of Competency:

Overhaul Manual Transmission

Module Title:

ASSEMBLING AND TESTING MANUAL TRANSMISSION

Technical Education and Skills Development Authority East Service Road, South Superhighway, Taguig, Metro Manila

AUTOMOTIVE INDUSTRY SECTOR

NATIONAL CERTIFICATE LEVEL II QUALIFICATION LEVEL

COMPETENCY-BASED LEARNING MATERIALS

No. Unit of Competency Module Title Code

1. Service Starting System • Servicing Starting System ALT723307

2. Service Charging System • Servicing Charging System ALT723308

• Servicing Cooling System ALT723309a

• Servicing Lubricating System ALT723309b

• Servicing Gasoline Fuel System ALT723309c

• Servicing Air Induction System ALT723309d

3. Service Engine Mechanical System

• Servicing Diesel Fuel Injector ALT723309e

4. Service Clutch System • Servicing Clutch System ALT723310

5. Service Differential and Front Axle

• Servicing Differential and Front Axle

ALT723311

6. Service Manual Steering System • Servicing Manual Steering System

ALT723312

• Pulling-out, Disassembling and Checking Manual Transmission

ALT723313a 7. Overhaul Manual Transmission

• Assembling and Testing Manual Transmission

ALT723313b

• Identifying and Explaining Hydraulic Brake System Operations and Functions

ALT723314a

• Servicing Brakes ALT723314b

8. Service Brake System

• Overhauling Brake Systems ALT723314c

9. Service Suspension System • Servicing Suspension System ALT723315

HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL

Welcome to the module in Assembling and Testing Manual Transmission. This module contains training materials and activities for you to complete.

The unit of competency "Overhaul Manual Transmission" contains knowledge, skills and

attitudes required for Automotive Servicing. It is one of the specialized modules at National Certificate level (NC III).

You are required to go through a series of learning activities in order to complete each

learning outcome of the module. In each learning outcome are Information Sheets and Resources Sheets (Reference Materials for further reading to help you better understand the required activities). Follow these activities on your own and answer the self-check at the end of each learning outcome. You may remove a blank answer sheet at the end of each module (or get one from your facilitator/trainer) to write your answers for each self-check. If you have questions, don’t hesitate to ask your facilitator for assistance.

Recognition of Prior Learning (RPL)

You may already have some or most of the knowledge and skills covered in this learner's

guide because you have:

• been working for some time

• already completed training in this area.

If you can demonstrate to your trainer that you are competent in a particular skill or skills, talk to him/her about having them formally recognized so you don't have to do the same training again. If you have a qualification or Certificate of Competency from previous trainings, show it to your trainer. If the skills you acquired are still current and relevant to the unit/s of competency they may become part of the evidence you can present for RPL. If you are not sure about the currency of your skills, discuss this with your trainer.

At the end of this module is a Learner’s Diary. Use this diary to record important dates, jobs

undertaken and other workplace events that will assist you in providing further details to your trainer or assessor. A Record of Achievement is also provided for your trainer to complete once you complete the module.

This module was prepared to help you achieve the required competency, in Assembling and

Testing Manual Transmission. This will be the source of information for you to acquire knowledge and skills in this particular trade independently and at your own pace, with minimum supervision or help from your instructor.

� Talk to your trainer and agree on how you will both organize the Training of this unit. Read through the module carefully. It is divided into sections, which cover all the skills, and knowledge you need to successfully complete this module.

� Work through all the information and complete the activities in each section. Read

information sheets and complete the self-check. Suggested references are included to supplement the materials provided in this module.

� Most probably your trainer will also be your supervisor or manager. He/she is there to

support you and show you the correct way to do things. � Your trainer will tell you about the important things you need to consider when you are

completing activities and it is important that you listen and take notes.

� You will be given plenty of opportunity to ask questions and practice on the job. Make sure you practice your new skills during regular work shifts. This way you will improve both your speed and memory and also your confidence.

� Talk to more experience workmates and ask for their guidance. � Use the self-check questions at the end of each section to test your own progress. � When you are ready, ask your trainer to watch you perform the activities outlined in this

module. � As you work through the activities, ask for written feedback on your progress. Your

trainer keeps feedback/ pre-assessment reports for this reason. When you have successfully completed each element, ask your trainer to mark on the reports that you are ready for assessment.

� When you have completed this module (or several modules), and feel confident that you

have had sufficient practice, your trainer will arrange an appointment with registered assessor to assess you. The results of your assessment will be recorded in your competency Achievement Record.

Date: Developed Date: Revised Page # Code No.

ALT723313b Assembling and Testing Manual Transmission

8/ 25/ 2003 06/26/07 1

QUALIFICATION : AUTOMOTIVE SERVICING NC II

UNIT OF COMPETENCY : Overhaul Manual Transmission

MODULE : Assembling and Testing Manual Transmission INTRODUCTION:

This module deals with assembling manual transmission component, installing and mounting transmission assembly. It also deals with the testing of manual transmission output.

LEARNING OUTCOMES: At the end of this module you will be able to:

1. Assemble manual transmission component; 2. Install and mount manual transmission and associated parts; and 3. Test manual transmission performance.

ASSESSMENT CRITERIA:

1. Manual transmission component parts cleaned, lubricated and coated with new

gear oil as per manufacturer’s manual. 2. Parts reference marks were used in assembling. 3. Assembling of transmission component was performed as per steps and procedure. 4. Bolts and nuts were torqued according to specifications and in correct sequence. 5. Correct tools were used for assembling. 6. Vehicle, workshop and parts safety requirements were applied. 7. Oil properly filled. 8. Transmission gear oil is filled properly and in appropriate level. 9. Transmission jack is positioned in accordance with safety procedure. 10. Transmission assembly is mounted to the engine/vehicle in correct steps as per

specification. 11. Attaching bolts were torqued according to specification and in correct sequence. 12. Transmission associated component were installed or mounted properly according

to steps and procedures. 13. Appropriate tools for the job were used. 14. Personal safety procedures were applied. 15. Transmission is tested while the engine is running and transmission in neutral

position. 16. Testing were conducted as per service manual. 17. Visual/ocular evaluation of transmission performance was conducted with emphasis

on performance of every shifting pattern, noise and operation. 18. Vehicle and shop work safety procedure is applied. 19. Personal safety requirement is observed.

PREREQUISITE:

Before you take this module you must complete first the modules: Set Up Work Area, Equipment as well as the Core and Common Competencies of Automotive Service Technician (NCII).



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MODULE : Assembling and Testing Manual Transmission

LEARNING OUTCOME #1 : Assemble manual transmission component ASSESSMENT CRITERIA:

1. Manual transmission component parts cleaned, lubricated and coated with new gear oil as per manufacturer’s manual.

2. Parts reference marks were used in assembling. 3. Assembling of transmission component was performed as per steps and procedure. 4. Bolts and nuts were torqued according to specifications and in correct sequence. 5. Correct tools were used for assembling. 6. Vehicle, workshop and parts safety requirements were applied. 7. Oil properly filled.

RESOURCES:

Equipment Supplies and Materials

1. Car equipped with manual transmission/ transaxle

2. Hand tools 3. Working table 4. Transaxle 5. Snap ring pliers 6. Punch 7. Press 8. Wrenches 9. Socket set 10. Dial gauge 11. Manual

12. Rags

13. Soap

14. Spare bolt

15. Clear glass

16. Apron/gloves

17. Clear pan/solvent

18. Mechanic’s wire

19. Transmission gear oil

REFERENCES:

1. Manual Transmission and Power Trains by John H. White, pp 453-460

2. The Automotive Power Train and Running Gear, Power Flow and Chassis Unit by Felizardo Y Francisco, Cayetano R. Rivera

3. Basic Auto Repair Manual Tools and Equipment



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Learning Outcome #1: Assemble manual transmission components

LEARNING ACTIVITIES SPECIAL INSTRUCTIONS

1. In the workshop with appropriate equipment and other instructional materials, the trainees will perform the correct procedure in assembling manual transmission components.

1.1 Read Information Sheet LO1-1

“Manual Transmission Components” 1.2 Follow the procedures in Operation

Sheet LO1-1 “Removing the Gearbox”

1.3 Perform Job Sheet LO1-1 "Assembling Manual Transmission Components”

1.4 Assemble different transmission

brands following Job Sheets LO1-2, LO1-3 and LO1-4 in the workshop and observe shop practices and safety.

• Analyze the function of the transmission

and its components. • Follow safety precautions. • Mark parts of manual transmission in

detailed position and assemble following the procedure. Follow the safety notes.

• Ask your instructor to evaluate your work

after performing the assembly.



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INFORMATION SHEET LO1-1 Manual Transmission Components

TRANSMISSION:

Cars need transmissions because of the physics of the gasoline engine. First, any engine has a redline -- a maximum rpm value above which the engine cannot go without exploding. Second, the engines have narrow rpm ranges where horsepower and torque are at their maximum. For example, an engine might produce its maximum horsepower at 5,500 rpm. The transmission allows the gear ratio between the engine and the drive wheels to change as the car speeds up and slows down.

Photo courtesy DaimlerChrysler

You shift gears so the engine can stay below the redline and near the rpm band of its best performance.

The name transmission refers to the series of parts used to transmit the engine torque

(turning effort) from the flywheel to the vehicle’s driving wheels. The transmission usually consists of four major components:

• Clutch

- friction, fluid, or electromagnetic types

• Gearbox

- manual or automatic

• Drive shaft

- propeller or drive shaft and universal joints

CONVENTIONAL COMPONENT LAYOUT

• Final drive assembly

- provides a suitable top gear ratio; - transmits drive to road wheels; - provides differential action between driving wheels when the vehicle is cornering



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ENGINE AND TRANSMISSION POSITION Location of engine and transmission assemblies in the vehicle, vary with different makes and models. This makes it essential that you refer to the maker’s instruction manuals to a certain in a correct and safe method of removal and replacement of these assemblies.

• Engine and transmission position in the vehicle may be: - Traditional front engine and rear wheel

drive. - Front engine with front and rear wheel

drive. - Front engine and front wheel drive - Rear engine and rear wheel drive

ENGINE IN THE FRONT – REAR WHEEL DRIVE

ENGINE IN THE FRONT – FRONT AND REAR WHEEL DRIVE

ENGINE IN THE FRONT – FRONT WHEEL DRIVE

ENGINE IN THE REAR – REAR WHEEL DRIVE



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DIFFERENTIAL: The differential mechanism is fitted in final drive units to apply equal torque to each drive wheel, yet allow them to turn at different speeds when the vehicle is turning or cornering.

• Conventional differential mechanisms are used on the majority of motor vehicles. - This type will only move the vehicle when traction on each driving wheel is equal.

• Limited-slip differentials perform the same functions as the conventional type differentials, but in addition, transfer the driving force to the wheel with traction, should the opposite wheel begin to slip.

When serving a vehicle fitted with a limited-slip differential, never run the engine while the transmission is in gear and one rear wheel is raised, The driving force to the wheel on the ground may cause the vehicle to move. This is most dangerous if the vehicle has other wheels removed. Portable ‘on car’ type wheels balances are not recommended for use on the rear wheels of cars equipped with a limited-slip differential. However, this type of balancer may be used by removing the wheel opposite to the one being balanced, with the complete assembly raised up. If a wheel is removed, replace at least two wheel nuts to prevent the brake drum from coming off.

DO NOT RUN THE ENGINE



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OPERATION SHEET LO1-1 Removing the Gearbox

The gearbox must be removed from the vehicle for proper inspection and servicing. Draining oil

• Avoid scalds from the hot oil when: - draining the gearbox and the final drive

housing; - disconnecting oil pipes and lines; - disconnecting oil coolers

• Ensure that the wheels are chocked before disconnecting drive and propeller shafts in the vehicle: - has a transmission parking brake; - is fitted with an automatic gearbox and

is engaged in the parked position; - has a manual shift gearbox which is

engaged in forward or reverse drive.

AVOID SCALDS WHEN DRAINING

Removing the gearbox When removing and replacing gearboxes

• Plug the opening in the gearbox extension housing, after removal of the drive shaft, to prevent oil spillage.

• Support the engine assembly before removing the transmission mountings. - Do not let the engine hang on the

remaining support mountings.

• Do not manually lift or support the weight of heavy transmission components during removal or replacement. - Use a transmission trolley or a garage

jack in conjunction with a suitable transmission cradle attachment.

Support the engine

REMOVING THE GEARBOX

Servicing and repair of these components often necessitates their removal from the vehicle,

To eliminate possible hazards when implementing this work, make reference to vehicle maker’s manuals, as the procedures will vary with the different transmission and power flow systems and layouts.

General safety precautions are to be observed.



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• Do not let the gearbox assembly hang on engine without support, as it: - may fall causing injury or damage - can distort the clutch disc assembly.

• Use proper work stands or fixtures to secure heavy transmission units when carrying out repairs. - Do not support it in a bench vice by

drain plugs or flanges, etc.

USE A TRANSMISSION PULLEY

Clutch When dismantling certain types of clutch pressure plate assemblies, care must be taken to relieve the force of the pressure plate coil springs before removing the retaining eye-bolt adjusting nuts, otherwise the compressed springs will cause parts to fly.

• Mark the clutch cover and pressure plate to ensure reassembly in the same relative position.

• Place the assembly on the bed of a press with the pressure plate resting on wooden blocks.

• Place a wooden block on top of the clutch cover.

• Carefully operate the press and compress the clutch springs. - remove the retaining eye-bolt nuts.

RESTRAIN THE PRESSURE PLATE SPRINGS

• Slowly release the force of the press so that the cover will rise upwards as the springs extend. - Lift off the cover and remove the clutch

springs. - The eye-bolts and levers can now be

removed.

DISMANTLE CLUTCH



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SYNCHRONIZER ASSEMBLY

Before disassembling the synchronizer assembly to examine the parts, file a scribe mark across the front face of the third and fourth synchronizer sleeve and hub. These marks should be aligned when assembling the synchronizer assembly to maintain mating parts if the same parts are used.

Parts to be examined are:

• The snap ring holding the synchronizer assembly in place on the intermediate shaft. The snap ring could be misplaced or have a sloppy fit.

• Synchronizer blocker rings. Refer to the section on examining the synchronizer blocker ring.

• Synchronizer hub. There should be no rotary looseness between the synchronizer hub and the intermediate shaft. If looseness exists, experiment with a new synchronizer huh and check for a loose fit. If the looseness is removed, the synchronizer assembly must be replaced.

• Worn synchronizer shift inserts and insert springs. These worn parts will permit the synchronizer sleeve to slide back and forth on the synchronizer hub.

The synchronizer hub parts cannot normally be purchased separately. Therefore, the

synchronizer hub, sleeve, inserts, and springs must be purchased as an assembly. The only parts of the synchronizer assembly that can be purchased separately from the sleeve and hub are the synchronizer blocker rings. The snap ring retaining the synchronizer assembly on the intermediate shaft can also be purchased separately. Gear Teeth

A chipped or damaged gear tooth makes a clicking sound. This problem is easy to locate; simply check all gear teeth for damage. If one gear tooth on the input shaft is damaged, the whole input shaft assembly must be replaced. Since the damaged input shaft gear meshes with a gear on the intermediate shaft, that mating gear should also be examined very closely. If both gears are damaged, both must be replaced to remove the clicking noise. If the mating gear is damaged, it must be replaced or of will reduce the new driving gear to its damaged state.

This completes the methods of examining and inspecting the most common causes of

manual shift transaxle problems. The next service procedures are assembling the transaxle subassemblies and transaxle, followed by installing the transaxle assembly into the vehicle.



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JOB SHEET LO1-1 Assembling Manual Transmission Components”

TRANSAXLE SUBASSEMBLY ASSEMBLY PROCEDURE 1. Insert the third and fourth synchronizer

hub into the third and fourth synchronizer sleeve and align the file marks.

NOTE: This alignment should also index the inserts with the scalloped (small curve) teeth placed 120 degrees apart on the inside diameter of the synchronizer sleeve.

NOTE: If the synchronizer blocker rings are not replaced, they should be matched with their respective gears. This whole alignment and matching process helps to ensure smooth gear shifting. A smooth shifting transaxle might be the operator’s only means of justifying the cost of the service work.

2. Assemble all three synchronizer assemblies following the steps outlined previously.

The Synchronizer inserts should align with the synchronizer sleeve scallops.

The synchronizer sleeve and hub must be aligned so that inserts index with the scallops.



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3. Install the antispin pin and first gear thrust washer on the intermediate shaft.

4. Organize the parts on the workbench, This ensures the proper location of gears, thrust washers, and snap rings to be installed onto the intermediate shaft.

5. Before installing each gear, lubricate the inside diameter with lubricating oil to ensure initial lubrication and make sure that the gear turns freely with minimum of 0.003” (0.076mm) clearance between the gears measured with a feeler gage.

Use the adapter and a hydraulic press to press on

the tight race of the intermediate shaft rear bearing.

Safety Note:

When pressing bearings on or off a shaft, always cover the pressing operation with a safety collar to restrict flying shrapnel in the event the bearing explodes.

6. Locate the special pressing arbor in contact with the rear bearing’s inner (tight) race. Using

a hydraulic press, drive the bearing assembly into place. After the rear bearing is seated, check the fourth speed gear for free rotation.

7. After installing the rear bearing outer snap ring and intermediate shaft snap ring, check all

gears for free rotation. Safety Note: Check all synchronizer blocker rings to be sure that they rotate freely and do not bind on adjacent cone clutches. 8. Remember that if the input shaft gear assembly or its bearing are replaced, the input shaft

select shim thickness must be recalculated. Refer to the service manual for this procedure. 9. With the input shaft in place, the intermediate shaft assembly and shift forks can be

installed into the transaxle housing. 10. Lubricate the reverse idler gear assembly and install in the transaxle housing. Seat the roll

pin into the roll pin notch. 11. With the shift rail and bearing retainer plate inside the transaxle housing, the parts for the

fifth gear can be organized on the workbench. 12. Install the input shaft fifth gear and snap ring, synchronizer, and shift fork and rail into the

transaxle housing.



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13. Shift the transaxle into neutral gear. With the fifth speed shift pin (located in the shift fork, insert into the shift fork and rail. With the fifth fork and rail adjusted to the other transaxle shift forks and rails, invert the fifth speed shift pin and tighten into place.

14. After installing the fifth gear strut retainer

plate and snap ring, install the rear end cover with new sealant. Tighten all rear end cover plate bolts and the fill plug.

The shift pin is located in the shift fork.

15. With new sealant on the contact surfaces, install the selector shaft housing. Be sure to

insert the bolts in their proper location. 16. Lubricate the new extension housing 0-ring and install the differential assembly, extension

housing, and bolts. Bolts should be torqued to manufacturer’s specifications. 17. Align and install the differential bearing retainer and torque the bolts to manufacturer’s

specifications. 18. Apply new sealer to the differential cover installing bolts and studs in proper locations.

Now the transaxle is ready to be installed.



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SUBASSEMBLIES ASSEMBLY PROCEDURE 1. Coat the inside diameter of the cluster gear assembly with petroleum jelly and insert the

dummy shaft. 2. Place the counter shaft needle bearings between the dummy shaft and the inside diameter

of the cluster gear assembly. 3. When the needle bearings are all in place, install at either end the bearing thrust washers

and the original or replacement cluster assembly thrust washers. 4. Place pilot end (front) of transmission output shaft upward.

Layout of the transmission output shaft

5. Lubricate the third speed gear and place on the output shaft with the cone clutch facing up. 6. Install the third gear synchronizer blocker ring so the cone clutch sits on the third gear

cone clutch. Service Tip:

The synchronizer sleeve has a large, deep groove located on the outside diameter at the rear of the synchronizer assembly. The synchronizer hub has a longer front hub than rear. When building up the synchronizer assembly align the file marks on the sleeve and hub and place the sleeve groove at the opposite end of the synchronizer hub from the long front hub. 7. Install the third and fourth synchronizer assembly with the longer front inner hub facing up.

The synchronizer sleeve should be facing downward,



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8. Be sure the notches on the synchronizer blocker rings align with the inserts of the synchronizer assembly.

9. Install the third and fourth synchronizer assembly snap ring. Tap the snap ring with a

hammer and punch to ensure it is seated. 10. Turn the rear of the output shaft upward to install the remaining output shaft parts. 11. Lubricate the inside diameter of the second speed gear and slide on the output shaft with

the cone clutch facing up. 12. Install the synchronizer blocker ring so the cone clutches meet. 13. Install the first and second synchronizer assemblies so the large, deep shift fork groove is

facing downward. 14. Install the first and second synchronizer snap ring making sure it is seated the output shaft

groove. 15. The first gear synchronizer blocker ring can be installed and the inserts aligned. 16. Lubricate the inside diameter of the first speed gear and install with the steel thrust washer

and the spring washer. 17. Using a hydraulic press install the rear bearing onto the output shaft. Install the rear

bearing snap ring. 18. Install the speedometer drive gear and retaining clip. 19. With the output shaft assembled, test your assembly work

a. Check that all gears on the output shaft rotate freely. b. Check that the synchronizer blocker rings are not jammed on the gear cone clutches c. Make sure all snap rings are seated into place

20. Place petroleum jelly into the socket at the rear of the transmission input shaft and install

the roller bearings.



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TRANSMISSION ASSEMBLY PROCEDURE 1. Place thrust rings and washers at either

end of cluster gear assembly.

Installing the rear transmission bearing on the transmission output shaft

NOTE: Petroleum jelly or heavy grease can be used to hold these parts in place during assembly.

2. Insert the cluster gear assembly, thrust

rings, washers, and dummy shaft through the rear opening of the transmission housing. Be sure the thrust washer tangs face away from the cluster assembly and the tangs index with the grooves inside the transmission housing.

3. Align the cluster assembly with the holes

in the transmission housing and insert the counter shaft and woodruff key from the rear.

4. Using a plastic hammer, tap the counter

shaft and woodruff key into place in the transmission housing while removing the dummy shaft.

Roller bearings being installed in the transmission input shaft using petroleum jelly or heavy grease to

hold rollers in place.

5. Lubricate the reverse idler gear inside diameter and install the reverse idler gear, shaft,

and woodruff key from the rear of the housing.



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6. With snap ring pliers, expand the extension housing snap ring and slide the extension

housing over the output shaft assembly. Be sure the snap ring seats in the rear bearing outer groove.

7. Place the fourth gear synchronizer blocker ring into place on the third and fourth

synchronizer assembly. Be sure the notches of the synchronizer blocker ring align with the synchronizer inserts.

8. Place the transmission input shaft on the pilot (front) of the output shaft. Service Tip:

Piece petroleum jelly on the rear surface of the transmission housing to hold the extension housing gasket in place.

9. Feed the input shaft, output shaft assembly, and extension housing through the rear

opening of the transmission housing. 10. The reverse idler might have to be moved back and forth on the shaft to accommodate the

assembly operation. 11. Align the extension housing bolt holes and install the extension housing bolts. Do not

tighten these bolts until the front transmission bearing is installed. 12. Install the large outer front bearing snap ring over the outer bearing race. 13. Slide the front transmission bearing onto the transmission input shaft and seat into place. 14. Install the small front transmission bearing snap ring. 15. Align the front bearing retainer and gasket to the transmission housing.

Be sure the lubricant drainage groove aligns with the transmission housing. Install the front bearing retainer bolts.

16. Tighten extension housing to transmission housing bolts. 17. Move all synchronizer sleeves to the neutral position. 18. Place the transmission cover gasket in place. 19. Shift the forks on the cover plate to the neutral position. 20. Install the cover plate with the shift forks seating into the synchronizer sleeves and tighten

all bolts. 21. The transmission should be shifted through all gear ranges before installing into the

vehicle.



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JOB SHEET LO1-2 ASSEMBLING A WARNER T-10 1. Before reassembling bearings and

spacers in countergear, inspect teeth closely for excessive wear, chips or cracks; replace it if worn, damaged.

2. While you’re at it, check spacers, countergear roller bearings for wear. Inspect countershaft, reverse idler; replace them if necessary.

2. Use a dowel pin or shaft to retain bearings spacers; slip solvent-cleaned bearings and washers into countergear. Dip in lube so they’ll stay in place.

4. The 40 rollers inside countergear are in 4 rows of 10 each, separately by two narrow spaces, one long spacer. Pin is removed as rollers go in.



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5. Liberal application cluster gear thrust hold them in countergear is transmission. of lube on washer helps place when

inserted into

6. Rest transmission on its side, with side cover opening toward assembler. Put countergear thrust washer in place; hold with a coat of heavy grease.

7. Set countergear in place at bottom of case; be sure the tanged thrust washers have not been moved or dowel pin has not slipped away from rollers.

8. Shaft must be removed or it wiIl interfere with assembly of mainshaft and clutch gear. Leave thrust washer in place, countergear at case bottom.

9. Reinstall the 14 roller bearings inside main drive gear; use heavy-duty grease to hold bearings in position while assembly is inserted.



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10. When assembling the front reverse idler gear, make sure the teeth are pointed forward with hub facing to rear of the transmission case.

11. The 1st 2nd and 3rd gears, with synchro rings, are assembled on mainshaft. Hub of 3rd notches on synchro ring should always face forward.

12. Install 3rd, 4th gear clutch assembly with taper to front. Be sure keys in hub match notches in 3rd gear synchro ring. Insert main drive gear.

13. Before assembly is put in case, put new selective snap rings (that’ll fit in groove) on mainshaft in front of 3rd~, 4th speed gear clutch unit.

14. Rear bearing retainer can be slid over end of mainshaft. Spread snap ring in pliers so it will drop around rear bearing when aligned with groove.



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15. First insert reverse idler shaft into housing, then slide flat thrust washer in place. Tang on thrust washer should face thrust portion of case.

16. Next slip reverse idler gear onto shaft, engaging spiines with portion of gear within case. Place new gasket on rear bearing retainer’s face.

17. Pull reverse shift shaft partially out of extension; rotate shaft to get reverse shift fork as far forward in rear extension housing as possible.

18. Now, you can start the extension onto the mainshaft while pushing in on shifter shaft to engage shift fork with reverse gear shift collar.

19. When fork engages shift fork, rotate shifter shaft to move reverse gear rearward, permitting extension to mate to transmission case.



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20. With pin in shifter lever boss, torque rear extension housing bolts to 40 ft -lbs. install rear extension-to-bearing retainer bolts, 25 ft-lbs. maximum

21. With hammer and punch, tap clutch bearing in place. Be sure bearing is clean, lubricated, checked for roughness (by turning race in hand.)

22. Use snap ring pliers to slide selective fit snap rings, spacer washer, bearing snap ring over maindrive gear and into proper places.

23. Be sure to use a new gasket that’s slightly moist with lube, before you bolt bearing retainer to front of 1-10 transmission case.

24. New front bearing retainer gasket should be firmly in place and the retainer snug on case. Use good sealer, torque capscrews to 18 ft.-lbs



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25. Shift forks must fit snugly in grooves on 3rd 4th speed clutch sliding sleeve and 1st and 2nd speed clutch sliding sleeve, as shown.

26. Shift trans into 2nd position side cover, attach new gasket, engage shift forks in collars; install side cover, seal and torque capscrews.

27. After trans is filled and shifter linkage is attached your just- like-new Warner T-10 transmission is all ready to tackle the streets again.



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JOB SHEET LO1-3 ASSEMBLING A MUNCHE 4-SPEED 1. Drain lube from trans; remove side cover,

clutch retainer housing, rear extension housing, countergear, main drive gear units; clean and inspect.

2. Begin assembly by checking bearings for undue wear, then lubricate with light engine oil Check gears for wear, clutch sleeves for sliding.

3. After inspecting all moving parts, insert rear bearing in rear bearing retainer; release snap ring, position correctly in retainer groove.

4. Once 1st and 2nd gears (with their synchros, clutch sleeves, etc.) have been installed on mainshaft, tap rear bearing retainer onto shaft.



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5. Spread snap ring with pliers, then ailow ring to align with groove in end of mainshaft to help retain rear bearing. Install reverse, anti-rattle springs.

6. Install 3rd and 4th gears (hub to front of trans), synchronizers and 3rd 4th gear clutch assemblies with both sleeves to front of trans case.

7. Cluster goes in bottom of case with all bearings held in place by dowel. Then tap main drive gear and bearing into hole in case; work from inside.

8. Position reverse idler gear thrust washer on machined face of ear cast in case of reverse idler shaft. Hold assembly in case with heavy lube coating.

9. Shove reverse idler gear next to thrust washer, with the hub facing to rear of case. Install flat thrust washer on reverse idler gear.



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10. Stick cage and its17 roller bearings into maindrive gear; use heavy grease to hold bearings in place.Put oil slinger (concaveforward) on gear.

11. Now you can lower mainshaft assembly into case. Be sure notches on 4th gear synchro ring correspond to the keys on the clutch assembly.

12. Align countergear with shaft in rear and hole in front of case, press countershaft in case, push assembly dowel out until shaft is flush with case.

13. Cut on rear of countershaft must be aligned so it will mate to similar cut in rear extension housing to keep shaft from spinning in trans case.

14. Install reverse idler shaft roll pin (pin

should be in vertical position), and thrust washer into gear, front boss of case, pick up front-tanged washer.



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15. Rear extension housing is turned to reveal shifter fork for reverse gear. Arrow shows slot that reverse idler shaft roll pin alions with.

16. Pull reverse shifter side of extension, to bring reverse extension housing detent position). shaft to left rotate shaft shift into (reverse

17. Start rear extension housing onto trans case, while slowly pushing it on the shifter shaft to engage the shift fork with the reverse shift collar.

18. Pilot reverse idler shaft into extension; slide onto case attach bolts. Line up shaft with holes in boss and insert lock pin. Install shifter, side cover.



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JOB SHEET LO1-4 ASSEMBLING A FORD 4-SPEED 1. Assembly is started by putting the cluster

and reverse goodies in position, but the cluster is lying on the bottom of the case and shaft.

2. The reverse shifter shaft is now in and secured. A set screw holds the shifter fork to the rail. Note the holes for two more shifter shafts.

3. Support thrust washer and low gear to prevent them from sliding off end of shaft; then carefully lower output shaft assembly into case.

4. Place front synchronizer into 3rd gear position; install set screw in 3rd and 4th gear shift fork. Move synchronizer to neutral.



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5. The mainshaft, with all the gears already on it, goes in through the top of the case. Then the shift forks and the shafts are put into their positions.

6. Tightening the set screw in the shift fork that helps secure it to the rail. All of the steps are described in detail in detail in genuine Ford manual.

7. The detent on the bottom shift rail screws in from the side of the case. Note dummy aluminum bearing temporarily holding mainshaft in position.

8. Another shift rail is tapped from the front. Bar across the front of the transhold the front of mainshaft in position while doing the good work.

9. Not many people have this press, but it’s the right way to put the rear bearing into the case — with no beating. Hammer mechanic, please take note.



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\10. After the bearing is in position, the snap ring slips on easily - if you have snap ring pliers. Another snap ring goes on the shaft against bearing.

11. After the main drive gear and its bearings are slipped into position, the front bearing retainer, with a new seal inside, is bolted on the case.

12. Standing the box on end makes it easier to move the gear cluster into position so the shaft can be inserted. Lower hand is catching dummy shaft.

13. The cluster gear shaft and reverse idler shaft are kept from turning by roll pins that must enter these recesses in the case to be held securely.

14. First a gasket, and then the tailshaft housing is slid into position. A new seal should be installed in the end of the housing to stop drip.



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16. Detent for the dropped into the place by the breather on top relieve pressure. top shift rail is hole, and held in cover. Note of housing to

17. The bolts are well greased so that the torque readings will be consistent but no sealer is used on the cover gasket. Fluid leaks are not a problem.

18. That’s right, even the cover is torqued. If you’re going to be super accurate, why not go all the way? Reminder: Don’t forget to put in lube.



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LEARNING OUTCOME #2 : Install and mount manual transmission and associated parts ASSESSMENT CRITERIA:

1. Transmission gear oil is filled properly and in appropriate level. 2. Transmission jack is positioned in accordance with safety procedure. 3. Transmission assembly is mounted to the engine/vehicle in correct steps as per

specification. 4. Attaching bolts were torqued according to specification and in correct sequence. 5. Transmission associated component were installed or mounted properly according to

steps and procedures. 6. Appropriate tools for the job were used. 7. Personal safety procedures were applied.

RESOURCES:


1. Hoist 2. Jack stands 3. Drop light 4. Wrenches 5. Transmission trolley 6. Car with manual transmission and

transaxle 7. Hand tools 8. Crocodile jack 9. Manual transmission 10. Working tables

11. Rags 12. Soap 13. Mechanic’s wire 14. Oil catch pan

REFERENCES:

1. Manual Transmission and Power Trains by John H. White

2. The Automotive Power Train and Running Gear, Power Flow and Chassis Unit, by Felizardo Y. Francisco, Cayetano R. Rivera




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Learning Outcome #2 : Install, mount manual transmission and associated parts


In the workshop with appropriate and equipment and other instructional materials, the trainees will perform the correct procedure in installing/ mounting manual transmission and associated parts. 1. Install transaxle

2. Inspect standard transmission

3. Evaluate the inspection. 4. Install transmission 5. Replace standard transmission

6. Evaluate the installation

Follow the procedures in examining and inspecting the most common causes of manual shift transaxle problem including its installation. • Follow the procedures in Job Sheet LO2-

1 “Transaxle Installation Procedure” • Follow the steps in Assignment Sheet

LO2-1 “Inspecting Standard Transmission”

• Report results in oral or written format

using criteria in the Self-Check LO2-1 • Follow the procedures in Job Sheet LO2-

2 “Transmission Installation Procedure” • Follow steps in Operation Sheet LO2-1

“Replacing Standard Transmission” • Report results in oral or written format

using criteria in the Self-Check LO2-2



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JOB SHEET LO2-1

TRANSAXLE INSTALLATION PROCEDURE 1. Have a colleague help place the transaxle assembly onto the transaxle jack. Chain and

install two locating pins in the engine block assembly. 2. Make up and install two locating pins in the engine block assembly. Service Tip:

In transmission work, housing and bolt hole alignment are important and often necessary. Get into the habit of having two or three aligning pins for each common bolt diameter. An aligning pin can be a bolt with the hex head removed and a radius ground on the end to ease piloting of parts through a hole. Often pin to ease installation and removal with a standard screwdriver.

3. Position the transaxle assembly and jack in place under the vehicle and align with the engine and clutch assembly.

4. At the rear of the transaxle, push the jack and transaxle toward the engine while aligning the two locating pins with their respective holes in the transaxle housing.

5. With the transaxle assembly in place, install and tighten the transaxle to the engine block bolts. Replace the two locating pins with the proper bolts.

6. Remove the safety chains and transaxle jack from under the vehicle.

7. Install the antirotational link, left engine mount, and splash shield.

8. When installing the left drive shaft, hold the inner universal joint assembly at the housing while aligning and inserting the spline into the transaxle housing.

9. Place the outer splined shfat into the steering knuckle support.

10. Install the lower ball joint into the left steering knuckle support.

NOTE: The original or equivalent bolt must be used. No substitutes are allowed.

11. Torque the steering knuckle clamp bolt I to manufacturer’s specifications.

12. Unwrap the speedometer pinion, adapter, and cable and install into the transaxle extension housing.

13. While supporting the right side inner universal joint housing, push the drive shaft into place.

14. Insert the outer end of the right drive shaft into the right side steering knuckle.

Tighten the steering knuckle clamp bolt to manufacturer’s specifications.

15. Install the lower ball joint stud into the steering knuckle and retain with the steering knuckle clamp bolt.



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16. Install the front wheel hub nut and wheel nuts according to the sequence outlined in the service manual.

17. Add lubricant to the proper level as recommended by the manufacturer.

18. Connect the gearshift operating lever and selector shaft.

19. Lower the vehicle to the floor

20. Torque the hub nut and wheel lug nuts to manufacturer’s specifications.

21. Repeat the gearshift linkage adjustment.

22. Adjust the clutch pedal clearance.

23. Connect the battery negative cable to the battery.

24. Remove the engine support fixture and install the #4 cylinder exhaust manifold bolt.

25. Remove fender covers.

26. Road test the vehicle for quiet operation, smooth upshifting, and downshifting.

FACTS TO REMEMBER:

1. Some of the factors that contribute to a transmission slipping out of gear center around the parts of a synchronizer assembly.

2. A clicking noise in one gear range during vehicle operation indicates a damaged gear tooth.

3. When assembling a synchronizer assembly, align the indexing marks.

4. During assembly always lubricate the gear’s inside diameter to provide initial lubrication and ensure easy rotation.

5. After pressing a bearing into a shaft, always check the gears turn freely on the shaft and that the synchronizer blocker rings are free.



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ASSIGNMENT SHEET LO2-1 INSPECTING STANDARD TRANSMISSION

OBJECTIVE What you need Tools to remove and replace a standard transmission

What you will do Inspect parts of a standard transmission

How well So that you can determine which parts are damaged and must be replaced.

If you feel able to meet this objective now, turn to the Self Check.

PURPOSE Standard transmission are powered by the engine through one or more drive couplings. This LE will show you how to inspect transmission parts for damage in order to determine if they must be replaced.

Materials and Equipment

• Vehicle

• Shop manuals

• Safety glasses

• Hand tools set

• Seal puller

• Seal driver

• Transmission gasket

• Transmission seals

• Can opener or oil spout

• Shop towels

• Jack stands

• Floor jack

• Drain pan

• Gasket sealer

• Creeper

• Transmission fluid

• Transmission jack

• Gasket scraper

• Fender covers

• Blowgun

• Air cornpressor



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INSPECTING STANDARD TRANSMISSION

STEP 1. Wash all bearings in clean solvent. STEP 2. Dry bearings by using air blow gun and compressed air. CAUTION: Hold bearings while blowing with compressed air to prevent bearings from

spinning in their race. STEP 3. Check bearings for roughness or pitting. STEP 4. Clean and inspect the inside of the transmission case for cracks. STEP 5. Clean and inspect all gears for broken teeth, wear or other damage. STEP 6. Inspect synchronizer assemblies for grooving or excessive wear. NOTE: Any parts showing damage or wear must be replaced.



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Self-Check LO2-1

Inspect Standard Transmissions Directions At this time, check your skills by reviewing the following criteria. 1. Bearings are cleaned and dried correctly. 2. Transmission parts are inspected for damage or excessive wear. 3. Parts to be replaced are determined. 4. All safety rules are observed.

If you do not feel you can do some of these skills, see your instructor for help.

After you have done all your checking remember to clean and put away your materials and equipment.



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JOB SHEET LO2-2

TRANSMISSION INSTALLATION PROCEDURE

1. Have a colleague help you lift the transmission onto the transmission jack. Wrap the safety chains around the transmission housing and transmission jack.

2. After aligning the transmission jack and transmission with the clutch assembly, shift the transmission into gear. Rotate the transmission output shaft so the transmission input shaft aligns and engages with the clutch driven disc splines.

3. Remove the safety chains from around the transmission housing and transmission jack. Slide the transmission off the transmission jack and into place.

4. Install and tighten the transmission mounting bolts to manufacturer’s specifications with a torque wrench.

5. Install the cross member and transmission mount.

6. Remove the masking tape from the rear universal joint and align the indexing marks on the rear universal joint yokes. Install the rear universal joint and be careful not to tighten the mounting U bolts.

7. Connect the speedometer cable.

8. Install the shift levers at the side of the transmission cover plate

9. Connect the backup light connector and the transmission control switch connector.

10. Remove the engine support stand.

11. Install transmission gear lubricant to the required level. Be sure to tighten the filler hole plug.

12. Lower the vehicle, but leave the driving wheels free of the floor.

13. Connect an exhaust system pipe to the vehicle.

14. Start the engine and operate the transmission through the various gear ranges checking for smooth shifting and quiet operation. If the transmission checks out satisfactorily, lower the vehicle to the floor.

15. The vehicle should now be road tested for smooth, quiet transmission operation.



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FACTS TO REMEMBER:

1. The parts on the four-speed transmission output shaft are the third and fourth synchronizer assembly, third speed gear, second speed gear, first and second synchronizer assembly, first speed gear, and the rear bearing assembly.

2. The synchronizer assembly hub will have a longer hub at the front than at the rear.

3. When assembling the synchronizer assembly, the synchronizer sleeve groove must be at the opposite end of the synchronizer assembly to the long hub on the synchronizer hub.

4. Synchronizer blocker ring notches must be always align with the synchronizer inserts.

5. After the assembling the output shaft, a good service technician always checks his or her work.

6. Cluster assembly thrust washer tangs must always face away from the cluster gear assembly.

7. When installing the front bearing retainer. The lubrication drainage groove must align with the transmission housing.

8. When installing the transmission, shift into gear so the transmission input shaft can be aligned with the clutch driven disc.

9. Indexing marks must be aligned when installing the drive shaft to maintain alignment and balance.

TRANSMISSION LUBRICANT LEVEL CHECK

Lubricant in a transmission reduces friction, wear, and heat. If the lubricant level is low, the rotating gear teeth cannot throw enough oil onto the synchronizer assemblies and rotating parts. Gear clashing problems and premature parts wear result from low lubricant levels.

When checking the lubricant be sure the transmission is at operating temperature. The lubricant level should be at the lower edge of the filler plug hole. If the transmission is cold, the lubricant level should be adjusted to approximately %“to ¾ (12 mm to 19 mm) below the filler plug hole.

These recommendations are important because when the lubricant is cold it contracts and when hot it expands. If the transmission is filled and when hot it expands. If the transmission is filled to the bottom of the filler plug hole when cold, heat will cause the lubricant to expand and, consequently, overfill the transmission. The surplus fluid could flood the front transmission seal and flow onto the clutch driven disc. Lubricant on the clutch driven disc causes clutch chatter and grab.



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OPERATION SHEET 2-1

REPLACING STANDARD TRANSMISSION STEP 1. Replace the transmission Here’s how:

a. Place transmission on transmission jack with input facing the clutch housing b. Raise transmission jack high enough to align input shaft clutch housing. c. Slowly and carefully roll transmission jack forward until the shaft goes into

transmission housing. NOTE: Make sure clutch release bearing is in place. d. Move transmission slightly to the left or right, up or down, until alignment dowel pins

go through the bolt holes in the transmission housing. e. Remove alignment dowel pins and start attaching the bolts with your fingers. f. Start the bottom attaching bolts. NOTE: Make sure bolts are started straight and not cross-threaded. g. Use socket and wrench and snug down transmission mounting bolts. NOTE: Alternate from one bolt to the other. Make sure the transmission case has equal

pressure applied to it. h. Use torque wrench and torque to specifications. Use the combination wrench to install the crossmember to the bolts. j. Use combination wrench to install transmission mounts to transmission and

crossmember NOTE: If any exhaust system parts were removed, replace them at this time. k. Remove engine support jack and wooden blocks I. Install shift linkages NOTE: Make sure the shift linkages do not bind and that they are properly attached m. Use pliers to connect speedometer cable.

n. Reconnect all wires that were attached to the transmission. NOTE: The wires and linkages should have been numbered with masking tape for ease in installation.



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o. Use crescent wrench or combination wrench to install drain plug. p. Use crescent wrench or combination wrench to remove filler plug found on side

transmission case. q. Fill the transmission with proper lubricant. NOTE: Check manual for type of lubricant to use and amount required to fill. r. Use crescent wrench or combination wrench to replace filler plug.

STEP 2. Install the drive shaft. STEP 3. Use the jack to raise the vehicle and remove jack stands. STEP 4. Lower the vehicle to the floor STEP 5. Clean the work area of all oil spills.

STEP 6. Return tools and equipment to their proper storage area.



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Self-Check LO2-2

Replace Standard Transmissions

Directions: At this time, check your skills by reviewing the following criteria.

1. Transmission is installed correctly. 2. Drive shaft is installed correctly. 3. All tools and equipment are returned to their proper storage area. 4. All safety rules are observed.

If you do not feel you can do some of these skills, see your instructor for help.

After you have done all your checking remember to clean and put away your materials and equipment.



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QUALIFICATION : AUTOMOTIVE SERVICING NC III



LEARNING OUTCOME #3 : Test manual transmission performance ASSESSMENT CRITERIA:

1. Transmission is tested while the engine is running and transmission in neutral position. 2. Testing were conducted as per service manual. 3. Visual/ocular evaluation of transmission performance was conducted with emphasis on

performance of every shifting pattern, noise and operation. 4. Vehicle and shop work safety procedure is applied. 5. Personal safety requirement is observed.

RESOURCES:


1. Car with manual transmission and transaxle.

2. Testing instruments

3. Hand tools

4. Wrenches

5. Socket wrench set

5. Rags

7. Soap

8. Fuel

9. Warning devices

10. Troubleshooting chart

REFERENCES:

1. Manual Transmission and Power Trains by John H. White

2. The Automotive Power Train and Running Gear, Power Flow and Chassis Unit, by Felizardo Y. Francisco, Cayetano R. Rivera




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Learning Outcome #3: Test manual transmission performance


In the workshop using appropriate tools and equipment and other instructional materials, the trainees will test newly repaired manual transmission.

1. Read: Steps in troubleshooting defective transmission and power train components.

2. Test : Newly repaired running manual

transmission.

3. Observe shop practices and safety.

4. Report results in oral or written format

• Job Sheet #LO3-1 “Testing Manual Transmission”

• Install the transmission into the vehicle and check for defects using the procedures in Job Sheet #LO3-1



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JOB SHEET LO3-1

TESTING MANUAL TRANSMISSION OBJECTIVE What you need A troubleshooting chart and a vehicle with

defective transmission and power train components

What will you do Troubleshoot transmission and power train problems and determine their causes

How well So that you identify at least 75% of the causes of noises and vibrations in the given transmission and drive trains

If you feel able to meet this objective now, turn to the self check.

PURPOSE Noises and vibrations are common in transmissions and drive trains.

Many of these can cause serious damage to the vehicle if not found and corrected. A mechanic must be able to troubleshoot and isolate the causes of these in order to make the correct repairs. In this Job Sheet you will learn how to find and identify these causes.

Materials and Equipment

• Motor or shop manual

• Troubleshooting checklist

• Vehicle with defective transmission and power train components



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STEP 1. Check noises in the clutch. Possible Cause 1. Dry clutch linkage 2. Worn release bearing. 3. Worn disc assembly 4. Worn release levers 5. Worn or dry pilot bushing. 6. Dry contact-pressure plate lugs in cover.

Correction 1. Lubricate where necessary 2. Replace release bearing 3. Replace disc assembly 4. Replace cover assembly 5. Lubricate or replace bushing 6. Lubricate very lightly

STEP 2. Check chatter in the clutch Possible Cause 1. Worn or damaged disc assembly. 2. Grease or oil on disc facings. 3. Improperly adjusted cover assembly. 4. Broken or loose engine mounts. 5. Misaligned clutch housing.

Correction 1. Replace disc assembly 2. Replace disc assembly cause of

contamination. 3. Replace cover assembly 4. Replace or tighten mounts 5. Align clutch housing and correct

STEP 3. Check why a clutch jumps out of gear Possible Cause 1. Gearshift linkage incorrectly adjusted. 2. Gearshift linkage bent or binding. 3. Clutch housing misaligned. 4. Worn pilot bushing 5. Worn or damaged clutch shaft roller

bearings. 6. Worn, tapered gear teeth; synchronizer

parts worn. 7. Shifter forks, shift rails, or detent-interlock

parts worn, missing, etc. 8. Excessive end play of output shaft gear

train, countershaft gear or reverse idler gear.

Correction 1. Adjust linkage 2. Correct bind, replace bent parts. 3. Check runout at rear face of clutch

housing. 4. Replace bushing. 5. Replace bearings. 6. Inspect and replace as required. 7. Inspect and replace as required 8. Replace thrust washers, and snap rings

(output shaft gear train)

STEP 4. Check why clutch is slipping. Possible Cause 1. Insufficient pedal free play. 2. Burned, worn or oil-soaked facings. 3. Weak or broken pressure springs.

Correction 1. Adjust release fork rod. 2. Replace disc assembly and correct

cause of contamination. 3. Replace cover assembly.



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STEP 5. Check why gears clash when shifting from one forward gear to another. Possible Cause 1. Incorrect clutch adjustment - 2. Clutch linkage binding 3. Gear shift linkage incorrectly adjusted,

bent or binding. 4. Clutch housing misalignment. 5. Damaged or worn transmission

components: shift forks, synchronizers, shift rails and interlocks. Excessive end play to worn thrust washers.

Correction 1. Adjust clutch 2. Lubricate or repair linkage as required 3. Adjust linkage, correct binds, replace

bent parts. 4. Check runout at rear face of clutch

housing. 5. Inspect components. Repair or replace

as required.

STEP 6. Check the causes of transmission noises. Possible Cause 1. Low fluid level 2. Wrong fluid 3. Dirt or chips in fluid 4. Plugged or restricted screen 5. Damaged screen to valve body gasket 6. Damaged or worn pump oil seals. 7. Loose converter to flywheel bolts. 8. Gearshift linkage bent, binding, or

adjusted wrong 9. Clutch housing aligned wrong.

Correction 1. Check for leakage and refill 2. Replace with proper fluid 3. Drain and flush transmission 4. Clean or replace screen 5. Replace valve body gasket. 6. Replace pump oil seals. 7. Tighten flywheel bolts 8. Adjust linkage, correct binds, replace

bent parts. 9. Check runout at rear of housing clutch.

STEP 7. Check why a transmission is locked in one gear. Possible Cause 1. Gearshift linkage binding or bent. 2. Transmission shifter lever attaching nuts

loose or levers are worn at shifter fork shaft hole.

3. Shift rails worn or broken, shifter fork lock plug missing or worn.

4. Broken gear teeth on countershaft gear, clutch shaft, or reverse idler gear.

Correction 1. Correct bind, replace bent components. 2. Tighten nuts, replace worn levers. 3. Inspect and replace worn or damaged

parts 4. Inspect and replace damaged part.



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STEP 8. Check why a transmission will not shift into a certain gears when all others are working correctly.

Possible Cause 1. Gearshift linkage not adjusted correctly 2. Bent shift rod at transmission 3. Transmission shifter levers reversed 4. Worn or damaged shift rails, shift forks,

detent-interlock plugs, loose setscrew in shifter fork, worn synchronizer parts.

Correction 1. Adjust linkage 2. Replace rod 3. Correctly position levers 4. Inspect and repair or replace parts as

required.

STEP 9. Check why a transmission shifts hard. Possible Cause 1. Incorrect clutch adjustment 2. Clutch linkage binding 3. Gearshift linkage incorrectly adjusted,

bent, or binding. 4. Bind in steering column, or column is

misaligned. 5. Incorrect lubricant 6. Internal bind in transmissions - e.g. shift

rails, interlocks, shift forks, synchronizer teeth.

7. Clutch housing misalignment.

Correction 1. Adjust clutch pedal free-play 2. Lubricate or repair linkage as required 3. Adjust linkage — correct any bind. Replace bent pads 4. Disconnect shift rods at column. Check

for bind/misalignment between tube and jacket by shifting lever into all positions.

Correct as required. 5. Drain and refill transmission. 6. Remove transmission and inspect shift

mechanism. Repair as required. 7. Check runout at rear face of clutch

housing. STEP 10. Check why it is difficult to shift the gears. Possible Cause 1. Excessive pedal free play 2. Excessive deflection in linkage or firewall 3. Worn or damaged disc assembly 4. Improperly adjusted cover assembly 5. Clutch disc splines sticking. 6. Worn or dry pilot bushing. 7. Clutch housing misaligned.

Correction 1. Adjust release fork rod. 2. Repair or replace linkage 3. Replace disc assembly 4. replace cover assembly 5. Remove disc assembly splines or replace

disc. 6. lubricate or replace bushing 7. Align clutch housing and free up



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STEP 11. Check why lubricant is leaking in differential and drive axles. Possible Cause 1. Lubricant level too high 2. Worn axle shaft oil seals 3. Cracked rear axle housing 4. Worn drive pinion oil seal 5. Scored and worn companion flange 6. Clogged vent 7. Loose carrier housing bolts or housing

cover screws

Correction 1. Drain excess lubricant 2. Replace worn oil seals with new ones.

Prepare new seals before replacement. 3. Repair or replace housing as required. 4. Replace worn drive pinion oil seal with a

new one. 5. Replace worn or scored companion

flange and oil seal. 6. Remove obstruction. 7. Tighten bolts or cover screws to

specifications and fill to correct level with proper lubricant.

STEP 12. Check for cause of noise in rear wheel. Possible Cause 1. Loose wheel 2. Spalled wheel bearing cup or cone 3. Defective or brinelled wheel bearing 4. Excessive axle shaft end-play 5. Bent or sprung axle shaft flange.

Correction 1. Tighten loose wheel nuts 2. Check rear wheel bearings. If spalled or

worn, replace. 3. Defective or brinelled bearings must be

replaced. 4. Readjust axle shaft end-play 5. Replace bent or sprung axle shaft.

STEP 13. Check for cause of noise in rear axle. Possible Cause 1. Insufficient lubricant 2. Improper ring gear and pinion adjustment 3. Unmatched ring gear and pinion 4. Worn teeth on ring gear or pinion. 5. End-play in drive pinion bearings. 6. Side-play in differential bearings 7. Incorrect drive gear lash 8. Limited-slip differential — moan and

chatter

Correction 1. Refil rear axle with crrect amount of the

proper lubricant. Also check for leaks and correct as necessary.

2. Check ring gear and pinion tooth contact 3. Remove unmatched ring gear and pinion.

Replace with a new matched gear and pinion set.

4. Check teeth on ring gear and pinion for contact. If necessary, replace with new matched set.

5. Adjust drive pinion bearing preload. 6. Adjust differential bearing preload 7. Correct drive gear lash 8. Drain and flush lubricant. Refill with

proper lubricant



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STEP 14. Check for cause of overheating. Possible Cause 1. Lubricant level too low. 2. Incorrect grade of lubricant 3. Bearings adjusted too tightly 4. Excessive wear in gears 5. Insufficient ring gear to-pinion clearance

Correction 1. Refill rear axle 2. Drain, flush and refill rear axle with

correct amount of the proper lubricant 3. Readjust bearings. 4. Cheek gears for excessive wear or

scoring. Replace as necessary. 5. Readjust ring gear and pinion backlash

and check gears for possible scoring. STEP 15. Check for cause of vibrations. Possible Cause 1. Unbalanced or damaged drive shaft 2. Worn universal joints 3. Misaligned drive shaft at companion

flange.

Correction 1. Check drive for damage and balance. 2. Check u-joints and replace as needed 3. Adjust and align drive shaft

STEP 16. Check to see if differential gears and pinion are scored. Possible Cause 1. Insufficient lubrication 2. Improper grade of lubricant 3. Excessive spinning of one wheel.

Correction 1. Replace scored gears. Scoring marks on

the pressure face of gear teeth or in the bore are caused by instantaneous fusing of the mating surface. Scored gears should be replaced. Fill rear axle to required capacity with proper lubricant.

2. Replace scored gears. Inspect all gears and bearings for possible damage. Clean and refill axle to required capacity with proper lubricant.

3. Replace scored gears. Inspect all gears, pinion bores and shaft for scoring, or bearings for possible damage.



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STEP 17. Check tooth breakage on ring gear and pinion. Possible Cause 1. Overloading 2. Erratic clutch operation 3. Ice-spotted pavements 4. Improper adjustment

Correction 1. Replace gears. Examine other gears and

bearings for possible damage. Avoid future overloading.

2. Replace gears, and examine remaining parts for possible damage. Avoid erratic clutch operation.

3. Replace gears. Examine remaining parts for possible damage. Replace parts as required.

4. Replace gears. Examine other parts for possible damage. Be sure ring gear and pinion backlash is correct.



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PERFORMANCE TEST Learner’s Name:

Date:

Competency: Overhaul Manual Transmission

Test Attempt 1

st 2

nd 3

rd

OVERALL EVALUATION

Level Achieved

PERFORMANCE LEVELS

4 – Can perform this skill without supervision and with initiative and adaptability to problem situations.

3 – Can perform this skill satisfactorily without assistance or supervision.

2 – Can perform this skill satisfactorily but requires some assistance and/or supervision.

1 – Can perform parts of this skill satisfactorily, but requires considerable assistance and/or supervision.

Directions: CALL INSTRUCTOR. Ask instructor to assess your performance in the following critical task and performance criteria below. You will be rate based on the overall evaluation on the right side.

Instructor will initial the level achieved.

PERFORMANCE STANDARDS

For acceptable achievement, all items should receive a “Yes” or “N/A” response.

Yes No N/A

1. Did you clean, lubricate and coat manual transmission components with new gear oil as per manufacturers manual?

2. Have you clean transmission bearings following the proper procedure?

3. Did you follow the correct steps in installing and mounting manual transmission?

4. Did you properly test the manual transmission performance meet in the required conditions?



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Learner’s diary

DIARY NOTES

Record important dates, jobs undertaken and other workplace events that will assist you in providing further details to your Assessor.

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Record of Achievement Module: Assembling and Testing Manual Transmission

Learning Outcome #1 - Assemble manual transmission component

Performance Criteria:

1. Manual transmission component parts cleaned, lubricated and coated with new gear oil as per manufacturer’s manual.

2. Parts reference marks were used in assembling. 3. Assembling of transmission component was performed as per steps and procedure. 4. Bolts and nuts were torqued according to specifications and in correct sequence. 5. Correct tools were used for assembling. 6. Vehicle, workshop and parts safety requirements were applied. 7. Oil properly filled.

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Learner has satisfied the above performance criteria. Learner’s signature: ………………………………………. Trainer’s signature: ……………………………………….. Date: ……………………………………………………….



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Record of Achievement

Module: Assembling and Testing Manual Transmission

Learning Outcome #2 - Install and mount manual transmission and associated parts


1. Transmission gear oil is filled properly and in appropriate level.

2. Transmission jack is positioned in accordance with safety procedure.

3. Transmission assembly is mounted to the engine/vehicle in correct steps as per specification.

4. Attaching bolts were torqued according to specification and in correct sequence.

5. Transmission associated component were installed or mounted properly according to steps and procedures.

6. Appropriate tools for the job were used.

7. Personal safety procedures were applied.

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Record of Achievement

Module: Assembling and Testing Manual Transmission

Learning Outcome #3 - Test manual transmission performance


1. Transmission is tested while the engine is running and transmission in neutral position.

2. Testing were conducted as per service manual.

3. Visual/ocular evaluation of transmission performance was conducted with emphasis on performance of every shifting pattern, noise and operation.

4. Vehicle and shop work safety procedure is applied.

5. Personal safety requirement is observed.

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EVIDENCE PLAN

Sector: AUTOMOTIVE SERVICING NC III Unit of Competency: OVERHAUL MANUAL TRANSMISSION Module Title: ASSEMBLING AND TESTING MANUALS TRANSMISSION

Ways in which evidences will be collected: (tick the column)

The evidence must show that the candidate … Dem

onstr

ation

Questionin

g

Inte

rvie

w

Port

folio

1. Assemble manual transmission components X

2. Install, mount manual transmission and associated parts

X

3. Test manual transmission performance X

Note: *Critical aspects of competency

Prepared by:

Instructor

Date:

Supervisor

Date:



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Demonstration Questions Satisfactory Response The candidate should answer the following questions: Yes No

1. What are the steps in cleaning the transmission bearing and associated components?

� �

2. Explain the steps/procedure in installing and mounting manual transmission and associated parts.

� �

3. Did you meet the required condition in testing manual transmission performance?

� �

� �

� �

� �

� �

� �

� �

� �

� �

� �

� �

� �

� �

� �

The candidate’s underpinning knowledge was:

Rating: _________

Feedback to candidate

The candidate’s overall performance was:

Rating: _________ Candidate’s signature:

Date:

Assessor’s signature:

Date:



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Demonstration Candidate’s name: Assessor’s Name: Competency Assessment Title: OVERHAUL MANUAL TRANSMISSION Qualification: AUTOMOTIVE SERVICING NC III Date of Assessment: Tome of Assessment: Instructions for Demonstration:

Given the following material, tools and equipment, the candidate must be able to overhaul the manual transmission.

a. Car equipment with manual transmission/transaxle b. Hand tools c. Working table, stand d. Manual

OBSERVATION Tick (�) to show if evidence is

demonstrated

During the demonstration of skills, did the candidate: Yes

1.0 – 3.0 No 5.0

ACTUAL

1. Clean, lubricate manual transmission component parts. � � �

2. Coat with nuts gear oil as per manufacturer’s manual � � �

3. Perform assembling manual transmission as per steps and procedures. � � �

4. Fill transmission gear oil properly and in appropriate level. � � �

5. Position transmission jack in accordance with safety procedure. � � �

6. Mount transmission assembly the engine/vehicle in correct steps as per specification. � � �

7. Install transmission associated component according to steps and procedure. � � �

8. Use appropriate tools and procedure for the job. � � �

9. Apply personal safety procedure. � � �

10. Torque bolts and nuts according to specifications and in correct sequence. � � �

11. Test transmission while the engine is running and transmission in neutral position � � �

12. Conduct visual/ocular evaluation of transmission performance of every shifting pattern, noise and operation.

� � �

� � �

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The candidate’s demonstration was:

Rating ______________



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TECHNICAL TERMS 1. Transaxle Power transmission device, attached to one end of the

transmission and driveshaft final drive and differential into a single assembly

2. Overdrive A device or transmission gear arrangement which cause the output shaft to overdrive or rotate faster than the input shaft.

3. Steering Column shift An arrangement in which the transmission shift lever is mounted on the steering column.

4. Synchomesh transmission

A transmission with a built-in device that automatically matches the rotating speed automatically matches the rotating speed of the transmission gears as they are about to mess there eliminating the need for double clutching.

5. Transmission Oil cooler

A small, sometimes finned, tube or tank, either mounted separately or included as part of the engine radiator, which cools the transmission fluid.

6. Transfer case An auxiliary

7. Transmission A metal case containing an assembly of shafts gears and related parts. used to transmit power from the engine to the drive shaft or final drive of an automatic vehicle; provide different gear ratios as well as neutral and reverse; may be manual, automatic or continuously variable.

8. Gears Wheel with meshing teeth that transmit power or turning force between shafts.

9. Bearing A part that transmit a load to a support and in so doing absorbs most of the friction of moving parts.

10. Gear Ratio A number of revolution of a driving gear required to turn a driver gear through one complete revolution.

11. Gear shift A linkage type mechanism by which the gears of an automotive transmission are engage and disengaged.

12. Synchronizer A device in the transmission that synchronizes gear about to be meshed so that no miss will occur.

13. Reverse Iidler gear in a transmission, an additional gear that must meshed to obtained reverse gear a gear use only in reverse. That does not transmit power when transmission is in any other position.

14. Ratio The relationship in size or quantity of two or more objects. A gear ratio is derived by dividing the number of teeth on the driver gear by the number of teeth on the driving gear.

15. Shift lever The lever used to shift gears in a transmission.

assembling and testing manual transmission

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