Assembling and Testing Manual Transmission

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COMPETENCY BASED LEARNING MATERIAL

Sector: Sector:

AUTOMOTIVE

Qualification: Qualification:

Automotive Servicing NC II

Unit of Competency: Unit of Competency:

Overhaul Manual Transmission

Module Title: Module Title:

ASSEMBLING AND TESTING M

ASSEMBLING AND TESTING MANUA

ANUAL TRANSMISSION

L TRANSMISSION

Technical Education

Technical Education and Skills Development Authority

and Skills Development Authority

East Service Road, South Superhighway, Taguig, Metro Manila East Service Road, South Superhighway, Taguig, Metro Manila

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AUTOMOTIVE

INDUSTRY SECTOR INDUSTRY SECTOR

NATIONAL CERTIFICATE LEVEL II

QUALIFICATION LEVEL QUALIFICATION LEVEL

COMPETENCY-BA

COMPETENCY-BASED

SED LEARNING M

LEARNING MATERIA

ATERIALS

LS

No.

No. Unit Unit of of Competency Competency Module Module Title Title CodeCode 1.

1. Service Service Starting Starting SystemSystem ••Servicing Starting SystemServicing Starting System ALT723307ALT723307

2.

2. Service Service Charging Charging SystemSystem ••Servicing Charging SystemServicing Charging System ALT723308ALT723308 •

•Servicing Cooling SystemServicing Cooling System ALT723309aALT723309a •

•Servicing Lubricating SystemServicing Lubricating System ALT723309bALT723309b •

•Servicing Gasoline Fuel SystemServicing Gasoline Fuel System ALT723309cALT723309c •

•Servicing Air Induction SystemServicing Air Induction System ALT723309dALT723309d

3.

3. Service Service Engine Engine MechanicalMechanical System

System

•

•Servicing Diesel Fuel InjectorServicing Diesel Fuel Injector ALT723309eALT723309e

4.

4. Service Service Clutch Clutch SystemSystem ••Servicing Clutch SystemServicing Clutch System ALT723310ALT723310

5.

5. Service Service Differential Differential and and FrontFront Axle

Axle

•

•Servicing Differential and FrontServicing Differential and Front

Axle Axle

ALT723311 ALT723311 6.

6. Service Service Manual Manual Steering Steering SystemSystem ••Servicing Manual SteeringServicing Manual Steering

System System

ALT723312 ALT723312

•

•Pulling-out, Disassembling andPulling-out, Disassembling and

Checking Manual Transmission Checking Manual Transmission

ALT723313a ALT723313a

7.

7. Overhaul

Overhaul Manual

Manual

Transmission

•

Assembling and Testing

Manual Transmission

ALT723313b

•

•Identifying and ExplainingIdentifying and Explaining

Hydraulic Brake System Hydraulic Brake System Operations and Functions Operations and Functions

ALT723314a ALT723314a

•

•Servicing BrakesServicing Brakes ALT723314bALT723314b

8.

8. Service Service Brake Brake SystemSystem

•

•Overhauling Brake SystemsOverhauling Brake Systems ALT723314cALT723314c

9.

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AUTOMOTIVE

INDUSTRY SECTOR INDUSTRY SECTOR

NATIONAL CERTIFICATE LEVEL II

QUALIFICATION LEVEL QUALIFICATION LEVEL

COMPETENCY-BA

COMPETENCY-BASED

SED LEARNING M

LEARNING MATERIA

ATERIALS

LS

No.

No. Unit Unit of of Competency Competency Module Module Title Title CodeCode 1.

1. Service Service Starting Starting SystemSystem ••Servicing Starting SystemServicing Starting System ALT723307ALT723307

2.

2. Service Service Charging Charging SystemSystem ••Servicing Charging SystemServicing Charging System ALT723308ALT723308 •

•Servicing Cooling SystemServicing Cooling System ALT723309aALT723309a •

•Servicing Lubricating SystemServicing Lubricating System ALT723309bALT723309b •

•Servicing Gasoline Fuel SystemServicing Gasoline Fuel System ALT723309cALT723309c •

•Servicing Air Induction SystemServicing Air Induction System ALT723309dALT723309d

3.

3. Service Service Engine Engine MechanicalMechanical System

System

•

•Servicing Diesel Fuel InjectorServicing Diesel Fuel Injector ALT723309eALT723309e

4.

4. Service Service Clutch Clutch SystemSystem ••Servicing Clutch SystemServicing Clutch System ALT723310ALT723310

5.

5. Service Service Differential Differential and and FrontFront Axle

Axle

•

•Servicing Differential and FrontServicing Differential and Front

Axle Axle

ALT723311 ALT723311 6.

6. Service Service Manual Manual Steering Steering SystemSystem ••Servicing Manual SteeringServicing Manual Steering

System System

ALT723312 ALT723312

•

•Pulling-out, Disassembling andPulling-out, Disassembling and

Checking Manual Transmission Checking Manual Transmission

ALT723313a ALT723313a

7.

7. Overhaul

Overhaul Manual

Manual

Transmission

•

Assembling and Testing

Manual Transmission

ALT723313b

•

•Identifying and ExplainingIdentifying and Explaining

Hydraulic Brake System Hydraulic Brake System Operations and Functions Operations and Functions

ALT723314a ALT723314a

•

•Servicing BrakesServicing Brakes ALT723314bALT723314b

8.

8. Service Service Brake Brake SystemSystem

•

•Overhauling Brake SystemsOverhauling Brake Systems ALT723314cALT723314c

9.

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HOW TO USE THIS COMPETENCY BASED LEARNING M

HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL

ATERIAL

Welcome to the module in

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

contains training materials and activities for you to complete. The unit of competency "

The unit of competency "Overhaul Manual TransmissionOverhaul Manual Transmission" contains knowledge, skills and" contains knowledge, skills and attitudes required for

attitudes required for Automotive Servicing.Automotive Servicing. It is one of the specialized modules at NationalIt is one of the specialized modules at National Certificate

Certificate level level (NC (NC III).III).

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

learning outcome of the module. In each learning outcome are Information Sheets Information Sheets andand Resources Sheets

Resources Sheets (Reference Materials for further reading to help you better understand the(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 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

each learning outcome. You may remove a blank answer sheet answer sheet at the end of each module (orat the end of each module (or get one from your facilitator/trainer) to write your answers for each self-check. If you have 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.

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

guide because you have:

•

• been working for some timebeen working for some time •

• already completed training in this area.already completed training in this area.

If you can demonstrate to your trainer that you are competent in a particular skill or skills, 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 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

again. If you have a qualification or Certificate of Competency from previous trainings, show it toCompetency from previous trainings, show it to your trainer. If the skills you acquired are still current and relevant to the unit/s of competency 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 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.

currency of your skills, discuss this with your trainer. At the end of this

At the end of this module is amodule is a Learner’s Diary Learner’s Diary . Use this diary to record . Use this diary to record important dates, jobsimportant dates, jobs undertaken and other workplace events that will assist you in providing further details to your undertaken and other workplace events that will assist you in providing further details to your trainer or assessor. A

trainer or assessor. A Record of AchievementRecord of Achievement is also provided for your trainer to completeis also provided for your trainer to complete once you complete the module.

once you complete the module.

This module was prepared to help you achieve the required competency, in Assembling and 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 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 knowledge and skills in this particular trade independently and at your own pace, with minimum supervision or help from your instructor.

supervision or help from your instructor.

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

and knowledge you need to successfully complete this module.

 Work through all the information and complete the activities in each section. ReadWork through all the information and complete the activities in each section. Read information sheets and complete the self-check. Suggested references are included to information sheets and complete the self-check. Suggested references are included to supplement the materials provided in this

supplement the materials provided in this module.module.

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

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 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.

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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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Date: Developed Date: Revised Page # Code No.

ALT723313b Assembling and Testing Manual Transmission 8/ 25/ 2003 06/26/07 1

MODULE : Assembling and Testing Manual Transmission LEARNING OUTCOME #1 : Assemble manual transmission component

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

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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

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Date:

Date: Developed Developed Date: Date: Revised Revised Page Page ## Code No.

Code No.

ALT723313b

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INFORMATION SHEET LO1-1

Manual Transmission Components Manual Transmission Components TRANSMISSION:

TRANSMISSION:

Cars need transmissions Cars need transmissions because of the physics of the because of the physics of the gasoline engine. First, any engine gasoline engine. First, any engine has a

has a redlineredline -- a maximum rpm-- a maximum rpm value above which the engine cannot value above which the engine cannot go without exploding. Second, the go without exploding. Second, the engines have narrow rpm ranges engines have narrow rpm ranges where horsepower and torque are at where horsepower and torque are at their maximum. For example, an their maximum. For example, an engine might produce its maximum engine might produce its maximum horsepower at 5,500 rpm. The horsepower at 5,500 rpm. The transmission allows the gear ratio transmission allows the gear ratio between the engine and the

between the engine and the drivedrive wheels to change as the car speeds wheels to change as the car speeds up and slows down.

up and slows down.

Photo courtesy DaimlerChrysler Photo courtesy DaimlerChrysler

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

performance.

The name transmission refers to the series of parts used to transmit the engine torque The name transmission refers to the series of parts used to transmit the engine torque (turning effort) from the f

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

The transmission usually consists of four major components:components:

•

• ClutchClutch

-- _{friction, fluid, or}_{friction, fluid, or}

electromagnetic electromagnetic types types • • GearboxGearbox -- _{manual or}_{manual or} automatic automatic •

• Drive shaftDrive shaft

-- _{propeller or}_{propeller or}

drive shaft and drive shaft and universal joints

universal joints CONVENTIONAL COMPONENT LAYOUT CONVENTIONAL COMPONENT LAYOUT

•

• Final drive assemblyFinal drive assembly

-- _{provides a suitable top gear ratio;}_{provides a suitable top gear ratio;} -- _{transmits drive to road wheels;}_{transmits drive to road wheels;}

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ENGINE AND TRANSMISSION POSITION ENGINE AND TRANSMISSION POSITION Location of engine and transmission

Location of engine and transmission

assemblies in the vehicle, vary with different assemblies in the vehicle, vary with different makes and models. This makes it

makes and models. This makes it essentialessential that you refer to the maker’s instruction that you refer to the maker’s instruction manuals to a certain in a correct and safe manuals to a certain in a correct and safe method of removal and replacement of these method of removal and replacement of these assemblies.

assemblies.

•

• Engine and transmission position in theEngine and transmission position in the

vehicle may be: vehicle may be: -

- Traditional Traditional front front engine engine and and rear rear wheelwheel drive.

drive.

-

- Front Front engine engine with with front front and and rear rear wheelwheel drive.

drive.

-

- Front Front engine engine and and front front wheel wheel drivedrive

-

- Rear Rear engine engine and and rear rear wheel wheel drivedrive

ENGINE IN THE FRONT – REAR WHEEL DRIVE ENGINE IN THE FRONT – REAR WHEEL DRIVE

ENGINE IN THE FRONT – FRONT AND REAR ENGINE IN THE FRONT – FRONT AND REAR

WHEEL DRIVE WHEEL DRIVE

ENGINE IN THE FRONT – FRONT WHEEL ENGINE IN THE FRONT – FRONT WHEEL

DRIVE DRIVE

ENGINE IN THE REAR – REAR WHEEL DRIVE ENGINE IN THE REAR – REAR WHEEL DRIVE

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Date:

Date: Developed Developed Date: Date: Revised Revised Page Page ## Code No.

Code No.

ALT723313b

ALT723313b Assembling and Testing Manual TransmissionAssembling and Testing Manual Transmission 8/ 8/ 25/ 25/ 2003 2003 06/26/0706/26/07 5 5

DIFFERENTIAL: DIFFERENTIAL:

The differential mechanism is fitted in final drive units to

The differential mechanism is fitted in final drive units to apply equal torque to each drive wheel,apply equal torque to each drive wheel, yet allow them to turn at different

yet allow them to turn at different speeds when the vehicle is turning or cornering.speeds when the vehicle is turning or cornering.

•

• Conventional differential mechanisms are used on the majority Conventional differential mechanisms are used on the majority of motor vehicles.of motor vehicles.

-

- This type This type will only will only move thmove the vehice vehicle when le when traction otraction on each n each driving driving wheel is wheel is equal.equal.

•

• Limited-slip differentials perform the Limited-slip differentials perform the same functions as the conventional type differentials,same functions as the conventional type differentials,

but in addition, transfer the driving force to the wheel with traction,

but in addition, transfer the driving force to the wheel with traction, should the oppositeshould the opposite wheel begin to slip.

wheel begin to slip.

When serving a vehicle fitted with a limited-slip When serving a vehicle fitted with a limited-slip differential, never run the engine while the differential, never run the engine while the

transmission is in gear and one rear wheel is raised, transmission is in gear and one rear wheel is raised, The driving force to the wheel on the ground may The driving force to the wheel on the ground may cause the vehicle to move. This is most dangerous if cause the vehicle to move. This is most dangerous if the vehicle has other

the vehicle has other wheels removed.wheels removed. Portable ‘on car’ t

Portable ‘on car’ type wheels balances are notype wheels balances are not recommended for use on the rear wheels of cars recommended for use on the rear wheels of cars equipped with a limited-slip differential. However, this equipped with a limited-slip differential. However, this type of balancer may be used by removing the wheel type of balancer may be used by removing the wheel opposite to the one being balanced, with the

opposite to the one being balanced, with the

complete assembly raised up. If a wheel is removed, complete assembly raised up. If a wheel is removed, replace at least two wheel nuts to prevent the brake replace at least two wheel nuts to prevent the brake drum from coming off.

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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.

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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.

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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.

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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.

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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

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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

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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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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. 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

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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.

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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.

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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 UNIT OF COMPETENCY : Overhaul Manual Transmission

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.

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