AURT206670A: Inspect and service transmissions (manual)



AURT206670AInspect and service transmissions (manual)LEARNER WORKBOOK? Commonwealth of Australia 2011ISBN: 978-1-876838-31-7This document is available under a “Free for Education” licence for educational purposes – see for details.This work is copyright. You may download, display, print and reproduce this material in whole or in part or in modified form (retaining this notice) for your personal, non-commercial use or use within your organisation. If you use, display, or reproduce this material or a modified form of it in whole or in part within your organisation you must include the following words in a prominent location within the material in font not less than size 12: ‘The views expressed in this publication do not necessarily represent the view of the Minister for Education or the Australian Government. The Australian Government does not give any warranty nor accept any liability in relation to the contents of this work’. Apart from any use as permitted under the Copyright Act 1968, all other rights are reserved. Requests and inquiries concerning reproduction and rights should be addressed to the Commonwealth Copyright Administration, Attorney General’s Department, Robert Garran Offices, National Circuit, Barton ACT 2600 or posted at . Funded under the Workplace English Language and Literacy (WELL) Program by the Australian Government Department of Education, Employment and Workplace Relations. The views expressed in this publication do not necessarily represent the view of the Minister for Education or the Australian Government. The Australian Government does not give any warranty nor accept any liability in relation to the contents of this work. TOC \o "1-2" \t "Heading 3,2,heading - activity,3" AURT206670A: Inspect and service transmissions (manual) PAGEREF _Toc300904257 \h 1Elements PAGEREF _Toc300904258 \h 1About the workbook PAGEREF _Toc300904259 \h 1Assessment PAGEREF _Toc300904260 \h 3Skills Recognition PAGEREF _Toc300904261 \h 4Access and equity PAGEREF _Toc300904262 \h 4Personal safety PAGEREF _Toc300904263 \h 5Heat PAGEREF _Toc300904264 \h 6Compressed air PAGEREF _Toc300904265 \h 7Chemical substances PAGEREF _Toc300904266 \h 8Equipment safety PAGEREF _Toc300904267 \h 9Hoists, jacks and stands PAGEREF _Toc300904268 \h 9Hand and power tools PAGEREF _Toc300904269 \h 10Oil draining equipment PAGEREF _Toc300904270 \h 11Oil storage device PAGEREF _Toc300904271 \h 12Environmental issues PAGEREF _Toc300904272 \h 13Waste oil PAGEREF _Toc300904273 \h 13Storage of waste oils PAGEREF _Toc300904274 \h 13Transport of waste oils PAGEREF _Toc300904275 \h 13Disposal of waste oils PAGEREF _Toc300904276 \h 14Oil spills PAGEREF _Toc300904277 \h 14Degreasing and parts washing PAGEREF _Toc300904278 \h 15Care of equipment PAGEREF _Toc300904279 \h 16Electronic testing and diagnostic equipment PAGEREF _Toc300904280 \h 16Vehicle protection PAGEREF _Toc300904281 \h 16Activity 1 PAGEREF _Toc300904282 \h 17Activity 2 PAGEREF _Toc300904283 \h 21Transmission gears PAGEREF _Toc300904284 \h 25Spur gears PAGEREF _Toc300904285 \h 25Helical gears PAGEREF _Toc300904286 \h 26Hypoid gears PAGEREF _Toc300904287 \h 27Functions and properties of lubricants PAGEREF _Toc300904288 \h 29Viscosity PAGEREF _Toc300904289 \h 29Oil or fluids PAGEREF _Toc300904290 \h 30Additives PAGEREF _Toc300904291 \h 30Manual transmission lubricants PAGEREF _Toc300904292 \h 31Extreme pressure (EP) additives PAGEREF _Toc300904293 \h 31Manual transmission lubricant ratings (GL) PAGEREF _Toc300904294 \h 32Selection and use of manual transmission oils PAGEREF _Toc300904295 \h 33Activity 3 PAGEREF _Toc300904296 \h 35Transmissions PAGEREF _Toc300904297 \h 39Transmission components PAGEREF _Toc300904298 \h 40Basic principles of the transmission PAGEREF _Toc300904299 \h 41Functions of the transmission PAGEREF _Toc300904300 \h 44Gear ratios PAGEREF _Toc300904301 \h 45Gear fundamentals PAGEREF _Toc300904302 \h 47Gear ratio PAGEREF _Toc300904303 \h 48Simple gear trains PAGEREF _Toc300904304 \h 49Calculating simple gear ratios PAGEREF _Toc300904305 \h 50Compound gear trains PAGEREF _Toc300904306 \h 53Calculating compound gear ratios PAGEREF _Toc300904307 \h 54Gear synchroniser PAGEREF _Toc300904308 \h 57Activity 4 PAGEREF _Toc300904309 \h 59Activity 5 PAGEREF _Toc300904310 \h 62Transfer case PAGEREF _Toc300904311 \h 70Service procedures PAGEREF _Toc300904312 \h 72Check oil levels in transmissions PAGEREF _Toc300904313 \h 73Check oil levels in transaxles PAGEREF _Toc300904314 \h 74Lubricate external components PAGEREF _Toc300904315 \h 75Visual checks PAGEREF _Toc300904316 \h 76Major service PAGEREF _Toc300904317 \h 80Activity 6 PAGEREF _Toc300904318 \h 81Activity 7 PAGEREF _Toc300904319 \h 85Glossary PAGEREF _Toc300904320 \h 87AURT206670A: Inspect and service transmissions (manual)This unit covers the competence required to inspect and service manual transmissionsThe unit includes identification and confirmation of work requirement, preparation for work, inspection, analysis and servicing of manual transmissions and completion of work finalisation processes, including clean-up and documentation.Elements1.Prepare to undertake the inspection of manual transmissions2.Prepare to service manual transmissions3.Carry out service4.Prepare equipment for use or storage.About the workbookThis workbook is designed to assist you in gaining underpinning knowledge and developing practical skills to achieve the competency standard AURT206670A Inspect and service transmissions (manual) within the context of light vehicles.This workbook contains:informationquestionspractical activitiesdirections to use additional resources.The workbook is divided into stages. At the end of a stage, you will see an icon (picture with a meaning) asking you to check your answers and/or practical activities with your trainer. This helps the trainer to monitor your progress.What do the icons mean?An icon is a picture with a meaning. In the workbook, these icons tell you something about:what to do next (activity, check your answers, watch a video clip) orthe text (this is a safety warning).Complete an activityCheck your answers with your trainerWatch this video clipSafety warningAssessmentTo meet the assessment requirements for this competency standard you must demonstrate the following:Knowledge of:Equipment, vehicle and personal safety requirementsTransmission lubricants and fluids and their applicationOperating principles of manual and belt drive transmissionsManual transmission service procedures.Practical ability to:Access, interpret and apply technical informationUse relevant tools and equipmentService manual and/or belt drive transmissionsCheck transmission for normal operationApply personal safety proceduresMaintain customer records.Skills Recognition You may already have knowledge and skills for all (or part) of this competency standard. If you believe you can demonstrate that you already have the skills and knowledge required, talk to your trainer about applying for Skills Recognition. This is also known as Recognition of Prior Learning (RPL), Recognition of Current competence (RCC), or simply Recognition.Skills Recognition is a process for gaining credit for those skills and knowledge gained through work experience, formal training or other life experience.Access and equityIn training, access and equity means ensuring that people with differing needs and abilities have the same opportunities to successfully gain skills, knowledge and experience through education and training. It is about removing barriers and providing the supports people need to access, participate and achieve, irrespective of their age, disability, colour, race, gender, religion, sexuality, family responsibilities or location. For students with disabilities, training organisations may make adjustments to ensure equal opportunity. Reasonable adjustments are designed to minimise the disadvantage experienced by learners with a disability and can include administrative, physical or procedural modifications. NOTE: If you believe you could benefit from support to help you overcome a barrier to participation, you should speak to your trainer or the person in your RTO responsible for access and equity.Personal safetyWhen servicing manual transmissions, various hazards are present. It is impossible to cover all hazards in this workbook, so this sections deals with three main hazards:HeatCompressed airChemical substances.If you have a different safety issue in your workplace, discuss it with your trainer. Figure 1: Personal Protective EquipmentYou should never work in an unsafe workplace. It is up to both you and your employer to identify and fix any potential workplace hazardsHeatScalds and burns are extremely painful and could endanger your life or career. Some substances and equipment which can cause burns include:fluids and lubricantshot componentshot exhaust systems.You should perform servicing and repair functions on cold manual transmissions. The fluid in the manual transmission of a vehicle that has been recently been driven can exceed temperatures of 100°C. At this temperature your skin, eyes and lungs are at risk.If you have to work on a hot manual transmission, you must use Personal Protective Equipment (PPE) to protect you.The following items are the suggested minimum safety requirements.Safety itemReasonSafety shieldProtects your face and head as well as your eyes. Safety glasses/goggles only protect your eyes.Heat resisting glovesProtect your hands and should be long enough to cover your overall sleeves. This prevents the hot manual transmission fluid from trickling down your arm.Full body overallsOnly wear a fully covering ‘or boiler’ type overall. “Action back” or “bib & brace” type overalls expose too much of your skin. Safety bootsLeather steel capped boots protect your feet and should be worn at all times in the pressed airThe pressure in the compressed (under pressure) air lines in a workshop could be as high as 850kPa (120psi). This pressure is needed to operate equipment (such as impact wrenches and air chisels), but it can be very dangerous when used to dry and ‘blow-off’ parts.If the compressed air ‘bounces’ or is reflected off components the following injuries may occur:Hard particles (small pieces) of dirt may be forced into your eyes or skinDeafness may occur due to punctured (pierced) eardrumsBlindness may occur because your eyeball is ‘popped out’ of the eye socketAir may be forced into the bloodstream causing severe pain or deathFriction (rubbing) burns could be caused by the air rushing past your skin.If you are using compressed air for any reason, you must use personal safety equipment to protect yourself.The following items are the suggested minimum safety requirements.Safety itemReasonSafety shieldProtects your face and head as well as your eyes. Safety glasses/goggles only protect your eyes.Full body overallsOnly wear a fully covering ‘or boiler’ type overall. “Action back” or “bib & brace” type overalls expose too much of your skin.Ear plugs or muffsProtects your ear drums and helps prevent industrial deafness.Leather safety glovesProtect you from the impact of hard particles forced off components.Pressure regulatorReduces air pressure so it is safer to ‘blow off’ water after parts have been cleaned. Less risk of dirt being blown around the workshop.Safety bootsProtect your feet and prevents injury in the pressed air noise can cause industrial deafness. When working with compressed air or loud electric tools you must use ear protection.Chemical substancesAll chemical manufacturing companies must by law provide a Material Safety Data Sheet (MSDS) for each product they make. An MSDS provides information on:the hazards of the chemicaladvice on suitable PPEhow to handle and store the chemical safelyfirst aid treatment if someone is exposed to the chemical.Chemical substances used in work on manual transmissions may include:manual transmission fluids and oilsadditivescaustic cleaning solutionshydrocarbon based cleaning solutionspetroleum gelshand cleaners.If you are working with any of these chemical substances you need to follow the correct handling procedure for their use. If unsure seek advice from your trainer.Safety itemReasonSafety shieldProtects your face and head as well as your eyes. Safety glasses/goggles only protect your eyes.Heat resisting glovesGloves protect your hands and should be long enough to cover your overall sleeves. This prevents the hot manual transmission fluid from trickling down your arm.Full body overallsOnly wear a fully covering ‘or boiler’ type overall. “Action back” or “bib & brace” type overalls expose too much of your skin.Safety bootsProtect your feet from spills.Equipment safetyThe equipment used to service manual transmissions vary from workshop to workshop. However, they fall into these main categories:Hoists & jacksHand and power toolsSpecial service toolsOil draining and storage equipmentElectronic systems protection devicesHand and power tools.Hoists, jacks and standsThe vehicle needs to be raised by a hoist or trolley jack and stands to access the transmission. There are many types of vehicle hoists and specific instructions will not be covered in this workbook.Follow manufacturer’s operating instructions. Do not use vehicle raising systems without the appropriate training and supervision from your trainer.Figure 2: Using a hoistPeople are seriously injured by vehicles falling off hoists or jacks in the workshop.ALWAYS follow safety procedures.Hand and power toolsThe safe use of hand tools and power equipment has been discussed in other workbooks and the same rules and precautions apply.Use the correct tools and equipment in the correct way. This will minimize (reduce) personal injury and reduce damage to the tools and equipment.Tension wrenchA tension wrench is a hand tool used to perform certain tasks on manual transmissions. It is a precision measuring instruments. It must be cared for, maintained and used like any other precision instrument such as a micrometer or dial indicator. It may look like a breaker bar, but it must never be used as one.Figure 3 Tension wrenchOil draining equipmentA standard light vehicle manual transmission may contain in excess of four litres of hot manual transmission fluid. This fluid must be drained, stored and disposed of correctly whenever a service on a manual transmission is performed. To ‘catch’ the draining fluid/oils:Do not use any container that leaks.The container may be a simple oil drum or an expensive ‘wine bowl’ and stand.Take the drained clutch fluid/oils and empty into the oil storage device immediately. This will reduce accidental spillage.Clean the container immediately after it has been emptied. This reduces the amount of fumes produced.Figure 4: Using ‘wine bowl’ oil storage equipmentWine bowls have a valve fitted to the base which is opened and closed by the oil storage device. If dirt or debris is trapped in this valve, the next time the wine bowl is used the old manual transmission fluid/oils will leak.Oil storage deviceThis is usually a large storage container situated under the ground or outside the workshop. In the service bays the oil from the wine bowl is poured into special connectors. These are connected by drainpipes to an external storage container.Periodically, an oil recycling or disposal company will send a tanker to your workplace to empty out the storage container.This equipment doesn’t need much maintenance. But you do need to ensure no solids go down the drainpipes and block them.Figure 5: Waste oil storageEnvironmental issuesThe motor vehicle repair industry has a number of waste streams that can potentially affect the environment. The Environment Protection Authority (EPA) is the government agency which regulates and monitors pollution and waste handling in the motor vehicle repair and service industry.The EPA recommends that premises assess the use of certain materials or equipment to try to minimise waste generation.Stockpiling or improperly disposing of wastes ‘out the back’ does not solve any problems, it creates them.Waste oilWaste oils include:used engine (sump) oilgear oildifferential oilautomatic transmission fluidbrake fluidother related products.These are prescribed industrial wastes. This means they are wastes which have potential risks to human health and the environment. The government regulates and manages their use and disposal through environment protection laws. Storage of waste oilsWaste oils should be securely (safely) stored in good quality bulk tanks or two hundred litre drums. Tanks and drums of oil must be stored on a concrete bunded area (an area with a low wall to contain spills), preferably under a roof.Transport of waste oilsTransport contractors who remove waste oil must use vehicles with a current waste transport permit issued by the EPA. The oil must be taken to premises licensed by the EPA for disposal, refining or re-use.The waste generator (producer) or an accredited agent must complete EPA waste transport certificates for each load taken away.Disposal of waste oilsWaste oils must not be tipped down storm water drains, sewers, onto soil or burnt.New oil and waste oil containers with residues, including oil filters, must not be burnt or placed in normal waste bins unless fully drained and cleaned.Oily or greasy rags and paper, oil soaked sawdust, plastics and rubber must not be burnt.An incinerator for the burning of industrial waste is not permitted, unless licensed or permitted by the EPA to do so in a pollution-controlled facility.Oil spillsAccidental oil spills can cause both safety and environmental hazards, so they must be controlled immediately. Large fines can be issued to individuals and organisations who breach environmental regulations.Spill kitSpill kits are specially designed to control and contain small oil or liquid spills. There are different types of spill kits designed for different types of liquids. Place the correct type of spill kit near where hazards may occur. It is your responsibility to find out how to correctly use a spill kit if there is an emergency spill.Figure 6: Spill kitDegreasing and parts washingDegreasing of engines and other large components may be done in:A bunded area or sealed bay with a concrete pad graded (sloping) to a sump. Washings flow to a silt/rubbish collector. Liquids from the collector are pumped to a specially designed oil and water separator. The separator discharges trade waste to the sewer (authorised by your local sewerage authority).A large caustic degreaser bathWaste solvents and sludge must be disposed of as prescribed wastes.A small degreaser trough and irrigator can be used for small parts. Waste solvent in these units is usually collected for recycling by contractors. 3348355109855747395109855Figure 7: Portable bunded wash areasCare of equipmentElectronic testing and diagnostic equipmentModern vehicles require the use of electronic testing and diagnostic equipment. Some could cost over $10,000. You must be extremely careful when using them.The following rules apply:Do not treat them roughly as they are delicate devices. Impact, water, solvents and sunlight easily damage the liquid crystal displays (LCD). In many cases the damage cannot be repaired.They are only accurate if they are connected and programmed correctly. If they are connected or programmed incorrectly, then:Internal circuit damage could happen.The vehicle’s electronic systems (i.e. ECU) could be damaged.The information given by the device could be incorrect, causing incorrect service and repair procedures to be performed on the manual transmissions.Store this equipment in a secure location when not in use. This will prevent loss, theft or accidental damage. Some workplaces have adopted a policy of instant dismissal for damage to electronic test equipment or scan toolsVehicle protectionAlways return the customer’s vehicle to them in a clean and undamaged condition. To ensure this, you must always use safe and appropriate workshop practices and have a professional approach to your work.When working on a vehicle you must:Take all precautions to prevent damage to the vehicle's paintwork and interiors. Use guard covers, floor mats and seat covers at all times. This will prevent grease and oil stains and scratches occurringOnly perform the work required by the customer. If you find that other work needs to be done, contact the customer and discuss the issues. Communication helps to reduce confusion and mistrust.Activity 1Material Safety Data SheetsStep 1Locate the Material Safety Data Sheets (MSDS) in your workshop. They should be in a folder marked “MSDS”. They can also be located on the manufacturer’s website.Step 2Ask your trainer to select one for you.Read the information it has on the following subjects:First-aid measuresHandling and storageExposure control/personal protection.Step 3Use the information on the MSDS sheet to complete the following chart.Product nameProduct applicationCompany nameEmergency phone numberFirst aid measuresEyes Skin Ingestion (internal organs) Inhalation (nose, mouth, windpipe, lungs) Handling and storage Handling precautions Fire prevention Storage conditions Exposure controls/personal protection Exposure limits (maximum time you should breathe fumes or have skin contact with the chemical)Protective clothing Respiratory protection (breathing mask) Ask your trainer to check your results before proceeding.Trainer Signature: Date:This page has been left blank intentionally.Activity 2Answer the following questions OR Tick the correct answer.Question 1The temperature of fluids and oils in transmissions can exceed 100°C.TrueFalseQuestion 2Safety shields protect your face and eyes.TrueFalseQuestion 3Ear protectors should be used in noisy environments.TrueFalseQuestion 4The pressure in compressed air lines could be as high as 850kPa.TrueFalseQuestion 5Three major hazards when working on transmissions are:Question 6What are three topics of information in a Material Safety Data Sheet? Question 7On the following chart, list the equipment in the workshop that is used to service transmissions.Hand toolsOil draining & storage equipmentQuestion 8Complete the following sentence.The Environment Protection Authority (EPA) is a government agency which: Question 9Empty plastic oil containers can be put straight in the normal rubbish bin.TrueFalseQuestion 10What should you do if you accidentally spill some oil at work?Question 11Complete the following sentence.Degreasing of engines should be done in Question 12If electronic testing devices are connected incorrectly the circuits could be damaged.TrueFalseQuestion 13Electronic testing devices are only accurate if programmed correctly.TrueFalseQuestion 14LCD displays can be severely damaged if exposed to direct sunlight for long periods.TrueFalseAsk your trainer to check your results before proceeding.Trainer Signature: Date:This page has been left blank intentionally.Transmission gears There are three types of gears used in manual transmissions:Spur or straight cut gearsHelical or angle cut gearsHypoid gears – curved teeth.Spur gearsSpur gears have teeth cut straight across the face of the gear. They are used to connect shafts (input and output) that are parallel (side by side) to each other.Figure 8: Spur gearWhen two spur gears are meshed together, the teeth transfer energy to each other. The shafts travel in opposite directions.Spur gears are very strong and are used for high load applications, for example, trucks, reverse gears and racing cars.Helical gearsUnlike spur gears, helical gears have the teeth of the gear on an angle or helix (spiral) to the force.Figure 9: Helical gearsWhen the gear teeth are meshing, the load is spread over a greater surface and over more than one tooth. Helical gears cannot slide in and out of mesh - the teeth on the gears are always in contact. This is known as constant mesh and is used in most manual transmissions.Because of their design, helical gears are quiet. For this reason they are used in cars and light truck applications.Hypoid gearsThese special final drive gears are found in some transaxles and final drive assemblies. The gear teeth do not roll against each other but have a wiping action. This requires a special extreme pressure (EP) hypoid specific oil with an API rating of GL - 4 or GL - 5.Figure 10: Hypoid gearThis page has been left blank intentionally.Functions and properties of lubricantsWhenever two or more surfaces are in contact, for example when gears are in mesh or bearings are supporting shafts, a rubbing force is created called friction. The amount of friction created is determined by these factors:how clean the surfaces areif the surfaces are dry or wetthe type of material the surfaces are made ofthe surface finish (are they rough or smooth)the load forcing the surfaces together.Friction is generated when the surfaces in contact resist (work against ) motion. They use energy to overcome the friction and generate heat at the surfaces. If this occurred continually the bearings in engines or gears would rapidly overheat and suffer severe damage.If the rubbing surfaces can be kept apart, then friction will not occur and heat will not be generated. This will extend the life of gears and bearings. The main function of a lubricant is to help keep the moving surfaces apart. Essentially, all lubricants reduce friction and overheating. Lubricants used in automotive applications are oils, fluids or greases.ViscosityA film (thin layer) of lubricant fills the gap between the two surfaces, so then the friction created is from the lubricant on metal, not metal on metal. The resistance to motion is due to the viscosity or thickness of the lubricant. The viscosity or thickness of the oil resists flowing. The thicker the lubricant, the higher the viscosity is e.g. 140 viscosity oil is thicker than 85 viscosity oil.High viscosity lubricant is harder to squeeze out from between the two rubbing surfaces when a load is applied. Motor vehicle manufacturers specify a lubricant with the right viscosity to handle the component's load without causing too much resistance to movement.Oil or fluidsThe most common lubricants used in motor vehicles are oils and fluids. They are created from minerals refined from crude oil. They are extremely stable (don’t easily change form) and very suitable for automotive use. Lubricants are made from distilled (made more pure) oil. Chemical additives with specific purposes are also added.AdditivesThere are many different additives. Here are a few types:Oxidation inhibitors (lessen the effect): When the oil combines with oxygen in the air and then comes in contact with hot surfaces, a chemical reaction called oxidisation occurs. This forms hard deposits which can be seen on pistons. These hard particles can also be carried around in the oil itself and be deposited in oil passages, tubes or pipes, blocking the oil flow. Oxidation inhibitors (sometimes called anti-oxidants) are used to reduce this chemical reaction.Detergents: Clean oil gradually gets a lot of contaminants (dirt) in it. These are the unwanted particles such as oxidation products. Detergents are used to keep the contaminants suspended (floating) in the oil. This prevents contaminants depositing (settling out) on components and allows the lubricant to carry the contaminants to the filtering devices for removal.Viscosity index improvers: Viscosity of lubricants can change dramatically when they are heated. These chemicals help the lubricant maintain its viscosity.Anti-foaming agents: In some cases the oil can froth or foam. These chemicals are added to the lubricant to prevent this from happening.Metal de-activators: Lubricants can corrode (eat away) the metals used in transmissions like brass and bronze. These chemicals help to prevent the corrosion. Anti-rust agents: Help to reduce the corrosion or rusting of the ferrous (iron-based) metals in the gears and the casing.Dispersants: Also keep the contaminants suspended in the lubricant. This helps reduce the amount of sludge deposits forming on the housing and keeps the working parts of the transmission clean.Extreme pressure additives: Needed in transmissions and final drives that use hypoid gears, where the pressure is greater.Manual transmission lubricantsLubrication of a manual transmission is achieved by placing sufficient lubricant within the transmission case so that at least one, or ideally all, of the gears dip into the oil. When the gears rotate (turn) the lubricant circulates (moves around) inside the transmission. This movement lubricates the various parts of the transmission.In some cases, there are lubricating holes in the valleys of the gear teeth. The lubricant is trapped between the gear teeth and the holes channel it into the bearings and/or bearing surfaces between the gear and the shaft it is running on.Manual transmissions generally use different oil than engine or automatic transmissions. The lubricants are formulated differently because in manual transmissions:the operating temperatures are much lower than in automatic transmissions, so they produce little or no hard carbon deposits. the pressure generated between the gear teeth is much higher than in automatic transmissions, so the lubricant must be able to withstand (not be affected by) these extreme pressures.Extreme pressure (EP) additivesExtreme pressure or EP additives fall into three main categories:Sulphur basedChlorine basedPhosphorus based.Sulphur based: Sulphur additives have good EP properties, but sulphur is highly corrosive to the bronze components. Less corrosive compounds are now used.Chlorine based: Chlorine based additives have good EP properties, but with high amounts of moisture and heat they can make the lubricant highly corrosive. There is also an environmental concern with using chlorine in the lubricant.Phosphorus based: The most commonly used EP additives are phosphorus based. These additives provide good anti-wear and EP properties. They also have good anti-oxidant and ashless properties required for gear oil of GL-4 and GL-5 classification.Manual transmission lubricant ratings (GL)The GL rating system is used to classify gear lubricants. The rating system is similar to the petrol engine oil S rating and diesel engine C rating systems (SA, SG or CA CG).GL = Gear LubricantS = Spark ignition (petrol)C = Compression ignition (diesel)Most modern manual transmission gear lubricants are in the GL-4, GL-5 & GL-5 Plus classification. The following chart outlines the GL Rating System.The GL Rating SystemAPI/G -1 Unfortified straight mineral oilAPI/GL-2Worm drive anti-wear mineral oilsAPI/GL-3Spiral bevel axles and some manual transmissionsAPI/GL-4Hypoid moderate high speed EP oilAPI/GL-5Hypoid shock load, high speed and torque EP oilAPI/GL-5 PlusSame as GL-5 plus friction modifier. For use in limited-slip differentialsHow to understand the rating system codesFor example, a lubricant with the code API GL-5.SAE 75W/90APIGL–5SAE75W90American Petroleum IndustryQuality and suitability to the transmission requirementsSociety of Automotive Engineers rating of viscosityOil viscosity at cold temperatureOil viscosity at operating temperature.Selection and use of manual transmission oilsTo ensure the correct oil is used, always refer to the manufacturer’s instructions or lubrication guides. Some manufacturers use engine oils and even automotive transmission oil in their manual transmissions. Vehicles made after 1986 require individual and special types of manual transmission lubricants, as prescribed by the vehicle manufacturer.Motor vehicle manufacturers and oil companies provide detailed information, which must be used to determine the correct fluid for a particular vehicle.Workshop manuals and oil company lubrication guides will be provided in the workshop.Figure 11: Transmission oilsMake sure you use the correct manual transmission lubricant. If you don’t, severe damage and/or incorrect operation of the transmission will occur.This page has been left blank intentionally.Activity 3Answer the following questions OR tick the correct answer.Question 1Viscosity is the property of the lubricant to resist flowing.TrueFalseQuestion 2Friction is generated when two surfaces slide over each other.TrueFalseQuestion 3What factors affect the amount of friction created between two surfaces?a. b. c. d. e. Question 4What is the function of these additives?Viscosity index improvers: Detergents: Question 5How does the lubricant move round and oil all the gears?Question 6Some gears have holes drilled in them to help lubricate the bearings inside the gear.TrueFalseQuestion 7High pressures are created between gear teeth within a manual transmission.TrueFalseQuestion 8An extreme pressure additive is used in most manual transmissions.TrueFalseQuestion 9What is GL-3 oil used for?Question 10Why are phosphorus EP additives better than sulphur and chlorine based ones?Question 11What are 2 reasons why manual transmissions use different oil than engine or automatic transmissions?Question 12Locate your workshop manuals and/or oil company lubrication guides.Choose four additional vehicles to add to the left hand column in the chart below.Locate the appropriate information to complete the details in the chart.The information for a VT Commodore has been provided as an example.Make & model of vehicleManufacturer’sspecificationsOil companyProductQuantity of fluid neededAPI & SAE ratingVT CommodoreHN1855CastrolVMX8W1.2 litresAsk your trainer to check your results before proceeding.Trainer Signature: Date:TransmissionsThe transmission is also known as the gearbox.In a rear wheel drive vehicle, it is located between the engine and the tail shaft.In a front wheel drive vehicle, it is attached to the engine but has shafts driving the front wheels.Figure 12: Position of rear wheel driveFigure 13: Position of front wheel driveTransmission componentsThe transmission contains a number of shafts, gears and bearings. These components work together to provide a variety of gear ratios to suit various driving conditions of the car. Figure 14: Transmission gears and shaftsGear leverUsed to change to a different gearSpeedo driveMeasures the road speed of the vehicleReverse idlerEngage it to reverse the direction of the main shaft (output)Cluster gearWhen engaged by the main gear drive, gives different gear ratiosInput shaftCollects drive from the turning enginesInput gearDirectly connected to the engine via the input shaft and transmits power to the other gearsMainshaft gearGears attached to the mainshaft and engaged as requiredMainshaft (output)Connected to the differential. It has gears attached and they are engaged as requiredBasic principles of the transmissionTorqueTo accelerate a stationary vehicle requires a large amount of torque (a twisting or turning force). Torque is produced in the engine when the burning fuel and air forces the pistons down. The piston pushes through the connecting rod which turns the engine crankshaft. The engine torque (or turning effort) is then transferred (moved on) through the clutch into the transmission.Unfortunately the internal combustion engine produces very little torque at low engine speed. Figure 15: Vehicle torqueThe gears in a transmission are able to multiply or increase engine torque.Figure 16: Multiplying torqueTorqueWhen is high torque used?High torque is needed to easily move a vehicle from a rest or to climb a hill. In low or first gear, the engine turns at high speed but the wheels turn at a low speed. This deliver the high torque needed but with low vehicle speed.Figure 17: Vehicle climbing a hillWhen is low torque used?Once the vehicle is moving, high torque is not needed. Higher gears can be selected to increase the vehicle speed but with reduced torque. Passenger vehicles are fitted with four, five and even six speed transmissions to match the road conditions.Figure 18: Vehicle driving on flatTorque Torque is a rotating or twisting force. The engine produces the torque to propel the vehicle. The gears inside the transmission increase the torque as a gear reduction or decrease the torque as an overdrive.Figure 19: Twisting motion of torqueWith trucks, high torque is required because of the heavy loads that have to be moved.The transmission fitted to a truck is able to greatly multiply the engine’s torque so that the vehicle can move from rest when transporting heavy loads.Figure 20: Trucks move heavier loads so need more torque.Functions of the transmissionThe gearsThe engine produces the torque to propel (move forward) the vehicle. The driver can select from the gears inside the transmission to increase the torque or decrease it.Manual transmission gears are used to:transmit movementchange the direction of movementincrease or decrease the applied force.Gear reductionA gear reduction reduces (makes smaller) the transmission output speed and increases the torque. The vehicle slows but the engine is working harder.Overdrive5th gear or overdrive is the opposite of a gear reduction. It increases the output speed but with reduced torque i.e. the engine is rotating at 2000 rpm and the output is approximately (almost, not exactly) 2400 rpm. This will result in:reduced engine speedreduced fuel consumption.Manual transmission functionsGearsFunctionNeutral position The engine can start and run, without moving the vehicle.A range of gear ratiosThe lower ratios can be used for starting off. The higher ratios allow the vehicle to increase in road speed.Reverse gear Allows the vehicle to travel backwards.Engine braking The lower ratios can be selected by the driver to slow down road speed when descending steep hills.Watch this video clip: Manual transmission layoutGear ratiosMomentsPin or FulcrumThe force that turns something is called the moment. A force applied to the lever in the diagram below will cause the lever to rotate around the fulcrum (pin).ForceLever Figure 21: The centre of the turning effect is called the fulcrumThe measurement of a moment is based on two things:The size of the force (measured in Newtons or N).The radius or perpendicular (vertical) distance from the force to the centre of the fulcrum (measured in metres).Example1Force applied to the lever = 100 NewtonsRadius = 200 mm (or 0.200 metres)Moment = Force x Radius= 100N x 0.200 metres= 20 Newton/metres (N/m)Figure 22: Moment calculationExample 2A torque or tension wrench measures the rotational (turning) force applied to bolts.Figure 23: Torque wrenchIf a tension wrench which is one metre long has a force of100 Newtons applied to it, the moment (or torque) would be:Moment= Force x Radius= 100 Newtons x 1 metre= 100 Newton/metres= 100N/mGear fundamentalsManual transmission gears are used to:transmit (send) movementchange the direction of movementincrease or decrease the applied force.Gears are round wheels with teeth machined on their outer diameter. They are commonly used to transmit turning effort from one shaft to another. Basically, one gear turns another gear of a different size to change output speed and torque (turning power).Figure 24: Gears of different sizesGear ratioGear ratio is the speed of the input shaft of a transmission, compared with the speed of the output shaft when a gear is selected. The gear ratio is determined by the number of teeth on the gears. This controls the speed difference between the input and output shafts.Gear ratios also modify the torque of the engine. When the output shaft speed is reduced the torque is increased. (eg. if the speed is halved the torque is doubled).Input shaftSmall gearIncreased torqueOutput shaftLarge gearDecreased speedFigure 25: Small gear driving a large gear Watch this video clip :Gear ratiosSimple gear trainsThere are two basic types of gear trains used in manual transmissions and transaxles. They are:Simple gear trainCompound gear train.Watch this video clip :Gear trainsWhat is a simple gear train?More than two gears are in mesh, and turn independently of each other.Usually used in transaxles fitted to front engine front wheel drive or rear engine rear wheel drive vehicles.Figure 26: Driver and driven gearsNOTE: D.O.R = direction of rotation. In the case above, the gears revolve in opposite directions.Calculating simple gear ratiosTo calculate the ratio of a simple gear train, only consider the first driver gear and the last driven gear. Intermediate or idler gears change the direction of rotation (D.O.R) but have no effect on the ratio. Figure 27: Idler gear doesn’t affect ratioFormula Ratio = Number of teeth on driven gearNumber of teeth on driver gearThe ratio of two gears in mesh is calculated using the number of teeth on the gears. Example 1Figure 28: Gear ratio 1:1Number of teeth on driven gear = 24Number of teeth on driver gear = 24Ratio = driven / driver= 24/24 = 1:1 1:1 = The driver gear turns one revolution in order to turn the driven gear one revolution..Example 2Figure 29: Gear ratio 2:1Number of teeth on driven gear = 24Number of teeth on driver gear = 12Ratio = driven / driver= 24/12 = 2:12:1 = The driver gear turns two revolutions in order to turn the driven gear one revolution.Example 3Figure 30: Gear ratio 1.5:1REMEMBER: The middle gear is an idler gear and has no effect on the ratio.Number of teeth on driven gear = 36Number of teeth on driver gear = 24Ratio = driven / driver= 36/24 = 1.5:11.5:1 = The driver gear turns one and a half revolutions in order to turn the driven gear one pound gear trainsA compound gear train combines some simple gear trains in series (usually two). Each set of simple gears has a ratio. To obtain the overall ratio you must multiply these individual ratios together.There are two gears on the same shaft. The driver input shaft and driven output shaft are usually in line with each other.The cluster gear in a manual transmission is a compound gear train. In this case one gear is a driver and the other gear is driven. Figure 31: Compound gear trainCalculating compound gear ratiosEach set of simple gears has a ratio.To obtain the overall ratio you must multiply these individual ratios together.Example 1Figure 32: Gear ratio 6:1First set of gearsTeeth on driven gear = 24Teeth on driver gear = 12Ratio 1 = driven / driver = 24/12 = 2:1Second set of gearsTeeth on driven gear = 30Teeth on driver gear = 10Ratio 2 = driven / driver = 30/10 = 3:1Multiply both ratios together = 2 x 3Overall ratio = 6:16:1 = The input shaft driver gear turns six revolutions in order to turn the output shaft driven gear one revolution.Example 2 This example is for the first gear on a conventional rear wheel drive five speed transmission.Observe the changes to the engine torque output and the transmission output revolutions as the gears go up in number. Figure 33: First gearGear type TeethCalculationRatio1. Input gear (driver)1224122:12. Cluster gear (driven)243. 1st gear cluster (driver)1224122:14. 1st gear mainshaft (driven) 24Overall ratio2:1 x 2:14:1This means in first gear the engine turns four times for the output of one.GearRatioTorqueSpeed RPM1st4:1100 Nm x 4 = 400 Nm of torqueInput ÷ ratio2000 ÷ 4 = 500 rpm (output speed)The engine produces 100 Nm of torque at 2000 revs per minute.If you select down to first gear:Torque increases by four times, from 100 Nm to 400 NmOutput speed reduces by four times, from 2000 rpm to 500 rpm.Gear synchroniserSo that gear changes can be made quickly and smoothly, most gearboxes have some, or all, of the output shaft gears in ‘constant mesh’ with the countershaft gears. If this is the case, small clutches are needed between the gears and the output shaft, so that only one gear will be driving the shaft at any one time. Smaller vehicles have synchronisers, combined with the clutches, which synchronise the speed of the gear and the shaft before the ‘dog’ clutch is engaged. The synchronisers are usually small friction ‘cone’ clutches that engage when the sleeve is moved with the hub along the shaft. To select a gear, the selector fork is moved by the driver, moving the sliding sleeve in the direction of a dog clutch, built into the gear. Figure 34: Gear synchroniserIf the dog clutch and the sliding sleeve are moving at different speeds the synchroniser will do two things:Block (stop) selection by stopping the sliding sleeve from moving.Cause the gear to speed-up or slow down to match the speed of the sliding sleeve (synchronise with it).Once the speed of the sliding sleeve and the gear are the same (synchronised) the sliding sleeve is allowed to engage (connect to) the dog clutch on the gear. Selection is then complete.This page has been left blank intentionally.Activity 4Answer the following questions OR Tick the correct answer/s.Question 1List three purposes of a manual transmission.a. b. c. Question 2If the driven gear of a simple gear train had 36 teeth and the driver gear had 12 teeth the gear ratio would be:3.2:13:14:1Question 3With reverse engaged, the reverse idler gear would rotate: In both directionsAnti-clockwiseClockwiseQuestion 4Look at the diagram below. Figure 35: Gear ratioWhat is name of this type of gearing?What is the ratio of the whole gear?Question 5What are the two things a synchroniser can do to make gear changes smoother?Question 6In third gear with the dog teeth engaged, the top gear (input shaft) is effectively locked to the output shaft.TrueFalseAsk your trainer to check your results before proceeding.Trainer Signature: Date:This page has been left blank intentionallyActivity 5Compound gear ratio calculationsIn the previous section of the workbook, you learned how to do compound gear ratio calculations for the first gear in a conventional rear wheel drive five speed transmission.Use that example to help you with the following plete the compound gear ratio calculations for second, third, fourth, fifth and reverse gears. Second gear - compound gear ratio calculationFigure 36: Second gearGear type TeethCalculationRatio1. Input gear (driver)12:2. Cluster gear (driven)243. 2nd gear cluster (driver)18:4. 2nd gear mainshaft (driven) 27Overall ratio: x ::This means the engine turns ________ times for the output of ______Complete the following chart:The engine is producing 100Nm of torque at 2000 rpm.GearRatioTorqueSpeed RPM2nd :Torque ratio of100Nm x = Nm of torqueInput ÷ ratio2000 ÷ = rpm (output speed)Outcome in second gear:Torque increased four times but the output speed is reduced from:2000 rpm to ______rpmThird gear - compound gear ratio calculation Figure 37: Third gearGear type TeethCalculationRatio1. Input gear (driver)12:2. Cluster gear (driven)243. 3rd gear cluster (driver)22:4. 3rd gear mainshaft (driven) 22Overall ratio: x ::This means the engine turns ________ times for the output of _______Complete the following chart:The engine is producing 100Nm of torque at 2000 rpm.GearRatioTorqueSpeed RPM3rd :Torque ratio of100Nm x = Nm of torqueInput ÷ ratio2000 ÷ = rpm (output speed)Outcome in third gear:Torque increased four times but the output speed is reduced from:2000 rpm to ______ rpmFourth gear - compound gear ratio calculationInput gear is directly connected to the mainshaft producing 1:1 ratioFigure 38: Fourth gearComplete the following chart:The engine is producing 100Nm of torque at 2000 rpm.GearRatioTorqueSpeed RPM4th :Torque ratio of100Nm x = Nm of torqueInput ÷ ratio2000 ÷ = rpm (output speed)Outcome in fourth gear:Torque increased four times but the output speed is reduced from:2000 rpm to _________ rpmFifth gear - compound gear ratio calculationFigure 39: Fifth gearGear type TeethCalculationRatio1. Input gear (driver)12:2. Cluster gear (driven)243. 5th gear cluster (driver)24:4. 5th gear mainshaft (driven) 60Overall ratio : x ::This means the engine turns ________ times for the output of _______Complete the following chart:The engine is producing 100Nm of torque at 2000 rpm.GearRatioTorqueSpeed RPM5th :Torque ratio of100Nm x = Nm of torqueInput ÷ ratio2000 ÷ = rpm (output speed)Outcome in fifth gear:Torque increased four times but the output speed is reduced from:2000 rpm to ________ rpmReverse gear - compound gear ratio calculationFigure 40: Reverse gearGear type TeethCalculationRatio1. Input gear (driver)12:2. Cluster gear (driven)243. 1st gear cluster (driver)24:4. 1st gear mainshaft (driven) 10Overall ratio : x ::This means the engine turns ____________ times for the output of _____Complete the following chart:The engine is producing 100Nm of torque at 2000 rpm.GearRatioTorqueSpeed RPMReverse :Torque ratio of100Nm x = NmInput ÷ ratio2000 ÷ = rpm (output speed)Outcome in reverse gear:Torque increased four times but the output speed is reduced from 2000 rpm to __________ rpmAsk your trainer to check your results before proceeding.Trainer Signature: Date:This page has been left blank intentionallyTransfer caseFour wheel drive vehicles contain drive lines to both the front and rear axle assemblies. This allows torque to be delivered to all wheels. The vehicles can be part-time four wheel drive, full time four wheel drive or all wheel drive.The transfer case is a small two speed transmission at the rear of the transmission which transfers power from two wheel to four wheel drive. The transfer case performs three functions:Transfers power from two wheel to four wheel driveIncreases torque and improve traction for “off-road” useProvides direct drive for high speed cruising.Part-time four wheel drivesLarger passenger vehicles and light commercial vehicles may have this arrangement. The engine is mounted longitudinally at the front of the vehicle, with a transmission and transfer case coupled to the rear of the engine.The transfer case is like a two speed gearbox. It provides a selectable high range for road use and a low range for off road conditions. This system permanently drives the rear wheels. However, there is also an option to direct drive to the front wheels.Figure 41: Part-time four wheel driveSmall four wheel drive vehiclesA front mounted engine with a transaxle driving the front wheels like a conventional front wheel drive vehicle.Also has an output shaft from the transfer case so the driver can select the rear wheel four wheel drive. The transfer case may also have a selectable low ratio for off-road use.Figure 42: Transaxle, four wheel driveThe transfer case may share the transmission oil, but in many cases they have their own oil supplyService proceduresDifferent workshops will have different procedures for servicing manual transmissions and transaxles. This workbook provides only one approach to this, as it is impossible to cover all possibilities in this workbook. If you have a different service procedure in your workplace, your trainer will be happy to discuss it with you.The servicing of manual transmissions and transaxles falls into two categories Minor service - lubricant level checkMajor service - lubricant replacement.There are many different arrangements in four wheel drives. So when servicing four wheel vehicles, always refer to manufacturer’s specifications for oil requirements, service intervals and adjustment procedures.Minor serviceA minor service is a routine procedure which is performed during the regular service of a vehicle. Things to check during a minor service are:oil levelslubricationvisual checksfunctional operation test. The service interval is determined by the manufacturer and is generally stated in the owner’s manual. Example: Every 10,000 kilometres or 6 months (whichever comes first).When the vehicle has exceeded its warranty period, it may be advisable to reduce the service interval, to extend the vehicle’s life.Check oil levels in transmissionsOil levels must be checked as a part of any service procedure. Most rear wheel drive vehicles have a plug on the side of the main transmission case to check the oil level. Unless otherwise specified, the oil level in the transmission case should be level with the bottom of the filler hole.Figure 43: Location of filler plugTo check the oil level, follow this procedure:STEPDONEClean the area around the filler plug. This prevents dirt etc. from entering the transmission.Remove the filler plug.Use a piece of wire (or even your little finger) to measure the oil level.Determine if the transmission needs topping up. If low, check for up the oil level, if necessary, with the correct type of oil through the filler hole.Clean off any spillage.Refit the filler plug. In most cases, use a sealant to prevent leakage.Check oil levels in transaxlesFront wheel drive and rear engine rear wheel drive vehicles are usually fitted with manual transaxles. Transaxles have both the transmission and final drive sections fitted to one housing. Transaxles have a dip stick or other measuring device fitted. Some transaxles have the dip stick scale moulded to the speedometer drive gear assembly. To check the oil level, follow this procedure:STEPDONEClean the area around the speedometer drive. This prevents dirt etc. from entering the transaxle.Remove the speedometer drive assemblyLook at the side of the speedometer drive to check the oil level scale. If low, check for leaks.Decide whether the transaxle needs topping-up.Correct the oil level if necessary by adding the correct type of oil through the speedometer drive hole.Re-check the oil level.Refit the speedometer drive assembly.Figure 44: Removing speedometer drive assemblyUse oil recommended by the vehicle’s manufacturer when topping- up any manual transmission or transaxle. If you do not use the correct oil, it could cause serious damage to the gearbox.Lubricate external componentsAll moving parts must be checked and lubricated as a part of any service procedure. It is possible that all the linkages are housed internally and therefore don’t need separate lubrication. Some of the external moving parts that need to be lubricated may include:Gear linkages – lubrication ensures smooth operation.Figure 45: Gear linkagesControl cables –lubrication ensures smooth operation and to prevent any vibrations from being transmitted to the vehicle’s body.Remote control rods – may be used on vehicles fitted with bench seats where the gear lever is not ‘on the floor’ but fitted to the steering column (‘on the tree’).Steering column – when the gear lever is fitted to the steering column, a special mechanism is fitted inside at the bottom of the steering column. It is extremely important to lubricate the external mechanism to prevent wear and to ensure smooth operation.Use light machine or general purpose oil or white grease. If linkages and bushes are rubber or plastic, check manufacturers’ recommendations. It may not be necessary to lubricate them.Visual checksVisual checks for potential problems are an important part of the service procedure. For example, if oil leaks are identified and repaired early, it will avoid the cost of expensive transmission overhauls.Oil leaksThese can occur at the following points:Bolts – Usually, bolts are fitted to blind holes and do not leak. But sometimes the bolt holes open inside the transmission case and can cause leakage.Shafts – Input, tail or drive shafts enter the transmission/transaxle and oil leaks are prevented by using lipped neoprene seals. Oil leaks from external drive or tail shafts are easy to see.An input shaft seal is housed inside the bell housing and is driven by the clutch, so a leak is identified by an oil stain or deposits on the bell housing.Rear main bearing - this will also leave an oil stain or deposits on the bell housing. [How can you tell the difference between a rear main bearing seal leak and an input shaft seal leak?Rear main bearing seal leakUsually engine oil Oil is black Input shaft seal leakUsually transmission/transaxle oil Oil is either brown or red Figure 46: Transmission componentsGaskets – In most cases, gaskets and sealants are used when two housings are joined together. These can leak as the materials get older. Draining/refilling plug – Leakage can occur due to incorrect assembly or lack of sealant being used when the plugs are refitted.Breather – The breather is located at the top of the transmission/transaxle. It relieves excess pressure in the housing, preventing oil leaks elsewhere. Sometimes oil can be forced out of the breather, which indicates that either the transmission/transaxle is over-full or it is malfunctioning.Speedometer drive assembly – The speedometer drive assembly is mounted on the output side of the transmission/transaxle. It has a neoprene O-ring to seal leaks. These seals get hard after a period of time and if disturbed may leak. Switches and sensors – If these are fitted to the transmission/transaxle they also have O-rings to seal for leaks, and are a potential (possible) leakage point.Shift linkages Check gear shift linkages for smooth and full travel. Damaged or incorrectly adjusted linkages can cause hard gear selection, and jumping out of gear under load. Refer to manufacturer’s adjustment procedures.Clutch affecting transmission operationIf the transmission is hard to change gears or grates when changing, check that the clutch is correctly adjusted. There may be too much clearance. Refer to manufacturer’s clutch specifications and adjustment procedures.Engine transmission mounts When inspecting a transmission or transaxle assembly, carefully lever against all the mounts to check for split, broken or oil-soaked mounts. Worn or loose mounts can create gear shift problems, poor clutch operation, vibration and shuddering.Figure 47:Manual transmission engine mountsFigure 48:Transaxle engine mountsRecord anything you find on the customer’s repair order or job card.It’s easy to forget something.Functional/operational testsOnce you have completed the vehicle servicing procedures it is also necessary to perform a functional test on the transmission/transaxle. This is usually done when the vehicle is road tested before or at the end of the vehicle’s service.Do not perform a road test unless authorised by your trainer. You are not yet a qualified mechanic.When performing the road test you must check the following on a transmission/transaxle:What to checkWhat to look forIn neutralAny gear or bearing noiseDoes the noise occur if clutch is engaged or disengagedSelection of first gearActual selectionCrunching during engagementSelection of reverse gearActual selectionCrunching during engagementAcceleration in first gearJumping out of gearNoiseDrive - car movesAcceleration in reverse gearJumping out of gearNoiseDrive - car movesUp shifts & downshiftsActual selectionCrunching during engagementJumping out of gearNoiseDrive - car movesOn accelerationJumping out of gearNoiseAll driving conditionsUphillJumping out of gearNoiseAll driving conditionsDownhillJumping out of gearNoiseMajor serviceThere is little difference between a minor and major service for a manual transmission.The main difference with a major service is that the old oil is drained and replaced with new oil. This procedure is usually after long periods of time (40,000 kilometres) or if the vehicle is used under severe driving conditions. The manufacturer provides this information in either the owner’s or workshop manual.Procedure to drain and refill the transmission/transaxle’s oil:1.Remove the fill/inspection plug on the side and the drain plug at the bottom of the transmission/transaxle.2.Drain the oil into a clean container.3.Inspect the oil and look for any foreign particles. This may indicate internal damage is about to happen, for example:Silvery metal particlesIndicates the gears or bearings may be damagedGold metal particlesIndicates thrust bearings or bushes may be breaking upSludgeCould indicate the incorrect oil has been used or that the transmission/transaxle has been operating under severe conditions.Dirt or gritCan enter the oil due to poor maintenance and service proceduresWaterIf the oil is milky, this indicates that water is present and may haveentered the transmission/transaxle via the breather4.Replace the drain plug. Use the manufacturer’s specified sealant in the plug’s threads.5.Refill the transmission/transaxle to the specified level, using the oil specified by the manufacturer.6.Refit the fill/inspection plug; use the manufacturer’s specified sealant in the plug’s threads. ALWAYS:Use the correct oil or fluids as specified by the manufacturer. Failure to do so may cause the transmission/transaxle to fail prematurely.Use the correct sealants as specified by the manufacturer. A lack of sealant can cause a leak and chemicals in an incorrect sealant can react with the oil or metals in the transmission/transaxle, causing severe damage.Activity 6Major serviceFollow the steps below and work through the plete the transmission service checklist on the next page as you go.Step 1 Position vehicle on hoist and raise correctly.Step 2 Drain and refill transmission / transaxle.Step 3 Refit and tension drain filler plug.Step 4 Ask the trainer to inspect the vehicle’s transmission and look at your checklist to see that all tasks have been completed.Step 5 Lower vehicle on hoist. Step 6 Clean up work area and return all tools and equipment.Ask your trainer to check your results before proceeding.Trainer Signature: Date:Transmission Service ChecklistCustomer name:Vehicle:Model:Transmission type:Manual / AutomaticTransmission / transaxle oilBrand:Volume:Oil grade:Viscosity:Oil code:Drain plug tension:Filler plug tension:Service intervals dates: Minor:Major:ComponentsServiceable?Unservice able?CommentsBoltsShaftsInputOutputDriveSelectorOtherGasketsDrain/refilling plugBreatherComponentsServiceable?Unservice able?CommentsSpeedometer drive assemblySwitches/sensorsPhysical componentsClutch operation systemClutch adjustmentGear shift linkagesWear / AdjustmentEngine transmission mountsMounting bolts correctly tightenedReverse lights operatingOil conditionMetal in oilSludgy or foamy oil Water in oilSufficient oilThis page has been left blank intentionallyActivity 7Answer the following questions OR tick the correct answer/s.Question 1Always use the oil or fluids specified by the manufacturer.TrueFalseQuestion 2The breather is located at the top of the transmission/transaxle. What is it used for? Question 3When draining a transmission or transaxle oil, what should you do with the dirty oil?Question 4How can you tell the difference between a leak in a rear main bearing seal and a leak in the input shaft seal leak?Question 5Name 3 external moving parts in a manual transmission that may need to be lubricated.1. 2. 3. Question 6What is the main difference between a minor and major service for a manual transmission?Question 7Silvery metal particles in the oil could indicate the gears or bearings may be damaged.TrueFalseAsk your trainer to check your results before proceeding.Trainer Signature: Date:GlossaryWORDMEANINGaccelerateGo fasterapproximately almost, not exactlyashlessProduces no (metallic) ash because as it does not contain any metalblock Prevent, stopbreachBreak the rulesbundedAn area with a low wall of concrete or similar, which acts as a barrier to contain spillsclassifyGroup together with similar itemscirculatesMoves round and round through the systemcompressedUnder pressure, made smallercontaminantsThings which contaminate, or make dirtycorrodeEat away at something, make it crumbledepositingLeaving behinddepositsSubstance left behind, stuck on somethingdisposalHow you get rid of something distilledMake it pure, take out the dirt etc.engage (a clutch)connect toexceedIs more than, bigger thanexposeLeave open to the airfilmThin layer on the surfacefriction.When two surfaces rub togetherfulcrumthe point something turns around generatorProducergradedSlopedhelicalShaped like a helix, or spiralhypoidA curved shapeinhibitorsMake something happen lesslongitudinallyAlong the lengthmaintainKeep minimizeMake as small as possibleminimumThe least or smallest possiblemomenta force that has a turning effect monitorsWatches, checks onparallelExactly side by sideparticlesVery small piecesperiodicallyAt regular timesperpendicular vertical potential, potentiallyPossible, possiblypremisesA place of work or businessprecisionBeing exact in small measurementsprescribed industrial wastesThe law prescribes, or states exactly, how this waste must be treated propel move forwardpuncturedPut a hole in itratiosreduces makes lessregulates Makes rules aboutresiduesAmounts of a substance still left after emptying or cleaningresist, resistingWork against rotateTurnrotational turningscaldsBurns from hot liquidsecurelySafely, can’t get outsituatedPlaced, locatedstableDoesn’t easily change form eg from liquid to a gassuspendedFloatingsynchroniseGet two things working ‘in time’ togethertorqueA twisting or turning forcetransfers, transferredPasses/ moved ontransmitMove onviscosityThe ‘thickness’ of a lubricant waste streamsTypes of wastewithstandHold out against ................
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