AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 1 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) AURT206670A

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 1

© Commonwealth of Australia 2011 AURT206670A Inspect and service transmissions (manual)

AURT206670A

Inspect and service transmissions

(manual)

AUR30405 CERTIFICATE III IN AUTOMOTIVE MECHANICAL TECHNOLOGY



Personal safety

• Safety shield

• Full body overalls

• Ear plugs or muffs

• Leather safety gloves

• Safety boots



Workplace hazards

Heat• Burn your skin

• What else?

Compressed air•Blow dirt in your eyes

•What else?

Chemical substances•Burn your eyes

•What else?

!



Equipment safety

Trolley jack

Safety standsDo not exceed the safe working load.

Do not work under vehicles supported only by a trolley jack.

ALWAYS use safety stands.

!

!

!



Equipment safety

Four post hoist Two post hoist

Follow manufacturer’s instructions when operating vehicle hoists.!



Environmental issues

Degreasing and parts washing•bunded washing area

•large caustic degreaser

•small degreaser trough

Waste oils•recycle waste oils

•safe disposal of oily rags



Material Safety Data Sheets

Must be provided by law.

For manual transmissions may cover:•manual transmission fluids and oils

•additives

•caustic cleaning solutions

•hydrocarbon based cleaning solutions

•petroleum gels

•hand cleaners.



Transmission functions

• Neutral position so engine can start and run without moving

• Range of gear ratios

• Engine braking

• Reverse gear.

Rear wheel drive transmission



Types of gears

Spur gears

Helical gears

Hypoid gears



Transmission components

Main shaft gear

Input shaft gear

Input shaft

Main shaft

Reverse idlerCluster gearCounter shaft

Speedometerdrive



• The amount of force required to rotate an object

• The gears inside a transmission increase or decrease the available engine torque.

Torque



Multiplying torque



Gear synchronizer



Gear ratio

When a gear is selected - the speed of the input shaft compared with the speed of the output shaft

1. How many teeth?

2. Driving gear teethDriven gear teeth

3. 20 ÷ 10

4. Gear ratio = 2:1

Input shaftDriven gear = 10 teeth

Output shaftDriving gear = 20 teeth



Compound gear ratios

• Multiple simple gear trains in series

• Each set of gears generates an individual ratio

• Multiply individual ratios together to work out overall ratio.

First simple gear train

Second simple gear

train



Compound gear ratios

Multiply both ratios together = 2 x 3

Overall ratio = 6:1

Second set of gears

Number of teeth on driven gear = 30

Number of teeth on driver gear = 10

Formula = driven/ driver 30/10 = 3

First set of gears

Number of teeth on driven gear = 24

Number of teeth on driver gear = 12

Formula = driven / driver 24/12 = 2



Transfer case

Three functions:1.Transfer power from two wheel to four wheel drive.

2.Increase torque and improve traction for “off-road” use.

3.Provide direct drive for high speed cruising.



4WD transaxle



Servicing transmissions

• Minor service - lubricant level check.

• Major service - lubricant replacement.

! Always use oil recommended by the vehicle’s manufacturer.

!If you do not use the correct oil, it could cause serious damage to the gearbox.



Oil leaks



Gear linkages

All moving parts must be checked and lubricated during service.



© Commonwealth of Australia 2011ISBN: 978-1-876838-37-9

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AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 1 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) AURT206670A