2 - AURTTX008 Student Version - 1-QnA

AUR50216
Student Name:
Student ID:
Assessment Summary
Unit Details 2 - AURTTX008 - Overhaul manual transmissions
This is a summative assessment, which requires

each student to have adequate practice prior
Assessment Type to undertaking this assessment
This assessment Must also be undertaken in a
simulated automotive workshop
Assessment 1 Written Task

Assessment Methods
Assessment 2 Demonstration
Version: 2.0 Acumen Education Pty Ltd © Page 1 of 59

Assessment Tool| AURTTX008
Contents
Assessment information............................................................................................. 3
Purpose................................................................................................................... 3
Unit description ..................................................................................................... 3
Key competencies............................................................................................... 3
Foundation skills .................................................................................................... 3
Performance evidence ...................................................................................... 4
Knowledge evidence ......................................................................................... 4
Assessment Conditions ........................................................................................ 4
Pre-requisites ......................................................................................................... 5
Terminology used ................................................................................................. 5
Completing the assessments/Expectations.................................................... 5
Assessment ............................................................................................................ 5
Summary of assessment methods and tasks .................................................. 6
Instructions: ............................................................................................................ 6
Required resources .............................................................................................. 6
Reasonable adjustment ..................................................................................... 6
Plagiarism policy................................................................................................... 7
Academic appeals ............................................................................................. 7
Reassessment process......................................................................................... 7
Assessment records.............................................................................................. 8
Declaration............................................................................................................ 8
Assessment submissions and contact details ................................................. 8
Assessment 1 – Written Questions ........................................................................................ 11
Instructions for Students: .................................................................................. 11
Assessment 2 – Practical demonstration ............................................................ 33
Instructions for Students: ........................................................................................................ 33
Decision-making rules ............................................................................................................ 33
Resources required for assessment: .................................................................................... 34
Observation Task ..................................................................................................................... 35
Repair Order 1 (Task 1) .................................................................................... 37
Skill Observation Checklist and Assessment Outcome: Assessment 2 – Task 1 ......... 40
Repair Order 2.................................................................................................... 45
Skill Observation Checklist and Assessment Outcome: Assessment 2 Task 2 ............ 48
Repair Order 3.................................................................................................... 53
Skill Observation Checklist and Assessment Outcome: Assessment 2 Task 3 ............ 56

Assessment information
Purpose This document represents the main assessment instrument for the unit of
competency AURTTX008 - Overhaul manual transmissions
Unit description
This unit describes the performance outcomes required to return a manual
transmission to original manufacturer tolerances and clearances. It involves
preparing for the task, dismantling and evaluating the transmission, carrying
out the overhaul procedures, reassembling and testing the transmission,
and completing workplace processes and documentation.
It applies to those working on manual transmissions in vehicles from all
sectors of the industry.
No licensing, legislative, regulatory or certification requirements apply to this
unit at the time of publication.
Key 1. Prepare to dismantle manual transmission
competencies 2. Dismantle and evaluate manual transmission and components
3. Carry out overhaul
4. Assemble transmission and components
5. Complete work processes
Foundation skills Learning skills to: Locate sources of information for manual transmissions
efficiently.
Reading skills to: Interpret and assess information from manufacturer
and workshop literature when seeking manual
transmission specifications and procedures.
Writing skills to: Legibly and accurately fill out workplace
documentation when reporting diagnostic findings,
making repair recommendations, and recording parts
and material used.
Oral Clarify instructions, report evaluation findings and make
communication overhaul recommendations.
skills to:
Numeracy skills to: Measure manual transmission components and use
basic mathematical operations, including addition,
subtraction, multiplication and division, to calculate
distances, areas, volumes, tolerances and deviations
from manufacturer specifications.
Planning and Plan own work requirements and prioritise and
organising skills to: sequence actions to achieve required outcomes and
ensure tasks are completed within workplace
timeframes.
Technology skills Use precision measuring equipment, such as vernier
to: calipers and micrometers
Use specialised manual transmission overhaul
equipment, such as:
• Dummy shafts
• Bearing pullers and presses.

Performance Evidence of the ability to:

evidence  overhaul three different manual transmissions, one of which must include
a transaxle transmission
Knowledge  work health and safety (WHS) and occupational health and safety
evidence (OHS) requirements relating to overhauling manual transmissions,
including procedures for using:
 specialised manual transmission overhaul tools, equipment
and machinery
 chemicals and toxic substances
 manual and mechanical lifting equipment
 environmental requirements, including procedures for trapping, storing
and disposing of fluids released from manual transmissions
 types, characteristics and operating principles of manual transmissions,
including transaxles and conventional transmissions
 manual transmission overhaul procedures, including:
 methods for cleaning and preparing manual transmissions for
overhaul
 transmission dismantling procedures
 transmission component inspection, measuring and
evaluation procedures, including:
 non-destructive testing procedures, including dye
penetrant testing and magnetic particle testing
 assessing transmission case damage and alignment to
engine
 measuring tolerances and clearances of components,
including extension housing seal and bushing, bearings,
gear wear and damage, synchroniser units and baulk
rings, shift rails and forks, detents and interlock systems,
and input, main, counter and output shafts
 transmission component repair and adjustment procedures, including:
 bearings and shims
 seals and bushings
 speedometer drive gears
 transmission assembly procedures, including procedures for adjusting
component tolerances, including:
 bearing preload
 shaft end float
 final drive bearing preload
 post-overhaul testing procedures for manual transmissions.
Assessment Assessors must satisfy NVR/AQTF assessor requirements.
Conditions Competency is to be assessed in the workplace or a simulated environment
that accurately reflects performance in a real workplace setting.
Assessment must include direct observation of tasks.
Where assessment of competency includes third-party evidence,

individuals must provide evidence that links them to the manual

transmissions that they have worked on, e.g. repair orders.
Assessors must verify performance evidence through questioning on skills
and knowledge to ensure correct interpretation and application.
The following resources must be made available:
1. mechanical repair workplace or simulated workplace
2. workplace instructions
3. manufacturer manual transmission specifications
4. three different manual transmissions requiring overhaul, one of which
must be a transaxle
5. tools, equipment and materials appropriate for overhauling and
adjusting manual transmissions
Pre-requisites NIL
Terminology The following terms are used in each assessment task to guide the student
used and assessor as to what is expected from each assessment task:
1. Instructions: Provides a brief description about the assessment task and
broadly indicates what the Student is required to do.
2. Conditions of assessment: Outlines the conditions in which the
assessment must be undertaken. In some cases, it will give options for
the student about what to base the assessment task on and whether it is
practical demonstration or project.
3. Description of task/decision making rules: Advises the student and the
assessor of the task description and the criteria that the assessment must
meet in order for a satisfactory result to be awarded.
4. Due Date - the date on which assessment falls due.
Completing the Assessors must ensure that students completely understand the assessment
assessments/Ex process and various assessment tasks before undertaking the assessments.
pectations This assessment tool is structured in a way that each assessment task clearly
outlines the:
• Instructions for completing the assessment task;
• Conditions in which the assessment must be conducted;
• Evidence that must be presented by the student; and
• Decision-making rules by which the evidence will be judged.
Every assessment task will require satisfactory completion in order for
students to be deemed Competent. The students will need to adhere to
any guidelines on length of answers required where stipulated. Please note,
a paragraph is three or more sentences.
This unit is being offered as a part of Diploma of Automotive Technology.

You will not qualify to receive Certificate of completion until you attain
competency in all the units offered as part of this qualification.
Assessment Each assessment task has a section for the assessor recording the
assessment outcome as either ‘Satisfactory’ (S) or ‘Not Satisfactory’ (NS).
Once the student satisfactorily completes all assessment tasks, the assessor

will complete the assessment summary cover sheet and record either a
“Competent” (C) or “Not Competent” (NC) outcome.
When awarding any assessment result, assessors must ensure that feedback
for the student is recorded in the spaces provided after each assessment
task and on the record of assessment outcome.
Summary of The assessment methods that are used in this assessment tool are:
assessment Assessment Method of
Description
methods and Task # Assessment
tasks 1 Questions You are required to answer 24 short answer
questions related to this unit.
2 Demonstrati Overhaul three different manual
on transmissions, one of which must include a
transaxle transmission.
Instructions: • You can seek clarification regarding the assessment required to be
done.
• You can ask for reasonable time from Assessor for preparation of project
or Assessment.
• You can seek information on additional reading material and reference
for completion of the assessments.
• If you have any special needs, you can seek assistance from Assessors
depending upon the nature of the need.
• You can seek assistance from assessor while using special diagnostic
equipment
• Review the observation checklist/decision making rules to know what is
expected of you. You may refer to the observation checklist for
observation based assessments at any stage prior to the
commencement of your assessment. You must not refer to this checklist
whilst you are being assessed.
• Your assessor will also explain to you the observation process prior to the
assessment.
Required Each assessment task in this assessment tool outlines specific resources that
resources the student must have access to as part of the assessment process.
Assessors must ensure that students have appropriate access to these
resources before any assessment is conducted.
Reasonable Acumen Education enables reasonable adjustments to be made to
adjustment assessment procedures for students with special needs, such as people with
disabilities or with language or literacy difficulties. Assessing knowledge is
usually assessed through written or oral, short-answer tests where assessors
seek to determine the extent of the student’s knowledge.
Following are some of the examples of adjustments that can be made for
the students:
• Ask questions orally instead of in a written format
• Provide equipment such as text enlargers, image enhancers, and voice
recorders.
• Give the student more time to complete the assessment;, allocate a
different time for completion of the assessment;

• Offer a separate, quiet room.
• Modifying or providing equipment
• Adapting delivery strategies
• Ensuring that course activities are sufficiently flexible, providing
additional support to student where necessary
• Customising resources and activities within the training package or
accredited course
• Monitoring the adjustments to ensure student needs continue to be met
Plagiarism Acumen education takes a systemic approach to the treatment of
policy plagiarism in academic work. The policy is intended to promote honesty in
learning and assessment and respect for the work of others. Contravention
of this policy will result in students being penalized.
Please read the plagiarism policy available in your student handbook and
to be aware of the consequences and to understand your rights and
responsibilities.
Academic • Where a student wishes to appeal an assessment they are required to
appeals notify their assessor in the first instance. Where appropriate the assessor
may decide to re-assess the student to ensure a fair and equitable
decision is gained. The assessor shall complete a written report
regarding the re-assessment outlining the reasons why assessment was
or was not granted.
• If this is still not to the student’s satisfaction the student shall formally
lodge an appeal by submitting a written letter within one week of
receiving the results using the form 10.1 for Complaints and appeals
outlining the reasons for the appeal. They shall lodge this with student
administrations department and the appeal shall be entered into the
‘complaints and appeals register’.
• The Operations Manager shall be notified and shall seek details from the
assessor involved and any other relevant parties. A decision shall be
made regarding the appeal either indicating the assessment decision
stands or details of a possible re-assessment by another assessor
appointed by Acumen.
The student shall be notified in writing of the outcome with reasons for the
decision. The student shall also be provided the option of activating the
external appeals process if they are not satisfied with the outcome. The
student is required to notify Acumen if they wish to proceed with the
external appeals process.
Reassessment 1. Student will be assessed as being competent only upon satisfactory
process completion of all the assessments in a unit.
2. If a student is not able to demonstrate satisfactory completion of all of
the required assessments of the unit, the result for that unit will be
recorded as Not Competent.
3. If a student has submitted all the tasks and successfully completed
more than 50%* of the assessment tasks for a unit, they will be provided
with specific feedback and invited to re-submit their assessment.

4. If a student has submitted and not successfully completed more than
50%* of the assessment tasks for a unit, they will be required to
undertake the unit again.
5. In the case of re-submission, the following actions shall occur:
o The student must apply for resubmission within one week of the result
is made available to him/her. This means that the student is
responsible to acknowledge that he/she has received the result and
has been deemed NC for the units of competency undertaken.
o Reassessment may need to be arranged every weekend on
Saturday evenings in order to minimize disruption.
6. If a student is assessed as “Not Competent’ after the resubmission, he or
she will be identified as a student-at-risk and an Academic
Performance Improvement (API) Plan will be created during an
Intervention Strategy Meeting between the Acumen’s Operations
Manager, Trainer & Assessor and student. The date for a third
assessment will be nominated by the student in consultation with Trainer
& Assessor, but should be no longer than 1 month from the previous re-
submission date.
7. One re-submission is allowable per unit per student free of cost.
Additional re-submissions will be charged at $200.
If the student remains ‘Not Competent’ after a third re-submission, he or

she will be notified that this result is final and he or she will be unable to
successfully complete the course in which they are enrolled at this point.
* Due to the variance in the amount of work completed for each

assessment task in a unit, 50% will be determined by the number of
assessment tasks submitted as opposed to the amount of evidence
submitted.
Assessment We are required to retain a copy of your assessment and all other
records evidentiary records. If you require a copy of this assessment submission
please be sure to copy it prior to submitting it to us.
Declaration You must sign the student declaration confirming the authenticity of your
submitted work, understanding the requirements to complete the
assessment tasks and that the assessment process including the provisions
for re-submitting and academic appeals were explained to you and that
you understand these processes on the assessment summary cover sheet.
Acumen Education cannot assess any submitted work until the declaration
is received.
Assessment You must submit this completed assessment tool to your trainer on the due
submissions and date. Please feel free to contact us if you have any questions regarding the
contact details assessment process:
Phone: 03 9044 6402/03 84151244

For Assessor Only -ASSESSMENT COVER SHEET

This form is to be completed by the assessor and used as a final record of student competency.
All student submissions including any associated checklists (outlined below) are to be attached to this cover sheet before placing on
the students file. Student results are not to be entered onto the Student Database unless all relevant paperwork is completed and
attached to this form.
Student
Student Name:
ID No:
Contact
Email:
number:
Unit Code &
AURTTX008 - Overhaul manual transmissions
Title
First Submission  Subsequent Submission 
Result
Please attach the following documentation to this form S = Satisfactory
NS = Not Satisfactory
Assessment 1  Written Task S | NS
Assessment 2  Demonstration S | NS
Final Assessment Result for this unit
(Student will be assessed as being competent only upon
satisfactory completion of all the above mentioned
 Competent  Not Competent (Comments)
assessments)
The Evidence provided is:
 Valid  Sufficient  Authentic  Current
Student Declaration:
I acknowledge that I understand the requirements to complete the assessment tasks. The assessment
process including the provisions for re-submitting and academic appeals were explained to me and I
understand these processes. I understand the consequences of plagiarism and confirm that this is my own
work and I have acknowledged or referenced all sources of information I have used for the purpose of this
assessment.
Student’s Signature: Date: _______/_______/_______

Final feedback:
Assessor: I declare that I have conducted a fair, valid,

Signature:
reliable and flexible assessment with this student, and I
have provided appropriate feedback.
Date: _______/_______/_______
Administrative use only
Entered onto Student

________________ ________________
Management Database
Date Initials

USE FOR REASSESSMENT ONLY
Assessment Task No/s
Components
Competent - C Not Competent - NC

Result of Reassessment
(Please circle the Final Assessment Outcome)
Feedback to Student
Please provide general feedback on the Student’s performance.
Assessor: I declare that I have conducted a fair, valid, reliable and flexible assessment with this student,
and I have provided appropriate feedback.
Trainer/Assessor Signature Date

Assessment 1 – Written Questions
Instructions for Students:
• This is the first of the two assessment tasks you must complete satisfactorily to be deemed
competent in this unit.
• In this task, you must answer twenty four questions that cover the knowledge requirements
of this unit.
• Read the Assessment description carefully.
• Assessment may be submitted in Microsoft Word format or may be handwritten.
• Clearly label your work with your name, unit code, unit title, Assessment Task and
respective Question number with the answer to all the documents and sheets that are
attached to your submission.
• Acknowledge clearly when and how you are drawing on the ideas or phrases of others.
• Consult your assessor when you are unsure about how to acknowledge the contributions of
others to your thought and writing.
• Read the Plagiarism policy and procedure carefully to understand the consequences that
you could face if your work is plagiarized.
• Seek clarification regarding the assessment required to be done, if you do not understand
the task.
• Ask for reasonable time from Assessor for preparation of project or Assessment.
• Seek information on additional reading material and reference for completion of the
assessments.
• Students with special needs can seek assistance from assessors depending upon the
nature of the need.
• Assessment may be completed in your own time and is due one week from the module
end date.
• Submit this document along with your assessment work.

Written Questions
List 5WHS and OHS requirements to be followed while carrying out manual
1
transmission overhauling with specific reference to manual lifting techniques.
Wear suitable PPE like safety boots, goggles, gloves and overalls.
• Do not carry heavy components or assemblies.
• Always use a transmission jack stand when removing a manual transmission.
• Store drained transmission fluids in a shelf in a lid container.
• Use proper equipment to drain hot fluid from transmission
• While cleaning transmissions use clean rags.
• Be careful not to crush your fingers or hands when installing transmission, as it is very heavy.
 Satisfactory  Not Satisfactory (Comments)

a) List 4 specialised tools & equipment used for overhauling a manual transmission
and explain their purpose.
2
b) List 4safety precautions to be followedwhile using specialised tools and equipment
for overhauling manual transmissions.
1. Hand tool
2. Power tool
3. Electrical tool
4. Compressed air tool
Safety precautions to be followed while using specialised tools and equipment for
overhauling manual transmissions. List 4.
1. keep the tools away from the oil and grease as these may turn slippery and may cause injuries while working.
2. Keep your hands, loose gloves, and loose clothing away from moving parts of electrical tools.
3. When using an air nozzle, always wear safety glasses or a face shield as the dirt particles and metal pieces bl
own by high-pressure air can penetrate your skin or get into your eyes.
4. Always be aware of striking an object with the full-face hammerhead.

3 List 4 safety precautions to be followed while operating hydraulic jack and hoist.
Hydraulic Jack
1. Wear overalls and boots.
2. Check that the equipment is safe to operate.
3. Locate the vehicle jacking points.
4. Never work under a vehicle without axle stand in place.
Hoist
1. Align the vehicle with the centre of the hoist and drive slowly into position.
2. Ensure that all locking devices are operational and in place.
3. Ensure that the lifting arms are located to the vehicle jacking points.
4. Wear eye protection, boots, overalls and gloves as appropriate.
a) List the methods used to clean the transmission.

4 b) List 2 safety precautions to be followed while handling chemicals and toxic
substances like cleaning solvents.
Cleaning the transmission before removing can show whether the sections have any damage and any damage o
n the housing. Hence, it reduces the risk of breaking the case.
By cleaning the outer area of the transmission with any oil can provide a proper grip to hold the transmission.
While overhauling the transmission, it is important to keep the gear assembly and other internal components cle
an from dust by cleaning the outer portion of the transmission.
Use a degreaser to clean the outside of the pan and brake cleaner to clean the inside and the gasket mating surf
aces.
1. Should not burn the transmission fluid, grease and other chemicals at any cause.
2. Avoid pouring the fluid in land or water. Because when it mixes with water, it may cause many dangerous pro
blems for all living things.

Describe what care should be taken with regard to clutch dust, while removing a
5
transmission or transaxle in about 30-40 words.
The clutch outer cable is fixed between the bulkhead end and the transmission end. Typically, either the outer or
inner cables will provide an adjustment facility comprising of an adjustment nut and a locking nut. By releasing t
he locking nut and adjusting nut, the clearance can be adjusted to specification.
According to environmental procedures, how would you trap, store and dispose of
6
the contaminated fluid from manual transmission? 60-90 words
It indicates the small metal parts that are shredded from the gears of the transmission due to
continues rotation and meshing with each gear.
Trapping fluid: Transmission fluids should be collected by using proper tools like funnel and tr
ays.
Storing fluids: Transmission fluids should be stored in spill proof containers and be
labelled to identify easily. It should not be mixed and stored with other fluids.
Disposing fluid: Used transmission fluids should be taken to your local used oil facility for recy
cling. Many council facilities such as transfer stations, waste management center’s or landfill
sites accept used oil.

7 Explain the three drive configurations in about 100-120 words.

1. Front Wheel Drive: Front-wheel drive (FWD) is a form of engine and transmission layout used in motor vehicle
s, where the engine drives the front wheels onlyo
ofiguration for cars.
Most rear-whest rear-wheeel drive vehicles feeture a longitudinnally mounted ennnine at the front of the cca.
3. Four Wheel Drive: Four-wheel drive, also called 4x4 ("four by four") or 4WD, refers to a two-axled vehicle dri Four Wheel
etrain
an c capable
apable of
ofppoviding
providing torqque
torque totoallallofoofis
its wheels
wheelssimultaneously.
siimultaneouslly.It may
It maay
be full-time
e full-tiieor
orrron-demand,
on-demand, and ad is
is typ
typ
ically
ly linked
linked
viia
viatransfer
a transfer
case
caseproviding
providingnan dditional
additional
otput
output
drivev
drive
shaft
shaft
and,and,
in many
in many instancces,
instances,additional
additionalgear
gear
r gs.
ranges.
A foufour--weel
four-wheel drive
drive
vehicle
vehicle
with
woorque
torque supplied
uppplied to
to both
both axles
xleesis
is described
dscribed as
as "al-weeel
"all-wheeldrive"
dr
drive"(AD).
(AWD).However,
However,
" "
four-wheel drive" typically refers to a set of specific components and functions, and intended off-road
off-r application,
which generally complies with modern use of the terminology.
Explain the gear theory and how does it apply in a manual transmission? 60-80
8
words.
Gear theory express the number of turns the drive gear makes compared to one turn of the driven gear it meshe
s with. Gears are wheels with teeth that mesh together.
This can happen either directly, as in a transmission where the wheels touch each
other or indirectly, as in a camshaft drive where a belt is used to make one gear turn another.
The gear ratio is dependent on the size of the two gear wheels working together.
Gear ratio rules
• The larger wheel will always rotate slower than the smaller wheel.
• The smaller wheel has to turn faster to keep up with the larger wheel.

Explain the process of preparing the transmission or transaxles before starting the
9
overhauling process in about 80-100 words.
The transmission is a system of gears that transfer the engine’s power to the drive wheels of the car. The transm
ission receives torque from the engine through its input shaft, when the clutch is engaged. This torque is then tra
nsferred through a set of gears that either multiply it or transfer it directly. The resultant torque turns the transmis
sion’s output shaft, which is indirectly connected to the drive wheels.
Follow the process
Drive train
Gear ratio
Briefly describe the sequence of dismantling a front wheel drive transaxle.(100-150

10 words)
Hint: Choose the basic dismantling procedure used in most vehicles.
Dismantling a front wheel drive transaxle are as follows.
Disconnect the negative terminal from the battery.
• Raise the front end of the vehicle and support it with safety positioned under the jacking points of the vehicle or raise the ve
hicle on a two post hoist.
• Position a clean drain tray under the transmission drain plug. Clean around the
area of the fill and drain plugs.
• Remove the drain and fill plugs and allow the transmission oil to drain.
• Disconnect the speedometer cable from the transmission.
• Release the clutch cable adjuster and remove the clutch inner cable from the
clutch release fork.
• Remove the electrical wiring from the bell housing bolt clips. Remove both front
wheels.
• Remove the undercover and side covers.
• Disconnect both lower suspension arms from the wheel hub assembly.
• Disconnect the tie rod ends from the wheel hub assembly.
• Pull out the drive shaft horizontally from the transaxle to prevent damage to oil
seal lip.

What is non-destructive testing procedure? Give 3 examples of non-destructive

11
testing on manual transmission.
Non-destructive testing procedures is a testing and analysis technique used by industry to evaluate the propertie
s of a material, component, structure or system for characteristic differences or welding defects and discontinuiti
es without causing damage to the original part. Three examples are as follows
Dye penetrant testing
Magnetic particle testing
Ground Penetrating Radar (GPR)

How do you perform dye penetrant test and magnetic particle testing to evaluate
12
the manual transmission? (100-120 words)
Dye Penetrant test
Before starting the process, cleaning is important ranging from grinding and wire brushing to merely wiping the
part with a rag moistened with the cleaner/ remover. The surface needs to be free of dirt, rust, scale, paint, oil,
and grease, and be smooth enough to wipe off the penetrant without leaving residue. Apply the penetrant by sp
raying or applying it with brush giving a soak time of maximum 30 minutes not longer than that so it does not dr
y. All penetrant should be removed with clean, dry, lint-free rags until thoroughly clean.
The transmission should be rubbed vigorously until the penetrant is not visible on the dry rags. Next, cleaner/ re
mover should be sprayed on another clean, dry, lint-free rag and used to vigorously rub the part again until ther
e is no penetrant visible on the rag. Then apply or spray light coating of developer on the part being examined.
The dwell time for developer is typically 10 to 60 minutes. Then, examine the part within the time frame designa
ted. If there is a crack or a minute flaw in the housing, then the penetrant bleeds out which must be wiped out.
Magnetic particle testing

It is a non-destructive testing method and used to detect surface and slightly subsurface flaws in most ferromag
netic materials such as iron, nickel, and cobalt, and some of their alloys. The process begins by running a magn
etic current through the component. This will create a “flux leakage field” at the site of the damage. The second
step involves spreading metal particles over the component. If there are any flaws on or near the surface, the flu
x leakage field will draw the particles to the damage site. This provides a visible indication of the approximate siz
e and shape of the flaw.

a) How would you assess the manual transmission case damage?60-70 words
13
b) What are the repair options available, if case is found damaged?50-60 words
First be sure that the crank flange is clean/rust free. Bolt up the flywheel and torque the bolts to spec.
Set up your dial indicator perpendicular to the flywheel clutch surface. This can be done by attaching the magnet
ic base to the oil pan or engine block.
Verify zero staring point and make number of revolutions.
If you end up with more than .005” TIR, there is a possibility that your flywheel is warped, damaged or needs to
be resurfaced. At this point it may also be necessary to check the crank flange for run out as well as to be sure t
hat it does not have any damage.
Once you have your flywheel runout within spec, you are ready to move onto checking the bell housing alignmen
t.
Checking for low transmission fluid – This should be the first thing you look at. A low level of transmission fluid is
the cause of the vast majority of transmission problems.
Inspecting the clutch – The way you drive can cause transmission trouble. "Riding the clutch", or not keep it fully
engaged while driving and downshifting instead of braking will lead to accelerated wear and tear.
Watching the torque converter – Revving the engine and streaking off at every light creates lot of damaging heat
in the torque converter.
Understanding lubrication – There are innumerable moving parts in an automatic transmission. It is important to
check the transmission fluid every 20,000 miles.
Not driving badly – The best way to avoid a transmission repair is not to do any harm to the mechanism, to begin
with. Avoid "grinding" the gears and using the clutch at the wrong time. You should also use first gear from a sta
nding start and not second gear – even though the latter is more easily engaged.
Describe the procedure to align the transmission to the engine. What are the
14
expected problems if it is misaligned? 100-150 words
Raise the transmission up into the transmission tunnel and align it with the clutch.
• Align the clutch and cover assembly using the special tool and tightening bolts to specific torque.
• Make sure that the release bearing sleeve end of the clutch fork is in place and slide the sleeve onto the main s
haft.
• Make sure there is no wire or cables that are in between the transmission and the engine.
• Using long and lengthy bolts that can guide with the engine housing which can align the transmission.
• Also use the dowel pins as guide for a proper fit.

 Satisfactory  Not Satisfactory
15 What are the common causes for transmission oil leaks? List 5.
Here are 5 of the most common causes of transmission fluid leaks

1 – Transmission Pan or Drain Plug
2 – Seals are Broken
3 – Transmission Pan Gasket Fails
4 – Torque Converter Leakage
5 – Fluid Line is Cracked

Describe the procedure to measure tolerances and clearances of below given

16
components: 30- 100 words each
Extension housing seal and bushing:
The casting should be inspected for cracks and damages. A case with worn bearing bores should be replaced. O
ther damages such as damaged threads may be repairable. Any burns on the mounting surface should be remov
ed as these will affect alignment of the parts.
Shafts (input and output, counter):

Inspect shafts for excessive wear and spline or tooth damage. Their bearing surface should be examined for po
ssible wear or damage from defective roller bearings. The same should be done for countershaft the spigot on t
he main shaft of rear wheel drive transmission and the shaft of trans axel that carry needle rollers for the consta
nt mesh gear. Long shaft such as main shaft should also be checked for run out on V block using dial gauge.
Gears:
Check for burrs and chipped teeth on all gears. Using feeler gauge, check the end play of countershaft gears an
d constant mesh gears. Adjust by fitting selective thrust washer or snap rings as required. The bores of gears su
ch as the constant mesh gear sand cluster gear should be checked to see that the bearing surface has not beco
me worn or damaged by the roller bearings.
Bearings:
After being thoroughly cleaned, bearings should be examined for the condition of their raceways and external s
urfaces, the amount of cage wear, the increase in internal clearance and degradation of tolerances. These sho
uld be carefully checked, in addition to examination for possible damage or other abnormalities, in order to dld be carefully
ermine the possibility for its reuse.

Shift Rails and Forks:

Check for smooth slide movement of fork on the rail. Check the fork and rails for any bends, cracks or excessive
wear. Check the ball and spring for wear and tension, since this will affect the gear shifting.
Synchronizer units and baulk rings :

Examine the splines of the synchronizer sleeve and hub and check the sleeve for free movement.
• Examine the baulk rings for wear and damage to the teeth and insert slots.
• Check gap between baulk ring and gear with feeler gauge.
Check each baulk ring by holding it hard and turning it against its mating cone on the constant mesh gear.
• Examine the ends of the inserts and bead for excessive wear.
• Check for the springs for installed positioned.

Detents and interlock systems

Check wear of the selector forks where they are in contact with the synchromesh sleeves.
• Check the dents balls and parts of the interlock device for wear or damage
• Check the dent and inter lock springs for any distortion.
• Check the selector rails for condition particularly the edge of the detent grooves which can become worn from t
he action of the dent balls.
a. Describe how you would inspect bearings in the Transmission/Transaxle

17 assembly. 100-150 words.
b. Describe the procedure to replace bearings. (80-120 words)
Bearings should be examined for the condition of their raceways and external surfaces, the amount of cage wea
r, the increase in internal clearance and degradation of tolerances. These should be carefully checked, in additio
n to examination for possible damage or other abnormalities, in order to determine the possibility for its reuse.

Bearing replacement procedure:

Park your vehicle on a flat surface
Use wheel chocks to secure wheels whose bearings you aren't replacing
Loosen the lug nuts and lift the wheel using a jack
Unscrew the lug nuts and remove the wheel
Remove the brake caliper
Remove the dust cover, cotter pin, and castle nut.
Remove the rotor.
Unscrew the hub bolts and remove the old hub
Disassemble the hub assembly.
Remove races and clean the knuckle
New races and new wheel bearings.
Replace all parts in reverse order
What are the conditions to replace shims while disassembling the differential or
18
transaxle? (40-60 words)
The differential, primary and secondary shafts must have a bearing clearance. This clearance is achieved by eit
her adding or removing shims between the main bearing of each shaft and the differential carrier main bearing.
To determine the correct shim thickness, place 3 or 4 short pieces of solder between the main bearing of each s
haft and the differential carrier main bearing.

Write down the procedure for replacing rear oil seal and bushing in rear wheel
19
drive transmission in about 40-60 words.
Seals are used because to avoid the leaks in the transmission. Wherever specified, sealants will be applied. Wh
en transmission overhauling is done, it is mandatory that old seal should be replaced with new one. These bushi
ngs may contain an oil hole that must match up with the oil supply passage in the housing. This is true of many b
ushings in transmission. Never deprive a spinning shaft of its lubrication. Bushings are made of brass or soft met
al so they wear before the slip yolk.
Scenario
Concern: Fluctuating speedometer needle
20 Combination cluster assembly and speed sensor is replaced but the speedometer
needle is still fluctuating. What could be other probable cause of this problem?
How would you rectify this issue?60-80 words
The passenger axle may need to be replaced. The speedometer cable may be damaged or broken. If the vehicl
e has cruise control, the cruise control transducer could be faulty and a new one should put in its place.
If it is an older car that has a cable for the speedometer, the cable may be damaged and the wire inside it broke
n or bent. If the vehicle has an electronic gauge, the cause may be a connectivity problem on the instrument clus
ter harness. The gauge itself could have stopped working.
To rectify this issue may remove or replace speedometer cable

How important is shim selection while inspecting the bearing preload and shaft end
21
float during transmission overhaul? 80-100 words
Bearings apart from being mounted on the shafts and housings have to be preloaded properly for their proper fu
nctioning. Preloading is the methodology by which we remove the internal clearance in the bearing by applying a
permanent thrust load to it. In other terms we can say that we push the bearing to such an extent that it has to
move only in the groove (raceway) and cannot move axially in either direction. By preloading, we tend to eliminat
e all the unnecessary clearances, which induces a rigidity to the bearings and thus to the system, the bearing su
pports.
By pulling the shaft by hand, the shaft movement can be measured in the dial indicator. It gives the measuremen
t or size of shim that can be used in the shaft to reduce play if required.
What is the importance of shaft end float preload adjustment? How would you
22
inspect the shaft end float in the transmission or transaxle? 140-160 words
The end float allows room for the formation of an oil film, misalignment, and thermal expansion of the bearing co
mponents. End float is the total distance the shaft can move between the two thrust bearings and is sometimes c
alled thrust bearing clearance.
With the help of a dial indicator, the end float can be measured. It should be located as close as possible to the s
haft. Axial proximity probes should be used to measure the gap along with dial indicator. By pulling the shaft by
hand, the shaft movement can be measured in the dial indicator. It gives the measurement or size of shim that c
an be used in the shaft to reduce play if required.

How do you measure final drive side bearing preload and corrected by shims? 150-
23
200 words.
hed, in additio
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eaminaation possibledamage
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esive preloaaaing
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he bearing
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et loadeedextremely,
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r the preloading of the bearings can be found. These methods of preloading are as important as the design and
selection of the bearings.

Explain the post-overhaul testing procedures for manual transmissionsin about 80-
24
100 words.
Check for position of wheel nuts for any movement or looseness.
• Check for cracked or broken nuts due to over tightening.
• Ensure there is no leakage ports on the tyres and puncture on surfaces.
• Make sure there is no wobbling of tyres when the wheel is spinning.
• Visually check for distortion of the rims.
• Check for worm components of suspension which might cause tyre vibration.
• Check for proper seal and any damage to sidewall which might cause deflation.
Workers have been seriously injured by blasted parts of the tyre/rim assembly or by the force of the sudden rele
ase of air pressure which has thrown them to the hard surface floor. In some cases, this has caused permanent
damage to hearing and eyesight.

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Unit Details 2 - AURTTX008 - Overhaul manual transmissions

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a) List the methods used to clean the transmission.

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7 Explain the three drive configurations in about 100-120 words.

ofiguration for cars.

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Briefly describe the sequence of dismantling a front wheel drive transaxle.(100-150

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Magnetic particle testing

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