AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 1 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) AURT206670A Inspect and service transmissions (manual) AUR30405 CERTIFICATE III IN AUTOMOTIVE MECHANICAL TECHNOLOGY

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 2 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) Personal safety Safety shield Full body overalls Ear plugs or muffs Leather safety gloves Safety boots

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 3 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) Workplace hazards Heat Burn your skin What else? Compressed air Blow dirt in your eyes What else? Chemical substances Burn your eyes What else? !

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 4 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) Equipment safety Trolley jack Safety stands Do not exceed the safe working load. Do not work under vehicles supported only by a trolley jack. ALWAYS use safety stands. ! ! !

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 5 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) Equipment safety Four post hoistTwo post hoist Follow manufacturers instructions when operating vehicle hoists. !

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 6 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) 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

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 7 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) 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.

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 8 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) Transmission functions Neutral position so engine can start and run without moving Range of gear ratios Engine braking Reverse gear. Rear wheel drive transmission

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 9 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) Types of gears Spur gears Helical gears Hypoid gears

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 10 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) Transmission components Main shaft gear Input shaft gear Input shaft Main shaft Reverse idler Cluster gear Counter shaft Speedometer drive

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 11 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) The amount of force required to rotate an object The gears inside a transmission increase or decrease the available engine torque. Torque

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 12 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) Multiplying torque

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 13 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) Gear synchronizer

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 14 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) 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 teeth Driven gear teeth ÷ Gear ratio = 2:1 Input shaft Driven gear = 10 teeth Output shaft Driving gear = 20 teeth

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 15 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) 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

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 16 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) 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

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 17 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) 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.

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 18 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) 4WD transaxle

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 19 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) Servicing transmissions Minor service - lubricant level check. Major service - lubricant replacement. ! Always use oil recommended by the vehicles manufacturer. ! If you do not use the correct oil, it could cause serious damage to the gearbox.

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 20 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) Oil leaks

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 21 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) Gear linkages All moving parts must be checked and lubricated during service.

AURT206670A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 22 © Commonwealth of Australia 2011AURT206670A Inspect and service transmissions (manual) © Commonwealth of Australia 2011 ISBN: This 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 Generals 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.