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
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© Commonwealth of Australia 2011 AURT206670A Inspect and service transmissions (manual)
Personal safety
• Safety shield
• Full body overalls
• Ear plugs or muffs
• Leather safety gloves
• Safety boots
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© Commonwealth of Australia 2011 AURT206670A 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?
!
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© Commonwealth of Australia 2011 AURT206670A Inspect and service transmissions (manual)
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.
!
!
!
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© Commonwealth of Australia 2011 AURT206670A Inspect and service transmissions (manual)
Equipment safety
Four post hoist Two post hoist
Follow manufacturer’s instructions when operating vehicle hoists.!
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© Commonwealth of Australia 2011 AURT206670A 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
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© Commonwealth of Australia 2011 AURT206670A 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.
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© Commonwealth of Australia 2011 AURT206670A 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
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© Commonwealth of Australia 2011 AURT206670A Inspect and service transmissions (manual)
Types of gears
Spur gears
Helical gears
Hypoid gears
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© Commonwealth of Australia 2011 AURT206670A Inspect and service transmissions (manual)
Transmission components
Main shaft gear
Input shaft gear
Input shaft
Main shaft
Reverse idlerCluster gearCounter shaft
Speedometerdrive
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© Commonwealth of Australia 2011 AURT206670A 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
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© Commonwealth of Australia 2011 AURT206670A Inspect and service transmissions (manual)
Multiplying torque
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© Commonwealth of Australia 2011 AURT206670A Inspect and service transmissions (manual)
Gear synchronizer
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© Commonwealth of Australia 2011 AURT206670A 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 teethDriven gear teeth
3. 20 ÷ 10
4. Gear ratio = 2:1
Input shaftDriven gear = 10 teeth
Output shaftDriving gear = 20 teeth
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© Commonwealth of Australia 2011 AURT206670A 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
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© Commonwealth of Australia 2011 AURT206670A 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
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© Commonwealth of Australia 2011 AURT206670A 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.
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© Commonwealth of Australia 2011 AURT206670A Inspect and service transmissions (manual)
4WD transaxle
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© Commonwealth of Australia 2011 AURT206670A Inspect and service transmissions (manual)
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.
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© Commonwealth of Australia 2011 AURT206670A Inspect and service transmissions (manual)
Oil leaks
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© Commonwealth of Australia 2011 AURT206670A Inspect and service transmissions (manual)
Gear linkages
All moving parts must be checked and lubricated during service.
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© Commonwealth of Australia 2011 AURT206670A Inspect and service transmissions (manual)
© Commonwealth of Australia 2011ISBN: 978-1-876838-37-9
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