AURT 206670 A AUR 30405 CERTIFICATE INSPECT AND

AURT 206670 A AUR 30405 CERTIFICATE INSPECT AND III IN SERVICE AUTOMOTIVE TRANSMISSIONS MECHANICAL(MANUAL) TECHNOLOGY AURT 206670 A Inspect and service transmissions (manual) © Commonwealth of Australia 2011 AURT 206670 A Inspect and service transmissions (manual)

AURT 206670 A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 2 Personal safety • Safety shield • Full body overalls • Ear plugs or muffs • Leather safety gloves • Safety boots © Commonwealth of Australia 2011 AURT 206670 A Inspect and service transmissions (manual)

AURT 206670 A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 3 Workplace hazards Heat • Burn your skin • What else? ! Compressed air • Blow dirt in your eyes • What else? Chemical substances • Burn your eyes • What else? © Commonwealth of Australia 2011 AURT 206670 A Inspect and service transmissions (manual)

AURT 206670 A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 4 Equipment safety Do not work under vehicles supported only by a trolley jack. ! Trolley jack © Commonwealth of Australia 2011 ! ! ALWAYS use safety stands. Do not exceed the safe working load. Safety stands AURT 206670 A Inspect and service transmissions (manual)

AURT 206670 A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 5 Equipment safety Four post hoist ! © Commonwealth of Australia 2011 Two post hoist Follow manufacturer’s instructions when operating vehicle hoists. AURT 206670 A Inspect and service transmissions (manual)

AURT 206670 A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 6 Environmental issues Waste oils • recycle waste oils • safe disposal of oily rags Degreasing and parts washing • bunded washing area • large caustic degreaser • small degreaser trough © Commonwealth of Australia 2011 AURT 206670 A Inspect and service transmissions (manual)

AURT 206670 A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 7 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. © Commonwealth of Australia 2011 AURT 206670 A Inspect and service transmissions (manual)

AURT 206670 A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 8 Transmission functions • Neutral position so engine can start and run without moving • Range of gear ratios • Engine braking • Reverse gear. Rear wheel drive transmission © Commonwealth of Australia 2011 AURT 206670 A Inspect and service transmissions (manual)

AURT 206670 A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 9 Types of gears Spur gears Helical gears Hypoid gears © Commonwealth of Australia 2011 AURT 206670 A Inspect and service transmissions (manual)

AURT 206670 A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 10 Transmission components Input shaft gear Main shaft gear Input shaft Main shaft Counter shaft © Commonwealth of Australia 2011 Cluster gear Reverse idler Speedometer drive AURT 206670 A Inspect and service transmissions (manual)

AURT 206670 A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 11 Torque • The amount of force required to rotate an object • The gears inside a transmission increase or decrease the available engine torque. © Commonwealth of Australia 2011 AURT 206670 A Inspect and service transmissions (manual)

AURT 206670 A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 12 Multiplying torque © Commonwealth of Australia 2011 AURT 206670 A Inspect and service transmissions (manual)

AURT 206670 A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 13 Gear synchronizer © Commonwealth of Australia 2011 AURT 206670 A Inspect and service transmissions (manual)

AURT 206670 A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 14 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? Input shaft Driven gear = 10 teeth 2. Driving gear teeth Driven gear teeth 3. 20 ÷ 10 Output shaft Driving gear = 20 teeth 4. Gear ratio = 2: 1 © Commonwealth of Australia 2011 AURT 206670 A Inspect and service transmissions (manual)

AURT 206670 A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 15 Compound gear ratios Second simple gear train First simple gear train • Multiple simple gear trains in series • Each set of gears generates an individual ratio • Multiply individual ratios together to work out overall ratio. © Commonwealth of Australia 2011 AURT 206670 A Inspect and service transmissions (manual)

AURT 206670 A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 16 Compound gear ratios Second set of gears First set of gears Number of teeth on driven gear = 30 Number of teeth on driven gear = 24 Number of teeth on driver gear = 10 Number of teeth on driver gear = 12 Formula = driven/ driver 30/10 = 3 driven / driver 24/12 = 2 Multiply both ratios together = 2 x 3 Overall ratio = 6: 1 © Commonwealth of Australia 2011 AURT 206670 A Inspect and service transmissions (manual)

AURT 206670 A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 17 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. © Commonwealth of Australia 2011 AURT 206670 A Inspect and service transmissions (manual)

AURT 206670 A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 18 4 WD transaxle © Commonwealth of Australia 2011 AURT 206670 A Inspect and service transmissions (manual)

AURT 206670 A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 19 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. © Commonwealth of Australia 2011 ! AURT 206670 A Inspect and service transmissions (manual)

AURT 206670 A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 20 Oil leaks © Commonwealth of Australia 2011 AURT 206670 A Inspect and service transmissions (manual)

AURT 206670 A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 21 Gear linkages All moving parts must be checked and lubricated during service. © Commonwealth of Australia 2011 AURT 206670 A Inspect and service transmissions (manual)

AURT 206670 A INSPECT AND SERVICE TRANSMISSIONS (MANUAL) 22 © Commonwealth of Australia 2011 ISBN: 978 -1 -876838 -37 -9 This document is available under a “Free for Education” licence for educational purposes – see http: //www. aesharenet. com. au/Ff. E 2 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 http: //www. ag. gov. au/cca. 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. © Commonwealth of Australia 2011 AURT 206670 A Inspect and service transmissions (manual)