Pulling Out Manual Transmission

COMPETENCY BASED LEARNING
MATERIAL
Sector:
AUTOMOTIVE
Qualification:
Automotive Servicing NC II
Unit of Competency:
Overhaul Manual Transmission

Module Title:
OVERHAULING MANUAL TRANSMISSION

PTC MALILIPOT
Basud Malilipot Albay
AUTOMOTIVE
INDUSTRY SECTOR
NATIONAL CERTIFICATE LEVEL II

QUALIFICATION LEVEL
COMPETENCY-BASED LEARNING MATERIALS

No.
Unit of Competency
Module Title
Code
1.
2.
3.
Service Starting System

Service Charging System
Service Engine Mechanical
System
4.
5.
Service Clutch System

Service Differential and Front Axle
ALT723307
ALT723308
ALT723309a
ALT723309b
ALT723309c
ALT723309d
ALT723309e
ALT723310
ALT723311
6.
Service Manual Steering System
7.
Overhaul Manual
Transmission
Servicing Starting System

Servicing Charging System
Servicing Cooling System
Servicing Lubricating System
Servicing Gasoline Fuel System
Servicing Air Induction System
Servicing Diesel Fuel Injector
Servicing Clutch System
Servicing Differential and Front
Axle
Servicing Manual Steering
System
Pulling-out,
8.
9.
Service Brake System
Service Suspension System
ALT723312
ALT723313a
Disassembling and
Checking Manual
Transmission
Assembling and Testing Manual
Transmission
Identifying and Explaining
Hydraulic Brake System
Operations and Functions
Servicing Brakes
Overhauling Brake Systems
Servicing Suspension System
ALT723313b
ALT723314a
ALT723314b
ALT723314c
ALT723315
HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL

Welcome to the module Pulling-out, Disassembling and Checking Manual
Transmission. This module contains training materials and activities for you to complete.
The unit of competency Overhaul Manual Transmission contains the knowledge,
skills and attitudes required for Automotive Servicing course. This is one of the modules
for National Certificate level III (NC III).
You are required to go through a series of learning activities in order to complete
each of the learning outcomes of the module. In each learning outcome there are
Information Sheets, Operation Sheets and job Sheets (Reference Materials for further
reading to help you better understand the required activities. Follow these activities on your
own and answer the self-check at the end of each learning activity.
If you have questions, dont hesitate to ask your facilitator for assistance.
Recognition of Prior Learning (RPL)

You may already have some or most of the knowledge and skills covered in this
learner's guide because you have:
been working for some time
already completed training in this area.
If you can demonstrate to your trainer that you are competent in a particular outcome,
you don't have to do the same training again.
Talk to your trainer about having them formally recognized. If you have a qualification
or Certificate of Competence from previous training, show it to you r trainer. If the skills you
acquired are still current and relevant to the unit/s of competency they may become part of
the evidence you can present for RPL. If you are not sure about the currency of your skills,
discuss this with your trainer.
After completing this module ask your trainer to assess your competency. Result of
your assessment will be recorded in your competency profile. All the learning activities are
designed for you to complete at your own pace.
Inside this learner's guide you will find the activities for you to complete and at the
back are the relevant information sheets for each learning outcome. Each learning outcome
may have more than one learning activities.
At the end of this learner's guide is a Learner Diary. Use this diary to record
important dates, jobs undertaken and other workplace events that will assist you in providing
further details to your trainer or an assessor. A Record of Achievement is provided for you
by your trainer to complete once you complete the module.
This module is prepared to help you achieve the required competency, in overhauling
manual transmission. This will be the source of information for you to acquire knowledge
and skills in this particular trade, with minimum supervision or help from your instructor.
With the aid of these materials you will acquire the competency independently and at your
own pace.
-
Talk to your trainer and agree on how you will both organize the training of this
unit. Read through the learning guide carefully. It is divided into sections which
cover all the skills and knowledge you need to successfully complete this module.
Work through all the information and complete the activities in each section and
complete the self-check. Suggested references are included to supplement the
materials provided in this module.
Most probably your trainer will also be your supervisor or manager. He/she is
there to support you and show you the correct way to do things. Ask for help.
Your trainer will tell you about the important things you need to consider when you
are completing activities and it is important that you listen and take notes.
Talk to more experienced work mates and ask for their guidance.
Use the self-check questions at the end of each section to test your own progress.
When you are ready, ask your trainer to watch you perform the activities outlined
in the learning guide.
As you work through the activities, ask for written feed back your progress your
trainer keeps feed/ pre-assessment reports for this reason. When for have
successfully completed each element, ask your trainer to mark on the report that
you are ready for assessment.
When you have completed this module (or several modules) and feel confident
that you have had sufficient practice your trainer will arrange an appointment with
you to asses you. The result of your assessment will be recorded in your
Competency Achievement Record.
Qualification: AUTOMOTIVE SERVICING NC II

Unit of Competency: OVERHAUL MANUAL TRANSMISSION
Module Title: PULLING OUT, DISASSEMBLING AND CHECKING MANUAL
TRANSMISSION COMPONENT
LEARNING OUTCOMES
At the end of this module, you will be able to:
1. Pull-out and dismount manual transmission and associated components;
2. Disassemble manual transmission; and
3. Inspect and check manual transmission components.
ASSESSMENT CRITERIA
1.1 Transmission gear oil is drained as per recommended procedure
1.2 Transmission jack is positioned per recommended procedure in accordance with
safety
1.3 Transmission associated bolts and nuts are removed according to sequence
1.4 Transmission attaching bolts and nuts are removed according to sequence and
loosening pattern
1.5 Vehicle and workshop safety procedure is applied
1.6 Personal and equipment safety is applied
2.1 Manual transmission is disassembled in correct steps and procedure as per
specification
2.2 Dismantled parts accurately logged and marked
2.3 Parts rinsed and washed with appropriate solution
2.4 Damaged parts replaced, reconditioned according to specification
2.5 Appropriate tools are use as per job requirement, vehicle safety procedure is applied.
2.6 Personal safety procedures is observed throughout the activity
3.1 Work out, cracked parts, gear back laser and end play were inspected and accurately
identified
3.2 Defects identified and corresponding recommendation is given
3.3 Instruments and testers are accurately used
3.4 No damage during inspection
Prerequisite:
Code No.
ALT723313a
Pulling Out, Disassembling and Checking Manual

Transmission Component
Date: Developed Date: Revised
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Page #

Learning Outcome #1: Pull-out and dismount manual transmission and associated
components.
Assessment Criteria:
1. Transmission gear oil is drained as per recommended procedure.
2. Transmission jack is positioned per recommended procedure in accordance with safety.
3. Transmission associated components were dismounted properly and conducted in
correct sequence.
4. Transmission attaching bolts and nuts are removed according to sequence and
loosening pattern.
5. Vehicle and workshop safety procedure is applied.
6. Personal and equipment safety is applied.
Resources:
Tools and Equipment
Hoist
Supplies and materials

Sandpaper
Jack stand
Paint brush
Drop light
Soap
Wrenches
Rags
Manual transmission
Oil catch pan
Jack
Masking tape
Hand tools
Mechanic's wire
Working tables
References:
1. Automotive Mechanics 10th Edition by Willia H. Crouse and Donald L. Anglin, pp 553-583
2. Manual Transmission by Kovace K. Creager, pp 451-460
3. Manual Transmission & Drive Trains by Jhon H. White, pp 453-460
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Learning Outcome 1:
Pull-out and Dismount Manual Transmission and Associated

Components.
LEARNING ACTIVITIES
SPECIAL INSTRUCTIONS
1. Read information on the purpose of

transmission or transaxles.
1.1 Information Sheet LO1-1 Purpose of

Transmission or Transaxles
2. Answer: Self-Check
1.2 Self-Check LO1-1
3. Apply and perform the correct procedures in

draining transmission gear oil and dismounting
manual transmission.
1.3 Operation Sheet LO1-1 Drain

Transmission Gear Oil and Dismount
Manual Transmission
5. Observe PPE safety precautions
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Information Sheet LO1-1 Purpose of Transmission or Transaxles

There are three reasons for having a transmission or transaxle in the automotive power train
or drive train. The transmission or transaxle can:
1. Provide the torque needed to move the vehicle under a variety of road and load conditions.
It does this by changing the gear ratio between the engine crankshaft and vehicle drive
wheels.
2. Be shifted into reverse so the vehicle can move backward.
3. Be shifted into neutral for starting the engine and running it without turning the drive wheels.
There are two basic types of transmissions and transaxles: manual and automatic. Manual
transmissions and transaxles are shifted manually, or by hand. Automatic transmission and
transaxles shift automatically with no help from the driver.
Difference between transmissions and transaxles
The manual transmission is an assembly of gears, shifts and related parts. These are
contained in a metal case or housing filled with lubricant. A manual transmission is used in sole
front-wheel-drive vehicles and in front-engine rear-wheel-drive vehicles. It is positioned between
the clutch and the driveshaft that carries engine power to the drive wheels. The engine, clutch,
transmission and driveshaft are all in a single line.
The manual transaxle is also an assembly of gears and shafts. It attaches to a frontmounted transverse engine and drives the front wheels. Rear-engine cars can use an enginemounted transaxle to drive the rear wheels. A few front-engine cars drive the rear wheels
through a rear-mounted transaxle.
The transaxle includes a final drive and a differential (front differential). These devices are
not found in the transmission. The final drive is a set of gears that provides the final speed
reduction or gear ratio between the transmission and the drive wheels. The differential permits
the drive wheels to rotate at different speeds when the vehicle turns from straight ahead.
Some transaxles include a viscous coupling and a center differential. These are used in
four-wheel-drive and all-wheel-drive power trains.
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Manual transmissions and transaxles

Older transmissions
are three-speed units.
They have three forward
gear ratios or speeds.
These are first or low,
second and third or high.
They also have reverse
and neutral.
Four-speed
transmission and
transaxles have been
widely used. They
provide first, second, third
and fourth. They also
have reverse and neutral.
Many transmissions
and transaxles are fivespeeds with a fifth
forward gear.
Figure LO1-1. Construction of a six-speed manual transmission.

(ZF of North America, Inc.)
Fourth gear in some four-speed units

and fifth gear in five-speed units is
overdrive. The output shaft turns faster
than, or overdrives the input shaft. This
allows a lower engine speed to keep the
vehicle moving at its desired road speed.
Better fuel economy and reduced engine
wear result, with less noise and vibration.
Some cars have a six-speed manual
transmission or transaxle. Both fifth and
sixth-gear are overdrive ratios. However,
these may not be usable during city driving
in heavy traffic.
Figure LO1-2. Location of the manual transmission in a

vehicle with front engine and rear-wheel-drive. (Mazda
Motors of America, Inc.)
The different gear ratios are necessary because the engine develops relatively little power at
low engine speeds.
The engine must be turning at a fairly high speed before it can deliver enough torque to start
the vehicle moving. This means the transmission or transaxle must be in first gear to start out.
After the vehicle is moving, progressively higher gears are selected (second, third, fourth, fifth)
to suit operating conditions. Usually, the vehicle is in top gear after reaching highway speed.
Moving the gearshift lever makes the shift which changes the gear ratio. In some vehicles, the
gearshift lever is on the steering column. In others, it is on the floor or in a center console.
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Figure LO1-3. Construction of a five-speed manual transaxle that includes a viscous coupling and a center
differential, for use in a vehicle with all-wheel drive, or four-wheel drive. (Chrysler Corporation)
Gears and Gearing

Gears are wheels with teeth that transmit
power between shafts. The teeth may be on
the edge of the wheel, on the side, or inside.
To transmit power, a gear on one shaft is
meshed with a gear on another shaft. To
mesh means that the teeth of a gear fit into the
spaces between the teeth of another gear.
When one gear turns, its teeth then force the
other gear to turn. The gear that is forced to
turn is the drive gear.
The relative speed of two meshed gears is
determined by the number of teeth in each
gear. This is the gear ratio.
If two meshing gears have the same number
of teeth, both will turn at the same speed.
When the driven gear has more teeth than the
driving gear, the driven gear turns more slowly
than the driving gear. For example, if the
driving gear has 12 teeth and the driven gear
has 24 teeth, the driving gear must turn two
times to turn the driven gear once. The gear
ratio between the two gears is two-to one. This
is written as 2:1.
Figure LO1-4. Power-flow from the engine crankshaft to

the wheels of a vehicle with front-wheel drive. (Chrysler
Corporation)
Figure LO1-5. Meshed spiral-bevel gears.
If a 12-tooth gear is meshed with a 36-tooth gear, the 12-tooth gear turns three times for every
revolution of the 36-tooth gear. The gear ratio is 3:1.
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Gear Ratio and Torque

The gear ratio changes as the number of teeth is the meshing gears change. At the same time,
torque also changes. Torque is a twisting or turning force that may or may not result in motion. It
is measured in pound-feet (lb-ft) and Newton-meters (N-m).
Figure LO1-6. Various types of gears.
To loosen and remove the top from

a screw-top jar, you must apply
torque to the top. To calculate
torque, multiply the applied force
times the distance through which
the force sets. The torque on a
gear is the force on a tooth
multiplied by the distance from the
tooth to the center of the gear. This
distance is the radius of a gear or
circle.
Figure LO1-7. Two revolutions of the small gear are required to turn
the larger gear once. This is a gear ratio of 2:1.
Two or more meshed gears make a gearset or a gear train. In a gear system, speed reduction
means torque increase.
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Also, speed increase means torque

reduction. An example of torque increase is
a car that has a gear reduction of 12:1 from
the transmission or transaxle to the drive
wheels. The crankshaft turns 12 times to
turn the drive wheels once. If the engine is
producing a torque of 100 lb-ft [135.6 N-m],
then a torque of 1200 lb-ft [1627 N-m] is
applied to the drive wheels.
Figure LO1-8. Torque is calculated by multiplying the
applied force times the distance through which the force
acts. (Ford Motor Company)
Note: Figure LO1-9 shows only one tire.
The torque is actually split
between the two drive wheels.
Each tire pushes against the road
with a torque of 600 pounds [2669
N]. Both tires together push with a
force of 1200 pounds.
Figure LO1-9. How torque at the drive
wheels pushes the vehicle forward. The
tire is turned with a torque of 1200 lb-ft
[1637 N-m]. Since the tire radius is 1 foot
[0.31 m], the push of the tire against the
ground is 1200 lb-ft. As a result, the
vehicle is pushed forward with a force of
1200 pounds [5338 N].
The radius of the tire in Figure LO1-9 is 1 foot [0.31 m]. With the torque acting on the ground at
a distance of 1 foot, the force of the tire pushing against the road is 1200 pounds [5338 N].
Manual Transmissions Construction
Manual transmissions, manual transaxles, and transfer cases are all various types of
gearboxes. A gearbox has:
1. Gears that transmit power.
2. Splined shafts that rotate while other parts slide on them.
3. Bearings that support the shafts and transfer the load to the case or housing.
In a gearbox, the gear teeth and other moving metal parts must not touch. They must be
continuously separated by a thin film of lubricant. This prevents excessive wear and early
failure. Therefore, a gearbox runs partially filled with a lubricant or gear oil. Oil seals prevent
loss of lubricant from between the case and the rotating shafts.
The manual transmission and transaxle in passenger cars have from four to six forward speeds.
A few vehicles with three-speed transmissions are still being driven. Many older vehicles and
some new ones have four speeds. However, a five-speed transmission or transaxle is used in
most cars today. Trucks and buses use bigger transmissions with 4 to 16 forward speeds.
Regardless of type, most manual transmissions and transaxles are similar. One difference is the
size and heaviness of construction. Another is that transmissions and transaxles with more
speeds have more gears and shafts.
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Figure LO1-10
shows a
disassembled
five-speed
manual
transmission
with the major
parts named.
Figure LO1-11
shows the
assembled gear
train of this
transmission. It
is made as a
four-speed and
with additional
parts as a fivespeed. The
main-drive gear
or clutch gear
drives the onepiece cluster
gear or
countergear.
In both
transmissions,
three other
helical gears on
the countergear
are in constant
mesh with gears
on the output
shaft. These
output-shaft
gears are the
first-speed gear,
second-speed
gear and thirdspeed gear.
Figure LO1-10. A disassembled five-speed manual transmission with the major parts
named. (Chevrolet Division of General Motors Corporation)
The gears on the output shaft (except for the reverse gear) mesh with the gears on the
countershaft. If the countershaft turns, the gears on the output shaft also turn.
No power flows through if the transmission is in neutral. Then none of the output-shaft gears are
locked to it. The gears have bushings or bearings that permit them to rotate freely on the output
shaft. During gear shifting, the gears themselves are not moved. The gears are locked to the
shaft by synchronizer action. Synchronizers are connecting devices that are splined to the
output shaft and rotate with it.
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Shift forks fit into grooves

in the synchronizer
sleeves. When the driver
moves the gearshift lever,
linkage carries the
movement to a shift fork.
The fork moves the sleeve
which then locks the
selected gear to the shaft.
In figure LO1-11a, two
synchronizers lock gears
to the transmission output
shaft. The five-speed
transmission has an
additional synchronizer (5th
synchronizer). It locks the
fifth-speed drive gear to
the countergear.
(A) FOUR-SPEED MANUAL TRANSMISSION

Figure LO1-11. Assembled gear train showing the additional parts needed to
make (A) a four-speed manual transmission into a (B) five-speed manual
transmission. (General Motors Corporation)
The only gear that actually

moves into mesh and in
many other transmissions
is the reverse-idler gear. It
slides on its shaft to
engage the reverse gear
on the countergear (the
spur gear). It also engages
reverse gear on the output
shaft. This causes the
output shaft to turn in the
opposite direction of inputshaft rotation.
(B) FIVE-SPEED MANUAL TRANSMISSION
Synchronizer Action
Synchronizers are used in
manual transmissions and
transaxles to prevent gear
clash during gear shifting.
These devices ensure that
gears and sliding sleeves
about to mesh rotate at the
same speed. The result is
a smooth engagement.
The synchronizer used in
the transmission shown in
figures LO1-10 and LO1-11
has synchronizing cones
on the gears and in the
synchronizer rings.
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Figure LO1-12. A disassembled synchronizer. (Chevrolet Division of General

Motors Corporation)

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10
Figure LO1-13. Operation of the synchronizer to engage a gear. (Deere & Company)
Three keys fit into slots in the synchronizer hub. The hub is splined to the transmission output
shaft. A pair of ring-shaped synchronizer springs apply a slight outward force against the keys.
The synchronizer sleeve fits over the hub. It has external splines or teeth that mesh with the
internal splines or teeth in the sleeve. The keys have raised sections that fit in the detent groove
in the sleeve. A detent is a small depression into which another part moves to provide a locking
effect.
Synchronization is a three-stage action. To shift the transmission into gear, the synchronizer
sleeve is moved toward the gear. The sleeve slides on the hub splines and carries the three
keys with it. The keys butt against the synchronizer ring and push it toward the gear. This brings
the cone surface in the ring into contact with the cone surface on the gear. Friction between the
synchronizer ring and the gear brings the two into synchronous rotation. They rotate at the
same speed.
When the external teeth on the synchronizer ring and on the gear rotate at the same speed, the
sleeve slides over them. This locks the gear to the shaft and completes the shift. Power flows
from the gear, through the synchronizer sleeve and hub, to the shaft. Similar actions take place
in synchronizers used for other gears. Some transmissions have a synchronizer for reverse.
A transmission that uses synchronizers is a synchromesh transmission. The shifts are
synchronized and the gears are in constant mesh.
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Manual Transmission Operation

The actions to obtain each gear in the five-speed manual transmission shown in figure 10 and
11B are described below. Figure LO1-14 shows the power-flow through the five-speed
transmission for each forward gear and reverse. Power-flow through the four-speed
transmission is the same as in the five-speed, except for fifth gear.
1. FIRST GEAR (Fig. LO1-14a). To shift into first,
depress the clutch pedal to disengage the
clutch. Move the gearshift lever into the first
position. This causes linkage in the
transmission to select the first position. This
causes linkage in the transmission to select the
first-reverse synchronizer and move its sleeve
locks to the first-speed gear. Since the
synchronizer-and-sleeve assembly are locked
to the output shaft, the first gear drives the
output shaft when the clutch is engaged.
In first gear, there is torque multiplication and speed reduction through the transmission. The
main-drive gear is smaller than the countergear it drives. This provides gear reduction.
There is more gear reduction as the small countergear drives the large first-speed gear. The
gear reduction can vary. A typical first-gear ratio is about 4:1. The crankshaft turns four times
to turn the output shaft once. There is further gear reduction through the final drive in the
rear drive axle.
2. SECOND GEAR (Fig. LO1-14b). To shift into
second, the first-second synchronizer sleeve
moves to the left. The sleeve moves through its
center or neutral position, un-locking the firstspeed gear and locking the second-speed gear
to the output shaft. The second-speed gear,
driven by the countergear second gear, now
drives the output shaft through the synchronizer
sleeve. There is less gear reduction than in first
gear because there is less difference in the size
of the gears. A typical gear ratio for second gear
is about 2.4:1. The input shaft turns 2.4 times to
turn the output shaft once.
3. THIRD GEAR (Fig. LO1-14c). In third, the firstsecond synchronizer sleeve moves to its
neutral position. The third-fourth synchronizer
sleeve moves to the right so that it meshes with
the third-speed gear. The countergear third gear
now drives the third-speed gear and the output
shaft through the synchronizer. A typical gear
reduction in third is about 1.5:1.
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4. FOURTH GEAR OR DIRECT DRIVE (Fig. LO114d). In fourth, the third-fourth synchronizer
sleeve moves to the left so that it meshes with
the main-drive gear on the end of the input
shaft. The output shaft is now driven by the
main-drive gear through the synchronizer. This
is direct drive and the gear ratio is 1:1.
5. FIFT GEAR OR OVERDRIVE (Fig. LO1-14e).

In fifth, both the first-second synchronizer and
the third-fourth synchronizer move to neutral.
The sleeve on the fifth synchronizer moves
forward. This locks the fifth-speed gear to the
countergear. The fifth-speed gear now turns fifth
gear which is splined to the output shaft.
Overdrive is provided because the fifth-speed
gear is larger than the gear it drives. A typical
overdrive gear ratio is 0.8:1. The output shaft
turns one complete revolution while the
countergear turns only 0.8 (a little more than
three-quarters) revolution.
6. REVERSE (Fig. LO1-14f). In reverse, all
synchronizer sleeves are in neutral. The
reverse-idler gear slides into mesh with reverse
gear on the output shaft. The countergear
drives the reverse-idler gear and it drives the
output shaft through the synchronizer sleeve.
The output shaft turns in the reverse direction
because of the reverse idler gear. A typical
reverse gear ratio is about 3.5:1
Figure LO1-14. Power-flow through a five-speed

manual transmission for each forward gear and
reverse. (Chrysler Corporation)
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Manual Transaxles Construction

A manual transaxle combines a manual
transmission (transmission section) and a drive
axle (differential section) in a single assembly.
Power flow from the engine enters the
transmission section through the input shaft.
Power leaves the transmission section through a
pinion gear on the transmission output shaft or
mainshaft.
The Pinion gear drives the ring gear in the
differential section. The ring gear sends the
power through the differential to the two frontaxle halfshafts. Then the halfshafts turn the
wheels and tires to move the car. The differential
allows the front wheels to travel different
distances as the vehicle is steered around a
curve.
Figure LO1-15 shows a four-speed transaxle.
The input shaft is part of the countergear or
cluster gear. Neutral is obtained when both
synchronizers are in their center positions.
Figure LO1-15. The manual transaxle combines the

manual transmission, final-drive gearing, and
differential into a single unit. (Ford Motor Company)
The four forward gears are obtained the same as in the manual transmission. Moving the
gearshift lever causes the first-second or third-fourth synchronizer sleeve to lock a gear to the
mainshaft.
Manual Transaxle Operation
The gears and shafts in the transmission
section of a five-speed transaxle are shown
with the case removed in figure LO1-16. This
is basically the same transaxle in figure LO115, with the addition of the fifth-gear shaft
assembly. Operation of both transaxles is the
same in all positions except fifth gear.
Figure LO1-17 shows the power-flow through
each gear position for the five-speed
transaxle. In first and second gear, the thirdfourth synchronizer sleeve remains in neutral.
When the driver moves the gearshift lever to
first, the first-second synchronizer sleeve
moves forward. This locks the first-speed gear
to the mainshaft. To shift to second, the firstsecond synchronizer sleeve moves to the rear.
This unlocks the first-speed gear and then
locks the second-speed gear to the mainshaft.
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Figure LO1-16. Gears and shafts in the transmission

section of a five-speed transaxle. (Ford Motor Co.)

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When the shift lever moves to third, the firstsecond synchronizer sleeve moves to neutral.
The third-fourth synchronizer sleeve moves
forward. This locks the third-speed gear to the
mainshaft. Shifting to fourth unlocks the thirdspeed gear and moves the synchronizer
sleeve to the rear. Fourth-speed gear is locked
to the mainshaft. If the cluster gear and fourthspeed gear are the same size, this provides
direct drive. The gear ratio is 1:1.
Fifth gear is obtained by placing both the firstsecond and third-fourth synchronizer sleeves
in neutral. Fourth gear on the cluster gear is in
constant mesh with the fifth-speed gear. When
the fifth-synchronizer sleeve moves to the rear,
it locks the fifth-speed gear to its shaft. On the
other end of the shaft a pinion gear is in
constant mesh with the ring gear. Power flows
from fourth gear on the cluster gear through
the fifth-speed gear and shaft. Then the power
flows from the pinion on the end of the shaft to
the ring gear.
To get reverse, the first-second and
third-fourth synchronizer sleeves move
to neutral. The fifth synchronizer is
disengaged. The reverse idler gear
moves to the rear. Its teeth now mesh
with the reverse gear on the cluster
gear and with the teeth on the 1:2
synchronizer sleeve or reverse-sliding
gear on the mainshaft. Power flow is
from the cluster gear and through the
reverse-idler gear which drives the
reverse-sliding gear. It reverses the
direction of the mainshaft rotation. The
pinion gear then drives the ring gear in
a reverse direction and the car moves
backward.
Note:
Figure LO1-17. Power flow through a five-speed manual

transaxle for each forward gear and reverse. (Ford Motor
Company)
Both the mainshaft and the fifth-speed gear shaft have pinion gears in constant mesh with the ring gear.
When one shaft drives the ring gear, the other shaft is unlocked and turns freely or freewheels.
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Dual-Range Transaxle
The dual-range transaxle is a four-speed unit.
The input shaft has two pinion gearsan input
low gear and an input high gear. These are in
constant mesh with matching gears on the
countergear. Operation of the range-selector
synchronizer determines which gear is locked
to the input shaft. This result in two-speed
ranges, the economy range and the power
range.
The transaxle has a total of eight forward
speeds. Fourth gear is an overdrive ratio in the
economy range. Two shift levers are required.
One is the gearshift lever. The other is the
range-selector lever. Its movement operates
the range-selector synchronizer.
Figure LO1-18. Control levers and linkage for a dualrange transaxle. (Chrysler Corporation)
Interlock Devices
Manual transmission
and transaxles use
various types of
interlock devices.
The interlock allows
only one
synchronizer sleeve
to move during
shifting. If more than
one is moved,
clashing and
damage would
result.
Figure LO1-19
shows one type of
interlock in the shift
linkage of a fivespeed manual
transaxle. This
interlock is a threepiece mechanism.
Code No.
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Figure LO1-19. An interlock in the internal linkage of a five-speed manual transaxle.

(Chrysler Corporation)

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When the driver moves the gearshift lever to any gear position, only the shift rail for that gear
can move. The interlock shuttles in the interlock plate and the interlock pin move into notches in
the shift rails. This prevents these rails from moving.
Figure LO1-20, Linkage between the gearshift lever on the steering column and the transmission.
(Chevrolet Division of General Motors Corporation)
Gearshifting and Shift Linkage (Steering-column and floor-shift levers)

Years ago, the automotive manual
transmission was a three-speed. The gearshift
lever was located on the floor of the drivers
compartment in an easy reach of the drivers
right hand. The lower end of the lever attached
to the shifting mechanism of the transmission.
Then the gearshift lever was moved to the
steering column, where the lever was most
accessible to the driver. This also provided
more leg room in the front seat. Today,
vehicles again use a floor-mounted gearshift
lever. Many times it is part of a center console.
Figure LO1-22 shows typical shift patterns for
manual transmission and transaxles.
Figure LO1-21. Linkage between the gearshift lever on

the floor and the transmission. (Chevrolet Division of
General Motors Corporation)
Figure LO1-22. Typical shift pattern for three-speed and

five-speed manual transmission. (ATW)
Shift Linkage
A variety of shift linkage arrangements have been used to connect the gearshift lever with the
transmission or transaxle. The basic action is the same for all. A shift requires two movements
of the gearshift lever. The first movement selects the shift fork and synchronizer for the desired
gear. The second movement causes the shift fork to move the synchronizer sleeve. This locks
the desired gear to the mainshaft.
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Figure LO1-20 shows the linkage from the

gearshift lever mounted on the steering
column to the transmission. Figure LO1-21
shows the linkage from a floor-mounted
gearshift lever to a four-speed transmission.
This arrangement is typical of external linkage
which is outside the transmission case. To
reduce wear and other problems, most
transmission and transaxles now have internal
linkage. The shift linkage is enclosed within
the transmission or transaxle case.
Figure LO1-23 shows the cable linkage for a
five-speed transaxle with a floor-mounted
gearshift lever. The ends of the cables attach
to the shift levers on the transaxle. The
selector cable selects which shift rail to move.
The shift cable then moves that shift rail
forward or backward.
Figure LO1-23. Cable linkage for a five-speed transaxle

with a floor-mounted shift lever. (American Honda Motor
Company, Inc.)
Lubrication (Gear lubricants)

A gear oil performs five jobs. It must:
1.
2.
3.
4.
5.
Lubricate gears and bearings to prevent wear.

Reduce friction and power loss.
Protect against rust and corrosion.
Remove particles from metal surfaces.
Help cool bearings and gears.
In addition, the lubricant helps reduce noise from the gearbox.

Most gear oil is a mineral oil refined from crude oil. Some gear oil is manufactured or synthetic
oil. Chemical additives are mixed with gear oil to improve its load carrying capacity. This makes
an extreme pressure (EP) lubricant. Other additives reduce the effects of heat on oil viscosity
and prevent foaming, rust, corrosion and oil-seal damage.
The gear oil used in many cars and trucks is relatively thick and has a viscosity ranging from
SAE 75W to SAE 140. Multigrade gear oils such as SAE 75-90 are also used. However, some
manufacturers specify synchromesh transmission fluid (STF) fro manual transmissions and
transaxles. Others are filled with automatic-transmission fluid.
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Operation Sheet LO1-1:
Drain Transmission Gear Oil and Dismount Manual

Transmission
In most cars, several

bolts attach the manual
transmission to the
clutch housing. A
crossmember supports
the rear of the
transmission. The front
end of the driveshaft
attaches to a universal
joint. A slip yoke is part
of the universal joint
and splined to the
transmission output
shaft. Shift rods may
connect the gearshift
lever to the shift levers
on the transmission.
Remove the
transmission following
the procedure in the
vehicle manual.
Figure LO1-24. A crossmember supports the rear of the transmission. Make index
marks on the rear axle yoke and driveshaft before removing the slip yoke from the
transmission. (Ford Motor Company)
1. These steps typically include

disconnecting the negative cable from the
battery and removing the gearshift knob
or lever.
2. Raise the vehicle on a lift and drain the
lubricant into a oil can big enough (about
3 liters or bigger) to contain the oil.
3. Disconnect the speedometer cable.
4. Then disconnect all wires and electrical
connectors attached to sensors and
switches in the transmission case, shift
cover and extension housing.
5. If necessary, remove part or all the
exhaust system to allow working room for
transmission removal.
6. Locate or make index marks on the rear axle yoke and on the driveshaft from the rear axle.
Do not allow the universal joint caps and bearings to fall off.
7. Pull the driveshaft back until the slip yoke slides off the transmission output shaft.
8. Support the rear of the engine with a support jack or safety stand.
9. Remove the transmission mount and cross member if necessary.
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10. Remove two upper bolts attaching the

transmission to the clutch housing and
install guide pins in the holes. The guide
pins prevent damage to the clutch friction
disc as the transmission is removed.
11. Then remove the other bolts.
12. With a helper or using a transmission
jack, slide the transmission rearward until
the input shaft clears the clutch housing.
13. Lower the transmission and move it out
from under the vehicle.
14. With the transmission out, inspect the
condition and tightness of the flywheel
and clutch.
Figure LO1-25. Checking lubricant level in manual

transmission (General Motors Corporation, Ford Motor
Company)
15. Inspect the pilot bearing or bushing in the

end of the crankshaft.
16. Perform any services required on the
flywheel and clutch before reinstalling the
transmission.
Figure LO1-26. Using guide pins during transmission

removal or installation to prevent damaging the friction
disc. (Buick Division of General Motors Corporation)
Figure LO1-27. Secure the transmission to the

transmission jack. Move the transmission rearward
until the input shaft clears the clutch housing and
lower the jack. (Ford Motor Company)
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Figure LO1-28. Manual transmission mounted on a

holding fixture above an oil-drain can. (Form Motor
Company)

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Self-Check LO1-1
Select the best answer.
1. Technician A says, in a gearset, speed reduction means torque. Technician B says speed
increase means torque reduction. Who is right?
a. A only
b. B only
c. both A and B
d. neither A nor B
2. A synchronizer does all the following except:
a. prevents gear clash during shifting
b. uses friction to make the gear synchronizer ring rotate at the same speed
c. locks a gear to the shaft
d. attaches directly to the shift rail
3. When the gear ratio through the transmission is 1:1, the transmission is in
a. overdrive
b. direct drive
c. underdrive
d. neutral
4. Power leaves the transmission section of a manual transaxle through a
a. pinion gear
b. ring gear
c. cluster gear
d. countergear
5. Technician A says when a five-speed manual transaxle is in fifth gear, the first-second and
third-fourth synchronizer sleeves are in neutral. Technician B says the fifth synchronizer is
disengaged. Who is right?
a. A only
b. B only
c. both A and B
d. neither A nor B
6. The dual-range transaxle has
a. an output shaft with two ring gears
b. an input shaft with two pinion gears
c. two countergears
d. two overdrive ratios
7. The purpose of an interlock device is to
a. lock the transmission to prevent theft
b. complete the electric circuit to the starting motor
c. Prevent locking two gears to the output shaft at the same time
d. interlock the shift lever to prevent shifting
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8. To shift into a gear, the first movement of the gearshift lever

a. moves the synchronizer
b. selects the synchronizer
c. meshes the gears
d. moves the synchronizer sleeve
9. Shift linkage enclosed within the transmission or transaxle case is called
a. external linkage
b. floor shift
c. column shift
d. internal linkage
10. The speedometer drive gear mounts on the
a. input shaft
b. countergear shaft
c. output shaft
d. fifth-gear shaft
Review Questions
1. Name the basic parts of a gearbox and describe the purpose of each.
2. What is a detent and what does it do in a manual transmission or transaxle?
3. What are the differences between a four-speed manual transmission and a five-speed
manual transmission?
4. How is reverse obtained in the gear train of a manual transaxle?
5. Describe the five jobs of a gear oil and the various types that are used in manual
transmission and transaxles.
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Answer Key LO1-1

1. C
2. D
3. B
4. A
5. A
6. B
7. C
8. B
9. D
10. C
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Learning Outcome #2: Disassemble manual transmission
1. Manual transmission is disassembled in correct steps and procedures as per
specification
2. Dismantled parts accurately tagged and marked
3. Parts rinsed and washed with appropriate solution
4. Damaged parts replaced, reconditioned according to specification
5. Appropriate tools are used as per job requirements, and vehicle safety procedure is
applied
6. Personal safety procedure is observed throughout the activity.
Resources:
Equipment
Manual transmission
Basic hand tools
Working tables
Transaxle
Snap ring pliers
Punch
Rubber mallet
Dial gauge
Lifter and jack stand
Car w/ manual transmission /transaxle
Wrenches
Socket set
Bearing puller
Press
Supplies and Materials

Rags
Soap
Paint brush
White board Marker
Permanent marker
Spare bolts
Clear glass
Apron
Gloves
Masking tape
Mechanic's wire
Cleaning pan
Cleaning solvent
Kerosene
Reference:
Automotive Mechanics 10th Edition by Willia H. Crouse and Donald L. Anglin, pp 553-583
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Learning Outcome 2:
Disassemble manual transmission
LEARNING ACTIVITIES
1. Perform the correct procedure in

disassembling, checking and cleaning manual
transmission components.
Read: Procedure in disassembling manual
transmission
1.1 Operation Sheet LO2-1
Clean all parts of manual transmission

Observe and perform best shop practices
3. Report results in oral or written format
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Operation Sheet LO2-1 Disassemble Manual Transmission

Manual Transmission Disassembly and Cleaning
Place the transmission in a holding fixture or on the workbench. Follow the procedure in the
vehicle service manual and disassemble the transmission. Your transmission might be different
from the one shown here.
Figure LO2-1. External Parts of a manual transmission.
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Disassembly
1. While disassembly can be achieved with
basic tools you'll also need external snap
ring pliers, retaining ring pliers, T40 Torx
bit, a drift punch and cold chisel. For
reassembly however you'll need access
to a press, bushing driver, calipers and a
dial indicator.
Figure LO2-2. Basic and special tools.
2. If you aren't sure whether or not you have

a World Class T5, the quickest external
check is to look at the counter-shaft
bearing cup, just below the bearing
retainer. It it is of the roller bearing type,
with Timken engravings (left) you have a
WC T5.
Currently, the TREMEC T-5 is being used on various
passenger car and light truck applications such as the
Ford Mustang, TVR Cerbera and Tuscan, Chevy
Blazer and S-10 Pickup, and Ssangyong Musso and
Korando.
Figure LO2-3. Location of world-class marks on the

manual transmission.
3. The disassembly process begins with

removing the shifter. Using a drift punch
drive the roll pin through the offset lever.
The pin will bottom out but not be
retrievable at this point.
Figure LO2-4. Using a drift punch to remove the shifter.
4. Remove the eight 15mm tail housing

bolts.
Figure LO2-5. Removing the tail housing bolts.

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5. While holding the offset lever back as

shown, tap the case with a hammer to
break the tailshaft housing free of the
case. Do not attempt to pry between the
mating surfaces.
Figure LO2-6. Tapping the case with a hammer.
6. The tailshaft housing can now be

removed buy sliding it straight back until it
is off the shifter shaft and main shaft.
Figure LO2-7. Sliding back the tailshaft housing.
7. At this point the speedometer drive gear

can be removed from the main shaft.
Depress the retaining clip and slide the
gear off, then remove the clip from the
shaft.
Figure LO2-8. Removing the speedometer drive gear.
8. T5 Speedometer drive gears come in

three tooth counts; 6 (black), 7 (yellow)
and 8 (green). By changing to the lower
count gear (6 or 7) you can compensate
for steep axle ratios and have accurate
speedometer readings. With a 6 tooth
gear, for instance, you can use an 18, 20,
and 21 tooth driven gear (on the end of
the speedo cable) for accurate reading
with 3.73, 4.10, or 4.30 gears
respectively. With the yellow drive gear
you can use 21 tooth speedo gear for
3.73's and 23 for 4.10.
Code No.
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Figure LO2-9. The speedometer drive gear.

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9. Start by removing the neutral safety

switch from the top cover.
Figure LO2-10. Removing the neutral safety switch.
10. Using needle nose pliers, reach into the

neutral switch port and remove the
activator pin. We're going to plug this port
since we have no plans to use a neutral
safeguard on the ignition switch.
Figure LO2-11. Removing the activator pin.
11. Remove the ten top-cover bolts using a

10mm socket. Use the pry slots at the
opposing corners of the case to break
loose the top cover. Do not try to lift or
force the cover off at this time.
Figure LO2-12. Removing top-cover bolts.
12. Push the cover over to the drain plug side

of the transmission case to move the shift
forks clear of the reverse mechanism,
allowing the cover to be lifted off the
case.
Figure LO2-13. Removing the case cover.
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13. Turning to the back of the case, we'll work

on removing the 5th gear assembly.
Using a drift punch, drive this roll pin out
of the 5th shift fork and shift rail.
Figure LO2-14. Removing the 5th gear assembly.
14. Using snap ring pliers, remove the snap

ring which secures the 5th synchronizer
assembly and 5th speed drive gear in
place.
Figure LO2-15. Removing the snap ring.
15. The entire 5th gear shift fork and gear

assembly can be pulled off the cluster
shaft and set aside.
Figure LO2-16. Pulling the 5th gear shift fork.
16. Back at the front of the case the bearing

retainer is removed to allow access to the
input shaft. Note the shim and bearing
race which are behind the bearing
retainer.
Figure LO2-17. Removing the bearing retainers.
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17. To remove the input shaft this crescent

shaped notch needs to face downward
(shown in up position.)
Figure LO2-18. Adjusting the notch of input shaft.
18. The input shaft can then be pulled out.

There will likely be loose roller bearings
which drop out. They can be discarded.
Figure LO2-19. Pulling out the input shaft.
19. Slide the bearing cup off the main shaft.
Figure LO2-20. Removing the bearing cup.
20. Carefully lift the output (main) shaft

assembly up and out through the top of
the case and set aside.
Figure LO2-21. Removing the main shaft assembly.
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21. Reach into the case and unhook the

spring from the 5th-Reverse (5-R) shift
rail assembly. Then pull the rail out of the
case.
Figure LO2-22. Pulling the rail out of the case.
22. Remove the retaining clip from the 5-R

shift lever and then remove the lever from
the case.
Figure LO2-23. Removing the retaining clip from the shift

lever
23. Shown is the 5-R shift lever assembly.

Note the torsion spring, this is found on
mid 1992 and newer World Class T5's.
Figure LO2-24. 5-R shift lever.
24. The 5-R shift levers and 5th shift forks

from pre 1992 WC T5's (top) and post
1992 with the torsion spring (bottom)
cannot be interchanged. The early T5's
use an extension spring.
Figure LO2-25. 5-R shift lever assembly.
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25. If the side of your T5 case has this pivot

pin below the back-up switch it indicates
the later style 5-R shift lever mechanism
with the torsion spring.
Figure LO2-26. Location of the pivot pin.
26. Use a cold chisel to pry down the lock

tabs on the bearing retainer. Then
remove the four T-40 Torx head screws.
Figure LO2-27. Removing the lock tabs with a cold chisel.
27. The bearing retainer is removed along

with the shims and bearing race. On a
standard rebuild we'd take note of the
shim stack height, but in the case of our
G-Force build up we'll check end play and
shim accordingly for the new gears.
Figure LO2-28. Removing the bearing retainer.
28. Next we'll remove the reverse idler shaft

and gear. Use a drift to punch out the roll
pin in the idler shaft. A fair warning, the
shaft will want to turn as you smack it so
aim carefully.
Figure 2-29. Removing the reverse idler shaft and gear.
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29. With the roll pin out we can push the idler
shaft out the back of the T5 case.
Figure LO2-30. Removing the idler shaft.
30. The reverse idler gear can be removed as

well. Be sure to grab the O-ring which sits
in front of the idler gear.
Figure 2-31. Removing the idler gear.
31. The final step to clear out the case

assembly is removal of the countershaft
gear. Push the gear forward so the shaft
and cone bearing protrude out the rear of
the case as shown. Then snip the bearing
cage to remove it from the shaft.
Figure 2-32. Removing the countershaft gear.
32. With the bearing cage removed the

countershaft gear assembly can be
guided out the top of the case.
Figure LO2-33. Removing the countershaft gear.
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33. Finally, use a hammer to knock out the

bearing cup out. We'll replace this with a
new piece.
Figure LO2-34. Removing the bearing cup.
34. The empty T5 case can now be

thoroughly cleaned with solvent. Be sure
to remove all metal debris stuck to the
magnet in the bottom of the case.
Figure LO2-35. Cleaning the T5 case.
Cleaning Transmission Parts

1. Cleaning Transmission Parts. Wash all transmission parts, except bearings and seals in
solvent. Brush or scrape all dirt from the parts. Do not damage parts with the scraper. Dry
each part with compressed air.
Caution: Always wear eye protection safety glasses, goggles or face shield when using compressed air or
solvent.
Some transmissions have a magnet at the bottom of the case. Clean the magnet with
solvent to remove any metal particles and dirt. To clean a switch or sensor, wipe it with a
clean shop towel. Never clean switches and sensors in solvent.
2. Cleaning Transmission Bearings. To clean a bearing, rotate it slowly in clean solvent to
remove all lubricant. Then hold the bearing assembly stationary so it will not rotate and dry it
with compressed air.
Caution: Never spin a ball or roller bearing with compressed air. Spinning a bearing after the lubricant is removed
[a dry bearing] may damage the bearing. A bearing spinning at high speed may fly apart injuring you or others.
As soon as the bearing is dry, lubricate it with transmission lubricant. This prevents
microscopic rust from immediately beginning to form on the bearing. Then place each
bearing in a clean plastic bag for later inspection.
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Self-Check LO2-1
Disassemble Manual Transmissions
Directions: At this time, check your skills by reviewing the following criteria.
1.
Transmission is disassembled correctly.
2.
Dismantled parts are accurately tagged and marked.
3.
Parts are rinsed and washed with appropriate solution.
4.
Damaged parts are replaced or reconditioned according to specifications.
5.
Tools are used properly
6.
All safety rules are observed.
If you do not feel you can do some of these skills, see your instructor for help.
After you have done all your checking
remember to clean and put away your
materials and equipment.
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Learning Outcome #3: Inspect and check manual transmission components.
1.
2.
3.
4.
Worn-out, cracked parts, gear backlash and endplay were inspected and accurately
identified.
Defects identified and corresponding recommendation is given.
Instruments and testers are accurately used.
No damage during inspection.
Resources:
Equipment
Mill file
Supplies and Materials

MP grease
Emery cloth
Trans. Lubricant
Repair manual
Putty knife
Reference:
Automotive Mechanics 10th Edition by Willia H. Crouse and Donald L. Anglin, pp 553-583
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Learning Outcome 3: Inspect and check manual transmission components

LEARNING ACTIVITIES
1. Apply and perform the correct procedures in

inspecting and checking manual components.
Read: Procedure in inspecting and checking
manual transmission components.
Operation Sheet LO3-1
Identify defects in manual transmission

components.
2. Answer: Self-Check after performing Operation
Self-Check LO3-1
Sheet LO3-1.
3. Observe PPE safety precautions
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Operation Sheet LO3-1. Inspecting and Checking Manual Transmission
Components
Inspecting Manual Transmission Parts
1. Inspect the transmission case for cracks and
worn or damaged bearing bores and threads.
2. Check the front and back of the case for nicks or
burrs that could cause misalignment with the
flywheel housing or extension housing.
3. Remove all burrs with a fine file.
4. Check the condition of the shift levers, shift rails,
forks, shafts and gears.
5. Replace the countergear and any other gear if
teeth are worn, broken, chipped or damaged.
6. Replace the countergear shaft if it is worn, bent
or scored. In some transmissions, the bushings in
the reverse gear and reverse-idler gear are not
serviced separately.
7. Replace the reverse-idler gear if the bushing is
worn. The new gear has a new bushing in it.
8. Check each synchronizer sleeve for the
movement on its hub.
9. Look for worn or damaged splines.
10. Inspect the teeth on each synchronizer ring.
11. Replace the synchronizer ring if it has chipped or

worn teeth or marks on the gear face.
12. Check the amount of synchronizer-ring wear by
placing the ring on its gear case.
13. With a thickness gauge, measure the clearance
between the side faces. A typical specification is
to replace the synchronizer ring or gear if the
clearance is less than 0.031 inch (0.8 mm).
14. Inspect the shaft fork and groove in the

synchronizer sleeve for wear or damage.
15. Position the shift fork in the synchronizer sleeve.
16. Measure the clearance between the fork and the
groove with a thickness gauge. A typical
specification is that the clearance is less than
0.031 inch (0.8 mm).
Figure LO3-1. Checking synchronizer for wear

and clearance. (Ford Motor Company)
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Inspecting Ball and Roller Bearings

To inspect a bearing, first clean it as described above. Metal particles clinging to the bearing
indicate it has become magnetized. Use a demagnetizer to remove the magnetism or replace
the bearing.
Figure 30 shows various types of roller-bearing failure and the recommended service
procedure. Figure 31 shows various ball-bearing failures. In addition, inspect for damage or
cracks around the snap-ring groove. Also, replace the bearing if the ball cage is cracked or
deformed. Replace any bearing that is broken, worn or rough.
1.
2.
3.
4.
If the bearing has no visible damage, give the bearing a spin test.
Lubricate the bearing races lightly with clean oil.
Turn the bearing back and forth slowly to coat the races and balls.
Hold the bearing vertically by the inner race. Some vertical movement between the inner
and outer races is acceptable.
5. Spin the outer ring several times by hand, not with compressed air.
6. If you notice roughness or vibration or if the outer ring stops abruptly, reclean the bearing.
7. Then lubricate it and spin it again. Roughness is usually caused by particles or dirt in the
bearing.
8. Discard the bearing if it is still rough after cleaning and lubricating three times.
9. Hold the bearing horizontally by the inner race with the snap-ring groove up.
10. Spin the outer race several times by hand.
11. Discard the bearing if it is still rough after cleaning and lubricating three times.
GOOD BEARING
BENT CAGE
CAGE DAMAGE DUE TO IMPROPER
HANDLING OR TOOL DAMAGE.
REPLACE BEARING.
METAL SHEARS ON ROLLER ENDS

DUE TO OVERHEAT, LUBRICANT
PROBLEM OR OVERLOAD.
RACE CRACKED DUE TO IMPROPER FIT,

COCKING OR POOR BEARING SEATS
REPLACE BEARING CHECK SEALS

AND CHECK FOR PROPER
LUBRICATION.
ALT723313a
CAGE DAMAGE DUE TO IMPROPER

HANDLING OR TOOL DAMAGE.
REPLACE BEARING.
CRACKED INNER RACE
BALLING
Code No.
BENT CAGE

ETCHING
BEARING SURFACES APPEAR GRAY OR
GRAYISH BLACK IN COLOR WITH
RELATED ETCHING AWAY OF MATERIAL
USUALLY AT ROLLER SPACING.
REPLACE BEARING - CHECK SEALS AND
CHECK FOR PROPER LUBRICATION.
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40
HEAT DISCOLORATION
BRINELLING
SURFACE INDENTATION IN RACES
CAUSED BY ROLLERS EITHER UNDER
IMPACT LOADING OR VIBRATION
WHILE THE BEARING IS NOT
ROTATING.
REPLACE BEARING IF ROUGH OR
NOISY.
HEAT DISCOLORATION IS DARK BLUE

RESULTING FROM OVERLOAD OR NO
LUBRICANT (YELLOW OR BROWN COLOR
IS NORMAL.
EXCESSIVE HEAT CAN CAUSE
SOFTENING OF RACES AND ROLLERS
FATIGUE SPALLING
FLAKING OF SURFACE METAL RESULTING
FROM FATIGUE.
REPLACE BEARING CLEAN ALL
RELATED PARTS.
TO CHECK FOR LOSS OF TEMPER ON

RACES OR ROLLERS A SIMPLE FILE TEST
MAY BE MADE. A FILE DRAWN OVER A
HARD PART WILL GLIDE READILY WITH
NO METAL CUTTING.
REPLACE BEARING IF OVER HEATING
DAMAGE IS INDICATED. CHECK SEALS
AND OTHER PARTS.
Figure LO3-2. Various types of roller-bearing failure and the

recommended service procedure. (Ford Motor Company)
Figure LO3-3. Ball bearing failures. (Ford Motor Company)
Manual Transaxle Troubles

Two types of manual-transmission and transaxle troubles are noise and improper operation.
The cause of either of these may be internal or external. Three general types of noise may
come from a manual transmission or transaxle. The type of noise provides information about
what is taking place inside the case to make that noise.
The sound of a periodic clunk indicates broken gear teeth. A growl or whine indicates a
defective bearing or worn teeth. A defective bearing usually produces a rough growl or grating
noise rather than a whine, which is more typical of gear noise. Gear clash during shifting often
indicates a worn defective synchronizer.
Code No.
ALT723313a

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41
Manual-Transmission Trouble Diagnosis

1. Manual Transmission Troubles
A complaint of transmission trouble may actually be a defective clutch. Check the clutch
first. If the trouble is in the external shift linkage, the linkage may need lubricating and
adjusting or a defective cable replaced.
Noise
Periodic clunk
Growl or whine
Gear clash
Cause
Broken teeth
Defective bearing or worn teeth
Defective synchronizer
Figure LO3-4. Three types of manual-transmission noise and their causes.
To determine the cause of other troubles, follow the steps in the manufacturers service
manual and in the Manual-Transmission Troubleshooting Chart (Table LO3-1).
Because of differences among manual transmissions, each possible cause and correction
may not apply to all transmissions. Refer to the troubleshooting chart and procedures in the
vehicle service manual.
Caution: Never go under a vehicle unless you are wearing eye protection-safety glasses or safety goggles. If
the vehicle is raised on a lift, lock the lift. If the vehicle is raised on a jack, be sure the vehicle is
properly supported on safety stands before going under it.
2. Hard Shifting into Gear

Difficulty in shifting into gear may be caused by improperly adjusted linkage between the
gearshift lever and the transmission. This greatly increases the force required to shift
gears. Hard shifting also results if the linkage is bent, jammed or rusted and in need of
lubrication. Other causes include a bent shift fork, a worn or defective synchronizer, a
twisted mainshaft and an improperly adjusted clutch.
3. Transmission Sticks in Gear
Conditions that cause difficulty shifting into gear can also cause the transmission to stick in
gear. These include improper shift-linkage adjustment and the linkage failing to move freely.
Other causes include improper clutch-linkage adjustment and any condition that prevents
the clutch from disengaging.
The transmission may stick in gear if the interlock device fails to operate properly and if a
synchronizer sleeve does not slide freely on the hub splines. Lack of lubricant in the
transmission or use of the wrong lubricant may also cause the transmission to stick in gear.
4. Transmission Jumps Out of Gear
Improperly adjusted shift linkage may cause the transmission to slip or jump out of gear.
Binding or an excessively stiff boot on the gearshift lever may pull it back to neutral from any
gear position. To check the boot, squeeze it. If the boot is too stiff, replace it.
Worn splines in the synchronizer sleeve or worn external teeth on the gear may cause the
transmission to jump out of gear. Both the sleeve and the external teeth often wear at the
same time. When this condition is found, replace both the sleeve and the gear.
Code No.
ALT723313a

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42
Sometimes the transmission begins jumping out of gear immediately after the clutch or
transmission has been serviced or replaced. Check for misalignment between the
transmission and the engine. A pulsating clutch pedal may indicate clutch-housing
misalignment. If the clutch housing is out of line, then so is the transmission.
4. Gear Clash When Shifting
A worn or defective synchronizer will cause
gear clash during shifting. This may be due
to a broken synchronizer spring or a worn
cone surface on a synchronizer ring. Gear
clash also occurs if the clutch does not fully
disengage and if a gear sticks on the
mainshaft.
Gear clash may occur if a sudden shift is
made to first or to reverse before the gears
stop moving. Some transmissions do not
have a synchronizer on first or reverse.
Figure LO3-4. A defective synchronizer, in neutral with
the key or strut out of position.
To shift into either of these positions without gear clash, the driver must wait until the gears
stop turning (spin down). Then the shift lever can be moved and the gears will mesh
without clashing.
A worn or dry pilot bearing or bushing may drag around the input shaft even after the clutch
is disengaged. This cause gear clash when shifting as will incorrect lubricant in the
transmission.
5. Transmission Noisy in Gear
Noise while the transmission is in gear
could result from any condition. The noise
could also be due to a defective friction
disc in the clutch or a defective engine
vibration damper. Other causes include a
worn or dry rear bearing on the
transmission output shaft, a loose gear on
the output shaft and worn or damaged gear
teeth, synchronizers, or speedometer
gears.
Transmission troubles may cause several
types of noise.
Figure LO3.5. Inspecting synchronizer ring and cone

surface for wear. (Ford Motor Company)
A whining or growling noise may be either steady or intermittent. It can be due to worn,
chipped, rough or cracked gears. As the gears continue to wear, the noise may take on a
grinding sound. It will be the loudest in the gear position that throws the greatest load on the
worn gears.
Bearing trouble often causes a hissing noise that develops into a bumping or thudding
sound as the bearing wears. Metallic rattles may be caused by worn or loose parts in the
Code No.
ALT723313a

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43
shift linkage, or by gears loose on the shaft splines. Sometimes noise from defective
cushions springs in the clutch friction disc or from the engine vibration damper carry into the
transmission. Typically, this noise is heard only at certain engine speeds.
While diagnosing transmission noise, listen carefully to determine in which gear position the
noise is loudest. This information helps pinpoint the worn or defective parts.
6. Transmission Noisy in Neutral
Noise heard with the transmission in neutral and the clutch engaged may be caused by
transmission misalignment with the engine. It may also be caused by a defect in any of the
parts that are rotating. Possible causes include a worn or dry bearing, a worn gear, a worn
or bent countergear, or excessive countergear endplay.
7. Transmission Noisy in Reverse
Noise in reverse is probably due to a
damaged or worn reverse idler gear or
bushing, reverse gear on the mainshaft or
countergear. A damaged shift mechanism
will also cause noise in reverse.
Figure LO3-6. Manual transmission with a broken

mainshaft which prevents power flow through the
transmission. (Toyotal Motor Sales USA, Inc.)
8. No Power Through Transmission

If no power flows through the transmission
when it is in gear and the clutch engaged,
the clutch may be slipping. Internal
transmission causes include teeth stripped
from gears, a broken shift fork or linkage
part, splines shared off and a broken gear
or shaft.
9. Transmission Oil Leaks
Figure LO3-7 shows various places
lubricant may leak from a manual
transmission. If the lubricant in the
transmission is not the correct type, it may
foam excessively. The foam will completely
fill the case and then begin to leak out. To
prevent foaming, fill the transmission with
the specified lubricant to the proper level.
An overfilled transmission, a loose drain
plug or fill or fill plug, and a cracked
transmission case or extension housing will
also leak oil.
Code No.
ALT723313a

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44
Figure LO3-7. Various places lubricant may leak from a

manual transmission. (Ford Motor Company)
Table LO3-1 Manual Transmission Troubleshooting Chart

PROBLEM
Will not shift

(control lever
moves)
POSSIBLE CAUSE
Control lever assembly broken or
Replace control lever and housing
Damaged offset lever, shift fork,
Remove extension or adapter and
Clutch not releasing

Improper or low transmission
Adjust or replace clutch

Add or drain and replace with
damaged
selector plate or selector arm
Hard shift or
control lever
will not move
into gear
lubricant
Shifter shaft or shift rail binding

Binding of sliding synchronizers or
gears
If reverse only, seized backup
switch
Worn or damaged flywheel pilot
bushing
Bell housing misaligned
Gears clash
when
shifting
Engine idle speed too high

Clutch damaged or out of
adjustment
Pilot bearing between input shaft

and output shaft binding
Damaged synchronizer
Bell housing misaligned
Code No.
ALT723313a
REMEDY
assembly
case cover. Check for damaged

parts. Replace damaged parts
proper
Lubricant (refer to paragraph 2-4
case
Cover. Check for damaged parts.
Replace damaged parts
case cover.
Reach down into transmission and
Check that synchronizers and
gears (parts
With shifting grooves) slide freely
on shafts.
Remove and replace damaged
parts.
Remove and check backup switch.
Replace if seized
Replace pilot bushing
Align bell housing to within 0.010
inch TIR on face and in bore.
Adjust idle speed to specifications
Adjust or replace clutch
Disassemble and check bearing
rollers,
Input shaft ID and output shaft OD.
Disassemble and check for
damaged
Synchronizer parts. Replace
damaged parts

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45
PROBLEM
POSSIBLE CAUSE
Damaged gear or gears

Worn or damaged flywheel pilot
bushing
Transmission
jumps out of
gear
Loose transmission or flywheel

housing
Bolts, improper alignment
Synchronizer damaged or
excessively worn
Blocking ring damaged, worn index

slots or friction surfaces worn or
damaged
Excessive countershaft end play
Shifting fork loose on shaft or rail;

Transmission
locked in one
gear
worn or damaged fork or inserts

Fork or offset lever loose on shaft
or rail
Worn or damaged forks, offset

lever, shaft or rail
Worn or damaged synchronizer

Worn or damaged gears
Transmission
noise. NOTE:
Make sure
noise is
coming from
transmission
and not clutch
release
bearing or
other
components.
Improper or low transmission

lubricant
Loose bolts or other attaching parts

Improper flywheel housing to
engine crankshaft alignment
Noisy transmission bearings
Noisy gears
Code No.
ALT723313a
REMEDY
Align bell housing to within 0.010
inch TIR on face and in bore

Disassemble and check for gear
damage.
Replace damaged gears
Replace pilot bushing
Torque bolts to specifications.
Realign if necessary
Disassemble and check for worn or
damaged synchronizer parts.
Disassemble and check blocking
ring for Damaged parts
Disassemble and check. Replace
worn or damaged parts. Reshim if
roller bearings used.
Disassemble and check for wear or
damage.
case cover. Check for loose parts

on shifter shaft or rail. Replace roll
pin(s). If still loose, replace shaft
or rail and/or attached parts as
required
case cover. Check for wear or
damage,
damaged synchronizer parts.
Replace worn or damaged parts
damaged gears. Replace worn or
damaged gears
Add or drain and replace with
proper lubricant (refer to
paragraph 2-4)
Make sure al attaching parts are
torqued to specifications
Check alignment and correct if
necessary per vehicle service
manual
Disassemble and check bearing,
bearing rollers and parts in and on
which they operate for wear or
damage.
Replace worn or damaged parts
damaged gears (including
speedometer gear). Replace worn

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PROBLEM
Transmission
leakage
POSSIBLE CAUSE
Leakage from other components

Vent or breather clogged
Too much or improper lubricant
Loose bolts at sealing faces
Improperly applied sealant
Worn or damaged oil seal
Code No.
ALT723313a
REMEDY
or damaged gears
Verify transmission leakage.
Thoroughly clean all exposed
surfaces, then check for leaks
Remove vent or breather and
clean or replace
Remove fill plug to check for
excess, or drain and replace
Torque bolts to specifications
Separate and thoroughly clean
leaking surfaces. Reapply sealant.
Replace parts and torque bolts to
specifications
Replace oil seal

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Manual-Transaxle Trouble Diagnosis

1. The manual transaxle includes a transmission section and a drive-axle or differential section.
Diagnosing trouble in the transmission section is similar to trouble-diagnosis of a manual
transmission. Take a road test with the driver, if possible. Find out when the trouble occurs.
Then refer to the trouble-diagnosis chart in the vehicle service manual.
Figure LO3-8 is a chart that lists various manual-transaxle troubles and their possible
causes. The chart can be used as a guide when diagnosing trouble in manual transaxle and
drive train of a front-wheel-drive vehicle. If the trouble is in the transmission section of the
transaxle, the Manual Transmission Trouble-Diagnosis Chart may also be helpful.
2. Manual Transaxle and Drive Train Noise
In a front-wheel-drive vehicle, the entire drive train is almost under the drivers feet. This
makes any drive-train noise more noticeable than in a rear-wheel-drive vehicle. The noise
can vary with vehicle size, type and size of engine, and amount of body insulation.
Noises that sound like they are coming from the drive train may actually be coming from the
tire, road surface, wheel bearings, engine or exhaust system. Transaxle gears may produce
some noise during abnormal operation. If the noise annoys the driver, determine if it is
excessive. Listed below are the steps in a typical procedure for identifying the source of
manual transaxle and drive-train noise.
a. Road test the vehicle by driving it on a smooth, level, paved road. This will reduce tire
and road noise to a minimum.
b. Drive the vehicle long enough to warm all lubricants.
c. Note the speed at which the noise occurs and in which gear.
d. Stop the vehicle in a safe area. Shift to neutral and listen for the noise. Then depress the
clutch pedal, shift into gear and listen for the noise.
Complaint
1. Noise is the same in drive or coast.
2. Noise changes on different types of road.

3. Noise tone lowers as car speed is lowered.
4. Noise is produced with engine running,
whether vehicle is stopped or moving.
5. Knock at low speeds.
6. Noise loudest during turns.
7. Clunk on acceleration or deceleration.
8. Clicking noise in turns.

9. Vibration
Code No.
ALT723313a
Possible Cause
a. Road noise
b. Tire noise
c. Front-wheel bearing noise
d. Incorrect drive-side angle [standing height]
a. Road noise
b. Tire noise
a. Tire noise
a. Engine noise
Transaxle noise
c. Exhaust noise
a. Worn CV joint
b. Worn side-gear-hub counterbore in differential
a. Differential-gear noise
a. Loose engine or transaxle mounts
b. Worn differential pinion shaft in case, or sidegear-hub counterbore in case worm oversize
c. Worn or damaged inboard CV joint
a. Worn or damaged outboard CV joint
a. Rough wheel bearing
b. Damaged drive-axle shaft
c. Out-of-round tire
d. Tire unbalance
e. Worn CV joint

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10. Transaxle noisy in neutral.

11. Transaxle noisy in gear.
12. Transaxle noisy in reverse
f.
a.
a.
b.
a.
15. Hard shifting into gear.
b.
a.
b.
c.
a.
b.
c.
d.
e.
f.
g.
a.
16. Transaxle sticks in gear.
b.
c.
a.
13. Transaxle noisy in all gears.

14. Transaxle jumps out of gear.
17. Gears clash when shifting.
18. Transaxle oil leaks.
b.
c.
a.
b.
c.
d.
a.
b.
c.
d.
e.
f.
Incorrect drive-axle angle

Damaged input-shaft bearing
Damaged or worn output-shaft gear
Damaged or worn synchronizer
Worn or damaged reverse idler gear or idler
bushing
Worn or damaged synchronizer
Insufficient lubricant
Damaged or worn bearings
Worn or damaged input shaft or output shaft
Worn or improperly adjusted linkage
Transaxle loose on engine
Shift linkage binds
Bent or damaged shift cables
Front-bearing retainer broken or loose
Dirt between clutch housing and engine
Soft gearshift lever seal or boot
Gearshift linkage out of adjustment or needs
lubricant
Clutch not disengaging
Internal trouble in transaxle
Gearshift linkage out of adjustment,
disconnected, or needs lubricant
Incorrect gearshift adjustment
Clutch linkage needs adjustment
Drive-axle seals faulty
Excessive lubricant in transaxle
Loose or broken front-bearing retainer
Front-bearing retainer O ring or lip seal
damaged
Lack of sealant between case and clutch
housing or loose clutch housing
Gearshift-lever seal leaks
Figure LO3-8. Manual-transaxle trouble-diagnosis chart.
e. Determine during which of the following driving conditions the noise is noticeable.
- Driving light acceleration or heavy pull.
- Float constant vehicle speed with light throttle on a level road.
- Coast partly or fully closed throttle with transaxle in gear.
- All of the above.
f. After testing the vehicle, consider the following
- If the noise is the same in drive or coast, it could be due to excessive angle of the
drive axles or halfshafts. The front suspension may be binding or the springs may be
weak. This could cause the drive-axle universal joints or CV joints to be driving
through an excessive angle.
- A knock at low speed could be caused by worn CV joints or by worn counterbores in
the side-gear hubs in the differential.
- A clunk or acceleration or deceleration could be caused by loose engine or transaxle
mounts, wear in the differential and worn or damaged CV joints.
Code No.
ALT723313a

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Other causes of noise are listed in the Manual Transaxle Trouble-Diagnosis Chart.
The noise may occur when the transaxle is shifted into only one of the forward gears
(item 11 in the Chart). Then a possible cause is defective synchronizer or output-shaft
gear for that speed.
Bearing noises are described in Figure LO3-15.
Figure LO3-9. Manual transaxle and drive train for a front-wheel drive vehicle (Chrysler Corporation)
3. Ball and Roller Bearing Noise

Ball and roller-bearings are used to support the shafts in the manual transaxle and drive
train. When these bearings become defective, they usually produce a rough growl or grating
noise rather than the whine that is typical of gear noise. If transaxle bearing noise is
suspected, the transaxle must be removed and disassembled so the bearings can be
inspected. Two other bearings that may become noisy are the differential side bearings and
the wheel bearings.
a. Differential Side-Bearing Noise. The differential side-bearings are overloaded. Their
noise will not lessen or disappear if the vehicle is run with the wheels off the ground.
Noise in this area can easily be mistaken for wheel-bearing noise.
Careful: Follow the procedure in the vehicle service manual for running the vehicle with the drive wheels off
the ground. If the wheels rotate while hanging, the excessive drive angle may damage the CV joints.
Support the vehicle with safety stands placed under the specified lift points.
b. Wheel-Bearing Noise. A rough wheel bearing produces a vibration or growl which

continues when the vehicle is coasting with the transaxle in neutral. The sound from a
wheel bearing that is not preloaded should lessen when the vehicle is run with the
wheels off the ground. A brinelled bearing causes a knock or click about every two wheel
revolutions. The bearing race is brinelled when it has an indentation caused by a ball or
roller. To check for brinelling, spin the wheel by hand.
4. Defective Power-Train Mount
A defective engine or power-train mount may cause a variety of clutch and transaxle
troubles. If the mount breaks, the engine transaxle assembly may move too much.
Code No.
ALT723313a

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This can prevent clutch disengagement

which results in gear clash when shifting.
Excess movement can cause the transaxle
to jump out of gear. A defective mount may
also make noise and transmit engine
vibration to the vehicle body.
To check the power-train mounts:
1. Raise the engine slightly to remove
weight from the mounts and place a
slight tension on them.
2. Watch the mounts while raising the
engine.
3. Replace a rubber mount if it has cracks
in the rubber, rubber separation from a
Figure LO3-10. Rubber-block type of manual-transaxle
mount. (Pontiac Division of General Motors
mount metal plate, or a split through the
Corporation)
center of the rubber.
4. Replace a hydraulic mount if it is leaking fluid. Movement between a mount metal plate
and its attaching point indicates loose fasteners.
5. Tighten the nuts or screws to the specified torque.
Manual-Transmission Maintenance
The manual transmission does not need
periodic service or routine maintenance.
Transmissions operated by external linkage
from the gearshift lever may require a shiftlinkage adjustment. Follow the procedure in
the vehicle service manual. Typically, this
adjustment is made by disconnecting the rods
from the levers on the transmission. Then
place the gearshift lever and the transmission
lever in neutral. Adjust the linkage by turning
the threaded pins on the rods until the pins will
slip in and then clip into the transmission
levers.
An automotive manual transmission holds

about three quarts or liters of lubricant.
Changing the lubricant is not required unless it
becomes contaminated or internal damage
occurs in the transmission. Check the lubricant
level periodically. A loss of lubricant indicates
leakage.
To check the lubricant level in the
transmission:
1.
Park the vehicle on a level surface.
2.
Turn the ignition key OFF and set the
parking brake.
Code No.
ALT723313a
Figure LO3-1. Checking lubricant level in manual

transmission. (General Motors Corporation, Ford Motor
Company)

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51
3.
4.
5.
6.
7.
Clean any dirt and grease from around the fill plug. Then remove the fill plug using
the proper wrench or socket.
Check the lubricant level. It should be even with the bottom of the hole.
If low, add the lubricant specified by the vehicle manufacturer. Different transmissions
require different lubricants, and some should not be mixed.
When the lubricant reaches the proper level, install the fill plug.
Tighten it to specified torque.
Code No.
ALT723313a

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Self-Check LO3-1
Select the best answer.
1. Hard shifting into gear may be caused by
a. a defective synchronizer
b. an improperly adjusted clutch
c. a twisted mainshaft
d. all of the above
2. The transmission may stick in gear because of all the following except
a. gearshift linkage out of adjustment
b. clutch not disengaging
c. stiff gearshift-lever boot
d. synchronizer sleeve binding
3. Technician A says the transmission may jump out of gear because of worn splines in the
synchronizer sleeve. Technican B says the transmission may jump out of gear because of
worn external teeth on the gear. Who is right?
a. A only
b. B only
c. both A and B
d. neither A nor B
4. Gear clash while shifting could be caused by
a. loose gears on the mainshaft
b. clutch not engaging
c. broken shift fork
d. worn synchronizer ring
5. Noise from the transmission in gear could be caused by
a. a worn or loose pilot bearing
b. excessive lubricant
c. worn or damaged gear teeth
d. all of the above
6. Noise from the transmission in neutral could be caused by
a. clutch not engaging
b. worn or dry bearing
c. chipped or broken teeth on mainshaft gears
d. defective extension-housing seal
7. Noise from the transmission in reverse could be caused by
a. worn or damaged reverse idler gear
b. defective front-bearing retainer
c. clutch not disengaging
d. all of the above
8. Transmission oil leaks may be caused by all the following except
a. jumping out of gear
b. foaming due to incorrect lubricant
c. excessive lubricant
d. damaged or missing oil seals
Code No.
ALT723313a

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Review Questions
1. What is the importance of road testing the car with the customer?
2. Describe how to road test a vehicle to locate manual-transaxle and drive-train noise.
3. How can you identify differential noise and wheel-bearing noise in a front-wheel drive
vehicle?
4. Explain how to clean and inspect manual-transmission parts.
5. Describe how to inspect ball and roller bearings.
Code No.
ALT723313a

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54
Answer Key LO3-1

1.
2.
3.
4.
5.
6.
7.
8.
Code No.
ALT723313a

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55
PERFORMANCE TEST
Learners Name:
Date:
Competency: Overhaul Manual Transmission
1st
Directions:
CALL INSTRUCTOR. Ask instructor
to assess your performance in the
following
critical
task
and
performance criteria below.
OVERALL EVALUATION
Level
Achieved
You will be rate based on the

overall evaluation on the right side.
Test Attempt
2nd
3rd
PERFORMANCE LEVELS
4 Can perform this skill without supervision and with initiative

and adaptability to problem situations.
3 Can perform this skill satisfactorily without assistance or
supervision.
2 Can perform this skill satisfactorily but requires some
assistance and/or supervision.
1 Can perform parts of this skill satisfactorily, but requires
considerable assistance and/or supervision.
Instructor will initial the level achieved.

PERFORMANCE STANDARDS
For acceptable achievement, all items should receive a Yes
or N/A response.
1.
Yes
No
N/A
Transmission gear oil was drained as per

recommended procedure
2.
Transmission jack is positioned per

recommended procedure in accordance with safety
3.
Transmission associated components were

dismounted properly and conducted in correct sequence
4.
Transmission attaching bolts and nuts are

removed according to sequence and loosening pattern
5.
Vehicle and workshop safety procedure is

applied
6.
Personal and equipment safety is applied
7.
Manual transmission is disassembled in

correct steps and procedure as per specification
8.
Dismantled parts accurately logged and

marked
9.
Parts rinsed and washed with appropriate

solution
10.
Damaged
parts
replaced,
reconditioned
according to specification
11.
Appropriate tools are use as per job

requirement, vehicle safety procedure is applied
12.
Personal safety procedures is observed

throughout the activity
13.
Work out, cracked parts, gear back laser

and end play were inspected and accurately identified
Code No.
ALT723313a

8/ 25/ 2003
09/21/16
Page #
56
14.
Defects
identified
and
corresponding
recommendation is given
15.
Instruments and testers are accurately used
16.
No damage during inspection
Code No.
ALT723313a

8/ 25/ 2003
09/21/16
Page #
57
Learners diary
DIARY NOTES
Record important dates, jobs undertaken and other workplace events that will assist you in providing further
details to your Assessor.
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Code No.
ALT723313a

8/ 25/ 2003
09/21/16
Page #
58
Record of Achievement
Module: Overhaul Manual Transmission
Learning Outcome #1 - Pull-out and dismount manual transmission and associated components
Performance Criteria:
1.
2.
3.
4.
Transmission gear oil is drained as per recommended procedure

Transmission jack is positioned per recommended procedure in accordance with safety
Transmission associated bolts and nuts are removed according to sequence
Transmission attaching bolts and nuts are removed according to sequence and loosening
pattern
5. Vehicle and workshop safety procedure is applied
6. Personal and equipment safety is applied
COMMENTS:
Learner has satisfied the above performance criteria.

Learners signature: .
Trainers signature: ..
Date: .
Code No.
ALT723313a

8/ 25/ 2003
09/21/16
Page #
59
Learning Outcome #2 - Disassemble manual transmission
1.
2.
3.
4.
5.
Dismantled parts accurately logged and marked

Parts rinsed and washed with appropriate solution
Damaged parts replaced, reconditioned according to specification
Appropriate tools are use as per job requirement, vehicle safety procedure is applied.
Personal safety procedures is observed throughout the activity
COMMENTS:

Date: .
Code No.
ALT723313a

8/ 25/ 2003
09/21/16
Page #
60
Learning Outcome #3 Inspect and check manual transmission components
1.
2.
3.
4.
Work out, cracked parts, gear back laser and end play were inspected and accurately identified
Defects identified and corresponding recommendation is given
Instruments and testers are accurately used
No damage during inspection
COMMENTS:

Date: .
Code No.
ALT723313a

8/ 25/ 2003
09/21/16
Page #
61
I. Terms and Definitions

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Power train - revolving components involved in the transmission of power from the
engine to drive wheels.
Gear ratio - the number of revolutions the driving gear must take to turn the driven gear
one revolution
Torque a turning or twisting force
Backlash the clearance or play between two gears in mesh
Endplay end-to-end movement in a gear shaft due to bearing clearances
Preload adjustment of antifriction bearings so that they are under mild pressure;
tested by the amount of torque in inch pounds required to turn the shaft
Gear reduction a combination of gears used to reduce the input speed to a lower
output speed
Constant mesh gears that are always in mesh with each other
Splines multiple keys in the general form of internal and external gear teeth, used to
prevent rotation of shaft
Auxiliary transmission a unit mounted behind the main transmission to provide
supplemental gearing
(Note: This provides greater reduction, closer splits, or an overdrive.)
Flywheel a rotating metal disc on the rear of a crankshaft designed to even out power
surges during power strokes and deliver energy back during other strokes
Clutch a device that connects or disconnects a power source from the part it
operates to provide a smooth transmission of torque to working parts in movement
Transmission a device in a power train that increases torque by changing gear ratios,
permitting a vehicle to move at varying speeds in both forward and reverse
Drive line components that transmits torque from the transmission to the differential;
made up of one or more drive shafts with universal and slip joints
Herringbone gears are really double helical gears with teeth angles reversed on
opposite sides
Planetary gears the outer ring gear has internal teeth which mate with teeth on
smaller planet gears; these gears mate with a center or sun gear
Worm gear the worm gear is actually a screw; the mating gear has teeth which are
curved at the tips to permit a greater contact area; it is capable of high speed reduction
Rack and pinion converts straight motion into rotary motion and vice versa
Plain bevel gears these gears permit the power flow to turn a corner; the gear
teeth are cut straight on a line with the shaft
Spiral bevel gears these gears permit the power flow to turn a corner; the teeth
are cut at an angle and used where higher speed and strength are required
Code No.
ALT723313a

8/ 25/ 2003
09/21/16
Page #
62

Pulling Out Manual Transmission

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COMPETENCY BASED LEARNING

Overhaul Manual Transmission

OVERHAULING MANUAL TRANSMISSION

NATIONAL CERTIFICATE LEVEL II

COMPETENCY-BASED LEARNING MATERIALS

Service Starting System

Service Clutch System

Service Manual Steering System

Servicing Starting System

Service Brake System

Service Suspension System

HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL

Recognition of Prior Learning (RPL)

Qualification: AUTOMOTIVE SERVICING NC II

Pulling Out, Disassembling and Checking Manual

Date: Developed Date: Revised

Qualification: AUTOMOTIVE SERVICING NC II

Supplies and materials

Oil catch pan

Pulling Out, Disassembling and Checking Manual

Date: Developed Date: Revised

Pull-out and Dismount Manual Transmission and Associated

1. Read information on the purpose of

1.1 Information Sheet LO1-1 Purpose of

1.2 Self-Check LO1-1

3. Apply and perform the correct procedures in

1.3 Operation Sheet LO1-1 Drain

1.4 Self-Check LO1-1

5. Observe PPE safety precautions

Pulling Out, Disassembling and Checking Manual

Date: Developed Date: Revised

Information Sheet LO1-1 Purpose of Transmission or Transaxles

Pulling Out, Disassembling and Checking Manual

Date: Developed Date: Revised

Manual transmissions and transaxles

Figure LO1-1. Construction of a six-speed manual transmission.

Fourth gear in some four-speed units

Figure LO1-2. Location of the manual transmission in a

Pulling Out, Disassembling and Checking Manual

Date: Developed Date: Revised

Gears and Gearing

Figure LO1-4. Power-flow from the engine crankshaft to

Figure LO1-5. Meshed spiral-bevel gears.

Pulling Out, Disassembling and Checking Manual

Date: Developed Date: Revised

Gear Ratio and Torque

Figure LO1-6. Various types of gears.

To loosen and remove the top from

Pulling Out, Disassembling and Checking Manual

Date: Developed Date: Revised

Also, speed increase means torque

Pulling Out, Disassembling and Checking Manual

Date: Developed Date: Revised

Pulling Out, Disassembling and Checking Manual

Date: Developed Date: Revised

Shift forks fit into grooves

(A) FOUR-SPEED MANUAL TRANSMISSION

The only gear that actually

Figure LO1-12. A disassembled synchronizer. (Chevrolet Division of General

Pulling Out, Disassembling and Checking Manual

Date: Developed Date: Revised

Pulling Out, Disassembling and Checking Manual

Date: Developed Date: Revised

Manual Transmission Operation