Assembling and Testing Manual Transmission

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

Module Title:
ASSEMBLING AND TESTING MANUAL TRANSMISSION
Technical Education and Skills Development

Authority
East Service Road, South Superhighway, Taguig, Metro Manila
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, Disassembling and
Checking Manual Transmission
Assembling and Testing
ALT723312
ALT723313a
ALT723313b
Manual Transmission
8.
9.
Service Brake System
Service Suspension System
Identifying and Explaining

Hydraulic Brake System
Operations and Functions
Servicing Brakes
Overhauling Brake Systems
Servicing Suspension System
ALT723314a
ALT723314b
ALT723314c
ALT723315
HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL

Welcome to the module in Assembling and Testing Manual Transmission. This module
contains training materials and activities for you to complete.
The unit of competency "Overhaul Manual Transmission" contains knowledge, skills and
attitudes required for Automotive Servicing. It is one of the specialized modules at National
Certificate level (NC III).
You are required to go through a series of learning activities in order to complete each
learning outcome of the module. In each learning outcome are Information Sheets and
Resources 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 outcome. You may remove a blank answer sheet at the end of each module (or
get one from your facilitator/trainer) to write your answers for each self-check. 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 skill or skills,
talk to him/her about having them formally recognized so you don't have to do the same training
again. If you have a qualification or Certificate of Competency from previous trainings, show it
to your 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.
At the end of this module is a Learners 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 assessor. A Record of Achievement is also provided for your trainer to complete
once you complete the module.
This module was prepared to help you achieve the required competency, in Assembling and
Testing Manual Transmission. This will be the source of information for you to acquire
knowledge and skills in this particular trade independently and at your own pace, with minimum
supervision or help from your instructor.
Talk to your trainer and agree on how you will both organize the Training of this unit.
Read through the module 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. Read
information sheets 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.
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.
You will be given plenty of opportunity to ask questions and practice on the job. Make
sure you practice your new skills during regular work shifts. This way you will improve
both your speed and memory and also your confidence.
Talk to more experience workmates 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 this
module.
As you work through the activities, ask for written feedback on your progress. Your
trainer keeps feedback/ pre-assessment reports for this reason. When you have
successfully completed each element, ask your trainer to mark on the reports 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 registered
assessor to assess you. The results of your assessment will be recorded in your
competency Achievement Record.
QUALIFICATION
AUTOMOTIVE SERVICING NC II
UNIT OF COMPETENCY :
MODULE
Assembling and Testing Manual Transmission
INTRODUCTION:
This module deals with assembling manual transmission component, installing and
mounting transmission assembly. It also deals with the testing of manual transmission
output.
LEARNING OUTCOMES:
At the end of this module you will be able to:
1.
2.
3.
Assemble manual transmission component;

Install and mount manual transmission and associated parts; and
Test manual transmission performance.
ASSESSMENT CRITERIA:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Manual transmission component parts cleaned, lubricated and coated with new
gear oil as per manufacturers manual.
Parts reference marks were used in assembling.
Assembling of transmission component was performed as per steps and procedure.
Bolts and nuts were torqued according to specifications and in correct sequence.
Correct tools were used for assembling.
Vehicle, workshop and parts safety requirements were applied.
Oil properly filled.
Transmission gear oil is filled properly and in appropriate level.
Transmission jack is positioned in accordance with safety procedure.
Transmission assembly is mounted to the engine/vehicle in correct steps as per
specification.
Attaching bolts were torqued according to specification and in correct sequence.
Transmission associated component were installed or mounted properly according
to steps and procedures.
Appropriate tools for the job were used.
Personal safety procedures were applied.
Transmission is tested while the engine is running and transmission in neutral
position.
Testing were conducted as per service manual.
Visual/ocular evaluation of transmission performance was conducted with emphasis
on performance of every shifting pattern, noise and operation.
Vehicle and shop work safety procedure is applied.
Personal safety requirement is observed.
PREREQUISITE:
Before you take this module you must complete first the modules: Set Up Work Area,
Equipment as well as the Core and Common Competencies of Automotive Service
Technician (NCII).
Code No.
ALT723313b
Date: Developed Date: Revised
8/ 25/ 2003
09/21/16
Page #
QUALIFICATION
MODULE
LEARNING OUTCOME #1 :
Assemble manual transmission component
1.
2.
3.
4.
5.
6.
7.
Manual transmission component parts cleaned, lubricated and coated with new gear oil
as per manufacturers manual.
Parts reference marks were used in assembling.
Assembling of transmission component was performed as per steps and procedure.
Bolts and nuts were torqued according to specifications and in correct sequence.
Correct tools were used for assembling.
Vehicle, workshop and parts safety requirements were applied.
Oil properly filled.
RESOURCES:
Equipment
Supplies and Materials
1. Car equipped with manual transmission/

transaxle
2. Hand tools
3. Working table
4. Transaxle
5. Snap ring pliers
6. Punch
7. Press
8. Wrenches
9. Socket set
10. Dial gauge
11. Manual
12. Rags
13. Soap
14. Spare bolt
15. Clear glass
16. Apron/gloves
17. Clear pan/solvent
18. Mechanics wire
19. Transmission gear oil
REFERENCES:
1.
2.
3.
Manual Transmission and Power Trains by John H. White, pp 453-460

The Automotive Power Train and Running Gear, Power Flow and Chassis Unit by
Felizardo Y Francisco, Cayetano R. Rivera
Basic Auto Repair Manual Tools and Equipment
Code No.
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Learning Outcome #1: Assemble manual transmission components

LEARNING ACTIVITIES
SPECIAL INSTRUCTIONS
1. In
the
workshop
with
appropriate
equipment
and
other
instructional
materials, the trainees will perform the
correct procedure in assembling manual
transmission components.
1.1 Read Information Sheet LO1-1 Manual
Transmission Components
Analyze the function of the transmission

and its components.
1.2 Follow the procedures in Operation

Sheet LO1-1 Removing the Gearbox
Follow safety precautions.
1.3 Perform Job Sheet LO1-1 "Assembling

Manual Transmission Components
Mark parts of manual transmission in

detailed position and assemble following
the procedure. Follow the safety notes.
Ask your instructor to evaluate your work

after performing the assembly.
1.4 Assemble different transmission brands

following Job Sheets LO1-2, LO1-3
and LO1-4 in the workshop and
observe shop practices and safety.
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INFORMATION SHEET LO1-1

Manual Transmission Components
TRANSMISSION:
Cars need transmissions
because of the physics of the
gasoline engine. First, any engine
has a redline -- a maximum rpm
value above which the engine cannot
go without exploding. Second, the
engines have narrow rpm ranges
where horsepower and torque are at
their maximum. For example, an
engine might produce its maximum
horsepower at 5,500 rpm. The
transmission allows the gear ratio
between the engine and the drive
wheels to change as the car speeds
up and slows down.
Photo courtesy DaimlerChrysler
You shift gears so the engine can stay below the redline and near the rpm band of its best
performance.
The name transmission refers to the series of parts used to transmit the engine torque
(turning effort) from the flywheel to the vehicles driving wheels.
The transmission usually consists of four major components:
Clutch
-
Gearbox
-
manual or
automatic
Drive shaft
-
friction, fluid, or
electromagnetic
types
propeller or
drive shaft and
universal joints
CONVENTIONAL COMPONENT LAYOUT
Final drive assembly

-
provides a suitable top gear ratio;

transmits drive to road wheels;
provides differential action between driving wheels when the vehicle is cornering
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ENGINE AND TRANSMISSION POSITION

Location of engine and transmission
assemblies in the vehicle, vary with different
makes and models. This makes it essential
that you refer to the makers instruction
manuals to a certain in a correct and safe
method of removal and replacement of these
assemblies.
Engine and transmission position in the

vehicle may be:
- Traditional front engine and rear wheel
drive.
ENGINE IN THE FRONT REAR WHEEL DRIVE
Front engine with front and rear wheel

drive.
ENGINE IN THE FRONT FRONT AND REAR
WHEEL DRIVE
Front engine and front wheel drive
ENGINE IN THE FRONT FRONT WHEEL

DRIVE
Rear engine and rear wheel drive
ENGINE IN THE REAR REAR WHEEL DRIVE
Code No.
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DIFFERENTIAL:
The differential mechanism is fitted in final drive units to apply equal torque to each drive wheel,
yet allow them to turn at different speeds when the vehicle is turning or cornering.
Conventional differential mechanisms are used on the majority of motor vehicles.

- This type will only move the vehicle when traction on each driving wheel is equal.
Limited-slip differentials perform the same functions as the conventional type differentials,
but in addition, transfer the driving force to the wheel with traction, should the opposite
wheel begin to slip.
When serving a vehicle fitted with a limited-slip

differential, never run the engine while the
transmission is in gear and one rear wheel is raised,
The driving force to the wheel on the ground may
cause the vehicle to move. This is most dangerous if
the vehicle has other wheels removed.
Portable on car type wheels balances are not
recommended for use on the rear wheels of cars
equipped with a limited-slip differential. However, this
type of balancer may be used by removing the wheel
opposite to the one being balanced, with the
complete assembly raised up. If a wheel is removed,
replace at least two wheel nuts to prevent the brake
drum from coming off.
Code No.
ALT723313b
DO NOT RUN THE ENGINE
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OPERATION SHEET LO1-1

Removing the Gearbox
The gearbox must be removed from the vehicle for proper inspection and servicing.
Draining oil
Avoid scalds from the hot oil when:

draining the gearbox and the final
drive housing;
disconnecting oil pipes and lines;
disconnecting oil coolers
Ensure that the wheels are chocked before

disconnecting drive and propeller shafts in
the vehicle:
has a transmission parking brake;
is fitted with an automatic gearbox
and is engaged in the parked position;
has a manual shift gearbox which
is engaged in forward or reverse drive.
AVOID SCALDS WHEN DRAINING
Removing the gearbox

When removing and replacing gearboxes
Plug the opening in the gearbox extension

housing, after removal of the drive shaft, to
prevent oil spillage.
Support the engine assembly before

removing the transmission mountings.
- Do not let the engine hang on the
remaining support mountings.
Do not manually lift or support the weight of Support the engine

heavy transmission components during
removal or replacement.
REMOVING THE GEARBOX
- Use a transmission trolley or a garage
jack in conjunction with a suitable
transmission cradle attachment.
Servicing and repair of these components often necessitates their removal from the vehicle,
To eliminate possible hazards when implementing this work, make reference to vehicle makers
manuals, as the procedures will vary with the different transmission and power flow systems
and layouts.
General safety precautions are to be observed.
Code No.
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Do not let the gearbox assembly hang on

engine without support, as it:
- may fall causing injury or damage
- can distort the clutch disc assembly.
Use proper work stands or fixtures to

secure heavy transmission units when
carrying out repairs.
- Do not support it in a bench vice by
drain plugs or flanges, etc.
USE A TRANSMISSION PULLEY
Clutch
When dismantling certain types of clutch
pressure plate assemblies, care must be taken
to relieve the force of the pressure plate coil
springs before removing the retaining eye-bolt
adjusting nuts, otherwise the compressed
springs will cause parts to fly.
Mark the clutch cover and pressure plate to

ensure reassembly in the same relative
position.
Place the assembly on the bed of a press
with the pressure plate resting on wooden
blocks.
Place a wooden block on top of the clutch
cover.
Carefully operate the press and compress
the clutch springs.
- remove the retaining eye-bolt nuts.
Slowly release the force of the press so
that the cover will rise upwards as the
springs extend.
- Lift off the cover and remove the clutch
springs.
- The eye-bolts and levers can now be
removed.
RESTRAIN THE PRESSURE PLATE SPRINGS
DISMANTLE CLUTCH
Code No.
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Page #
SYNCHRONIZER ASSEMBLY
Before disassembling the synchronizer assembly to examine the parts, file a scribe mark
across the front face of the third and fourth synchronizer sleeve and hub. These marks should
be aligned when assembling the synchronizer assembly to maintain mating parts if the same
parts are used.
Parts to be examined are:
The snap ring holding the synchronizer assembly in place on the intermediate shaft. The
snap ring could be misplaced or have a sloppy fit.
Synchronizer blocker rings. Refer to the section on examining the synchronizer blocker
ring.
Synchronizer hub. There should be no rotary looseness between the synchronizer hub
and the intermediate shaft. If looseness exists, experiment with a new synchronizer huh
and check for a loose fit. If the looseness is removed, the synchronizer assembly must
be replaced.
Worn synchronizer shift inserts and insert springs. These worn parts will permit the
synchronizer sleeve to slide back and forth on the synchronizer hub.
The synchronizer hub parts cannot normally be purchased separately. Therefore, the
synchronizer hub, sleeve, inserts, and springs must be purchased as an assembly. The only
parts of the synchronizer assembly that can be purchased separately from the sleeve and hub
are the synchronizer blocker rings. The snap ring retaining the synchronizer assembly on the
intermediate shaft can also be purchased separately.
Gear Teeth
A chipped or damaged gear tooth makes a clicking sound. This problem is easy to locate;
simply check all gear teeth for damage. If one gear tooth on the input shaft is damaged, the
whole input shaft assembly must be replaced. Since the damaged input shaft gear meshes with
a gear on the intermediate shaft, that mating gear should also be examined very closely. If both
gears are damaged, both must be replaced to remove the clicking noise. If the mating gear is
damaged, it must be replaced or of will reduce the new driving gear to its damaged state.
This completes the methods of examining and inspecting the most common causes of
manual shift transaxle problems. The next service procedures are assembling the transaxle
subassemblies and transaxle, followed by installing the transaxle assembly into the vehicle.
Code No.
ALT723313b
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09/21/16
Page #
JOB SHEET LO1-1

Assembling Manual Transmission Components
TRANSAXLE SUBASSEMBLY ASSEMBLY PROCEDURE
1.
Insert the third and fourth synchronizer

hub into the third and fourth synchronizer
sleeve and align the file marks.
NOTE: This alignment should also index
the inserts with the scalloped (small
curve) teeth placed 120 degrees apart on
the inside diameter of the synchronizer
sleeve.
NOTE: If the synchronizer blocker rings
are not replaced, they should be matched
with their respective gears. This whole
alignment and matching process helps to
ensure smooth gear shifting. A smooth
shifting transaxle might be the operators
only means of justifying the cost of the
service work.
2.
The Synchronizer inserts should align with the

synchronizer sleeve scallops.
Assemble all three synchronizer

assemblies following the steps outlined
previously.
The synchronizer sleeve and hub must be aligned so that inserts index with the scallops.
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Page #
3.
4.
5.
Install the antispin pin and first gear

thrust washer on the intermediate shaft.
Organize the parts on the workbench,
This ensures the proper location of gears,
thrust washers, and snap rings to be
installed onto the intermediate shaft.
Before installing each gear, lubricate the
inside diameter with lubricating oil to
ensure initial lubrication and make sure
that the gear turns freely with minimum of
0.003 (0.076mm) clearance between the
gears measured with a feeler gage.
Use the adapter and a hydraulic press to press on
the tight race of the intermediate shaft rear
bearing.
Safety Note:
When pressing bearings on or off a shaft, always cover the pressing operation with a safety
collar to restrict flying shrapnel in the event the bearing explodes.
6.
Locate the special pressing arbor in contact with the rear bearings inner (tight) race. Using
a hydraulic press, drive the bearing assembly into place. After the rear bearing is seated,
check the fourth speed gear for free rotation.
7.
After installing the rear bearing outer snap ring and intermediate shaft snap ring, check all
gears for free rotation.
Safety Note:
Check all synchronizer blocker rings to be sure that they rotate freely and do not bind on
adjacent cone clutches.
8.
Remember that if the input shaft gear assembly or its bearing are replaced, the input shaft
select shim thickness must be recalculated. Refer to the service manual for this procedure.
9.
With the input shaft in place, the intermediate shaft assembly and shift forks can be
installed into the transaxle housing.
10. Lubricate the reverse idler gear assembly and install in the transaxle housing. Seat the roll
pin into the roll pin notch.
11. With the shift rail and bearing retainer plate inside the transaxle housing, the parts for the
fifth gear can be organized on the workbench.
12. Install the input shaft fifth gear and snap ring, synchronizer, and shift fork and rail into the
transaxle housing.
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10
13. Shift the transaxle into neutral gear. With

the fifth speed shift pin (located in the
shift fork, insert into the shift fork and rail.
With the fifth fork and rail adjusted to the
other transaxle shift forks and rails, invert
the fifth speed shift pin and tighten into
place.
14. After installing the fifth gear strut retainer
plate and snap ring, install the rear end
cover with new sealant. Tighten all rear
end cover plate bolts and the fill plug.
The shift pin is located in the shift fork.
15. With new sealant on the contact surfaces, install the selector shaft housing. Be sure to
insert the bolts in their proper location.
16. Lubricate the new extension housing 0-ring and install the differential assembly, extension
housing, and bolts. Bolts should be torqued to manufacturers specifications.
17. Align and install the differential bearing retainer and torque the bolts to manufacturers
specifications.
18. Apply new sealer to the differential cover installing bolts and studs in proper locations.
Now the transaxle is ready to be installed.
Code No.
ALT723313b
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Page #
11
SUBASSEMBLIES ASSEMBLY PROCEDURE

1.
Coat the inside diameter of the cluster gear assembly with petroleum jelly and insert the
dummy shaft.
2.
Place the counter shaft needle bearings between the dummy shaft and the inside diameter
of the cluster gear assembly.
3.
When the needle bearings are all in place, install at either end the bearing thrust washers
and the original or replacement cluster assembly thrust washers.
4.
Place pilot end (front) of transmission output shaft upward.
Layout of the transmission output shaft
5.
Lubricate the third speed gear and place on the output shaft with the cone clutch facing up.
6.
Install the third gear synchronizer blocker ring so the cone clutch sits on the third gear
cone clutch.
Service Tip:
The synchronizer sleeve has a large, deep groove located on the outside diameter at the
rear of the synchronizer assembly. The synchronizer hub has a longer front hub than rear.
When building up the synchronizer assembly align the file marks on the sleeve and hub and
place the sleeve groove at the opposite end of the synchronizer hub from the long front hub.
7.
Install the third and fourth synchronizer assembly with the longer front inner hub facing up.
The synchronizer sleeve should be facing downward,
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12
8.
Be sure the notches on the synchronizer blocker rings align with the inserts of the
synchronizer assembly.
9.
Install the third and fourth synchronizer assembly snap ring. Tap the snap ring with a
hammer and punch to ensure it is seated.
10. Turn the rear of the output shaft upward to install the remaining output shaft parts.
11. Lubricate the inside diameter of the second speed gear and slide on the output shaft with
the cone clutch facing up.
12. Install the synchronizer blocker ring so the cone clutches meet.
13. Install the first and second synchronizer assemblies so the large, deep shift fork groove is
facing downward.
14. Install the first and second synchronizer snap ring making sure it is seated the output shaft
groove.
15. The first gear synchronizer blocker ring can be installed and the inserts aligned.
16. Lubricate the inside diameter of the first speed gear and install with the steel thrust washer
and the spring washer.
17. Using a hydraulic press install the rear bearing onto the output shaft. Install the rear
bearing snap ring.
18. Install the speedometer drive gear and retaining clip.
19. With the output shaft assembled, test your assembly work
a. Check that all gears on the output shaft rotate freely.
b. Check that the synchronizer blocker rings are not jammed on the gear cone clutches
c. Make sure all snap rings are seated into place
20. Place petroleum jelly into the socket at the rear of the transmission input shaft and install
the roller bearings.
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13
TRANSMISSION ASSEMBLY PROCEDURE

1.
Place thrust rings and washers at either

end of cluster gear assembly.
Installing the rear transmission bearing on the

transmission output shaft
NOTE: Petroleum jelly or heavy grease can be used to hold these parts in place during
assembly.
2.
Insert the cluster gear assembly, thrust

rings, washers, and dummy shaft through
the rear opening of the transmission
housing. Be sure the thrust washer tangs
face away from the cluster assembly and
the tangs index with the grooves inside
the transmission housing.
3.
Align the cluster assembly with the holes

in the transmission housing and insert the
counter shaft and woodruff key from the
rear.
4.
Using a plastic hammer, tap the counter

shaft and woodruff key into place in the
transmission housing while removing the
dummy shaft.
Roller bearings being installed in the transmission
input shaft using petroleum jelly or heavy grease
to hold rollers in place.
5.
Lubricate the reverse idler gear inside diameter and install the reverse idler gear, shaft,
and woodruff key from the rear of the housing.
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6.
With snap ring pliers, expand the extension housing snap ring and slide the extension
housing over the output shaft assembly. Be sure the snap ring seats in the rear bearing
outer groove.
7.
Place the fourth gear synchronizer blocker ring into place on the third and fourth
synchronizer assembly. Be sure the notches of the synchronizer blocker ring align with the
synchronizer inserts.
8.
Place the transmission input shaft on the pilot (front) of the output shaft.
Service Tip:
Piece petroleum jelly on the rear surface of the transmission housing to hold the extension
housing gasket in place.
9.
Feed the input shaft, output shaft assembly, and extension housing through the rear
opening of the transmission housing.
10. The reverse idler might have to be moved back and forth on the shaft to accommodate the
assembly operation.
11. Align the extension housing bolt holes and install the extension housing bolts. Do not
tighten these bolts until the front transmission bearing is installed.
12. Install the large outer front bearing snap ring over the outer bearing race.
13. Slide the front transmission bearing onto the transmission input shaft and seat into place.
14. Install the small front transmission bearing snap ring.
15. Align the front bearing retainer and gasket to the transmission housing.
Be sure the lubricant drainage groove aligns with the transmission housing. Install the front
bearing retainer bolts.
16. Tighten extension housing to transmission housing bolts.
17. Move all synchronizer sleeves to the neutral position.
18. Place the transmission cover gasket in place.
19. Shift the forks on the cover plate to the neutral position.
20. Install the cover plate with the shift forks seating into the synchronizer sleeves and tighten
all bolts.
21. The transmission should be shifted through all gear ranges before installing into the
vehicle.
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JOB SHEET LO1-2

ASSEMBLING A WARNER T-10
1.
Before reassembling bearings and

spacers in countergear, inspect teeth
closely for excessive wear, chips or
cracks; replace it if worn, damaged.
2.
While youre at it, check spacers,

countergear roller bearings for wear.
Inspect countershaft, reverse idler;
replace them if necessary.
2. Use a dowel pin or shaft to retain bearings

spacers; slip solvent-cleaned bearings and
washers into countergear. Dip in lube so
theyll stay in place.
4.
The 40 rollers inside countergear are in 4

rows of 10 each, separately by two
narrow spaces, one long spacer. Pin is
removed as rollers go in.
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5.
Liberal application cluster gear thrust

hold them in countergear is transmission.
of lube on washer helps place when
inserted into
6.
Rest transmission on its side, with side

cover opening toward assembler. Put
countergear thrust washer in place; hold
with a coat of heavy grease.
7.
Set countergear in place at bottom of

case; be sure the tanged thrust washers
have not been moved or dowel pin has
not slipped away from rollers.
8.
Shaft must be removed or it wiIl interfere

with assembly of mainshaft and clutch
gear. Leave thrust washer in place,
countergear at case bottom.
9.
Reinstall the 14 roller bearings inside

main drive gear; use heavy-duty grease
to hold bearings in position while
assembly is inserted.
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10. When assembling the front reverse idler

gear, make sure the teeth are pointed
forward with hub facing to rear of the
transmission case.
11. The 1st 2nd and 3rd gears, with synchro

rings, are assembled on mainshaft. Hub
of 3rd notches on synchro ring should
always face forward.
12. Install 3rd, 4th gear clutch assembly with

taper to front. Be sure keys in hub match
notches in 3rd gear synchro ring. Insert
main drive gear.
13. Before assembly is put in case, put new

selective snap rings (thatll fit in groove)
on mainshaft in front of 3rd~, 4th speed
gear clutch unit.
14. Rear bearing retainer can be slid over

end of mainshaft. Spread snap ring in
pliers so it will drop around rear bearing
when aligned with groove.
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
18
15. First insert reverse idler shaft into

housing, then slide flat thrust washer in
place. Tang on thrust washer should face
thrust portion of case.
16. Next slip reverse idler gear onto shaft,

engaging spiines with portion of gear
within case. Place new gasket on rear
bearing retainers face.
17. Pull reverse shift shaft partially out of

extension; rotate shaft to get reverse shift
fork as far forward in rear extension
housing as possible.
18. Now, you can start the extension onto the

mainshaft while pushing in on shifter
shaft to engage shift fork with reverse
gear shift collar.
19. When fork engages shift fork, rotate

shifter shaft to move reverse gear
rearward, permitting extension to mate to
transmission case.
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
19
20. With pin in shifter lever boss, torque rear

extension housing bolts to 40 ft -lbs.
install rear extension-to-bearing retainer
bolts, 25 ft-lbs. maximum
21. With hammer and punch, tap clutch

bearing in place. Be sure bearing is
clean, lubricated, checked for roughness
(by turning race in hand.)
22. Use snap ring pliers to slide selective fit

snap rings, spacer washer, bearing snap
ring over maindrive gear and into proper
places.
23. Be sure to use a new gasket thats

slightly moist with lube, before you bolt
bearing retainer to front of 1-10
transmission case.
24. New front bearing retainer gasket should

be firmly in place and the retainer snug
on case. Use good sealer, torque
capscrews to 18 ft.-lbs
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
20
25. Shift forks must fit snugly in grooves on

3rd 4th speed clutch sliding sleeve and 1st
and 2nd speed clutch sliding sleeve, as
shown.
26. Shift trans into 2nd position side cover,

attach new gasket, engage shift forks in
collars; install side cover, seal and torque
capscrews.
27. After trans is filled and shifter linkage is

attached your just- like-new Warner T10 transmission is all ready to tackle the
streets again.
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
21
JOB SHEET LO1-3

ASSEMBLING A MUNCHE 4-SPEED
1.
Drain lube from trans; remove side cover,

clutch retainer housing, rear extension
housing, countergear, main drive gear
units; clean and inspect.
2.
Begin assembly by checking bearings for

undue wear, then lubricate with light
engine oil Check gears for wear, clutch
sleeves for sliding.
3.
After inspecting all moving parts, insert

rear bearing in rear bearing retainer;
release snap ring, position correctly in
retainer groove.
4.
Once 1st and 2nd gears (with their

synchros, clutch sleeves, etc.) have been
installed on mainshaft, tap rear bearing
retainer onto shaft.
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
22
5.
Spread snap ring with pliers, then ailow

ring to align with groove in end of
mainshaft to help retain rear bearing.
Install reverse, anti-rattle springs.
6.
Install 3rd and 4th gears (hub to front of

trans), synchronizers and 3rd 4th gear
clutch assemblies with both sleeves to
front of trans case.
7.
Cluster goes in bottom of case with all

bearings held in place by dowel. Then tap
main drive gear and bearing into hole in
case; work from inside.
8.
Position reverse idler gear thrust washer

on machined face of ear cast in case of
reverse idler shaft. Hold assembly in
case with heavy lube coating.
9.
Shove reverse idler gear next to thrust

washer, with the hub facing to rear of
case. Install flat thrust washer on reverse
idler gear.
Code No.
ALT723313b
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09/21/16
Page #
23
10. Stick cage and its17 roller bearings into

maindrive gear; use heavy grease to hold
bearings in place.Put oil slinger
(concaveforward) on gear.
11.
Now you can lower mainshaft assembly

into case. Be sure notches on 4th gear
synchro ring correspond to the keys on
the clutch assembly.
12. Align countergear with shaft in rear and

hole in front of case, press countershaft
in case, push assembly dowel out until
shaft is flush with case.
13. Cut on rear of countershaft must be

aligned so it will mate to similar cut in
rear extension housing to keep shaft from
spinning in trans case.
14. Install reverse idler shaft roll pin (pin

should be in vertical position), and thrust
washer into gear, front boss of case, pick
up front-tanged washer.
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
24
15.
Rear extension housing is turned to

reveal shifter fork for reverse gear. Arrow
shows slot that reverse idler shaft roll pin
alions with.
16. Pull reverse shifter side of extension, to

bring reverse extension housing detent
position). shaft to left rotate shaft shift
into (reverse
17. Start rear extension housing onto trans

case, while slowly pushing it on the
shifter shaft to engage the shift fork with
the reverse shift collar.
18. Pilot reverse idler shaft into extension;

slide onto case attach bolts. Line up shaft
with holes in boss and insert lock pin.
Install shifter, side cover.
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
25
JOB SHEET LO1-4

ASSEMBLING A FORD 4-SPEED
1.
Assembly is started by putting the cluster

and reverse goodies in position, but the
cluster is lying on the bottom of the case
and shaft.
2.
The reverse shifter shaft is now in and

secured. A set screw holds the shifter fork
to the rail. Note the holes for two more
shifter shafts.
3.
Support thrust washer and low gear to

prevent them from sliding off end of shaft;
then carefully lower output shaft
assembly into case.
4.
Place front synchronizer into 3rd gear

position; install set screw in 3rd and 4th
gear shift fork. Move synchronizer to
neutral.
Code No.
ALT723313b
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Page #
26
5.
The mainshaft, with all the gears already

on it, goes in through the top of the case.
Then the shift forks and the shafts are put
into their positions.
6.
Tightening the set screw in the shift fork

that helps secure it to the rail. All of the
steps are described in detail in detail in
genuine Ford manual.
7.
The detent on the bottom shift rail screws

in from the side of the case. Note dummy
aluminum bearing temporarily holding
mainshaft in position.
8.
Another shift rail is tapped from the front.

Bar across the front of the transhold the
front of mainshaft in position while doing
the good work.
9.
Not many people have this press, but its

the right way to put the rear bearing into
the case with no beating. Hammer
mechanic, please take note.
Code No.
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27
\10. After the bearing is in position, the snap

ring slips on easily - if you have snap ring
pliers. Another snap ring goes on the
shaft against bearing.
11. After the main drive gear and its bearings

are slipped into position, the front bearing
retainer, with a new seal inside, is bolted
on the case.
12. Standing the box on end makes it easier

to move the gear cluster into position so
the shaft can be inserted. Lower hand is
catching dummy shaft.
13. The cluster gear shaft and reverse idler

shaft are kept from turning by roll pins
that must enter these recesses in the
case to be held securely.
14. First a gasket, and then the tailshaft

housing is slid into position. A new seal
should be installed in the end of the
housing to stop drip.
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09/21/16
Page #
28
16. Detent for the dropped into the place by

the breather on top relieve pressure. top
shift rail is hole, and held in cover. Note
of housing to
17. The bolts are well greased so that the

torque readings will be consistent but no
sealer is used on the cover gasket. Fluid
leaks are not a problem.
18. Thats right, even the cover is torqued. If

youre going to be super accurate, why
not go all the way? Reminder: Dont
forget to put in lube.
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
29
QUALIFICATION
MODULE
Install and mount manual transmission and associated parts
1. Transmission gear oil is filled properly and in appropriate level.
2. Transmission jack is positioned in accordance with safety procedure.
3. Transmission assembly is mounted to the engine/vehicle in correct steps as per
specification.
4. Attaching bolts were torqued according to specification and in correct sequence.
5. Transmission associated component were installed or mounted properly according to
steps and procedures.
6. Appropriate tools for the job were used.
7. Personal safety procedures were applied.
RESOURCES:
Equipment
1.
2.
3.
4.
5.
6.
11. Rags
12. Soap
13. Mechanics wire
14. Oil catch pan
Hoist
Jack stands
Drop light
Wrenches
Transmission trolley
Car with manual transmission and
transaxle
7. Hand tools
8. Crocodile jack
9. Manual transmission
10. Working tables
REFERENCES:
1.
2.
3.
Manual Transmission and Power Trains by John H. White

The Automotive Power Train and Running Gear, Power Flow and Chassis Unit, by
Felizardo Y. Francisco, Cayetano R. Rivera
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
30
Learning Outcome #2 : Install, mount manual transmission and associated parts

LEARNING ACTIVITIES
In the workshop with appropriate and

equipment and other instructional materials,
the trainees will perform the correct procedure
in installing/ mounting manual transmission
and associated parts.
Follow the procedures in examining and

inspecting the most common causes of
manual shift transaxle problem including its
installation.
1. Install transaxle
Follow the procedures in Job Sheet LO21 Transaxle Installation Procedure
2. Inspect standard transmission
Follow the steps in Assignment Sheet

LO2-1 Inspecting Standard
Transmission
Report results in oral or written format

using criteria in the Self-Check LO2-1
Follow the procedures in Job Sheet LO22 Transmission Installation Procedure
Follow steps in Operation Sheet LO2-1

Replacing Standard Transmission
Report results in oral or written format

using criteria in the Self-Check LO2-2
3. Evaluate the inspection.

4. Install transmission
5. Replace standard transmission
6. Evaluate the installation
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
31
JOB SHEET LO2-1

TRANSAXLE INSTALLATION PROCEDURE
1.
Have a colleague help place the transaxle assembly onto the transaxle jack. Chain and
install two locating pins in the engine block assembly.
2.
Make up and install two locating pins in the engine block assembly.
Service Tip:
In transmission work, housing and bolt hole alignment are important and often necessary.
Get into the habit of having two or three aligning pins for each common bolt diameter. An
aligning pin can be a bolt with the hex head removed and a radius ground on the end to ease
piloting of parts through a hole. Often pin to ease installation and removal with a standard
screwdriver.
3.
Position the transaxle assembly and jack in place under the vehicle and align with the
engine and clutch assembly.
4.
At the rear of the transaxle, push the jack and transaxle toward the engine while aligning
the two locating pins with their respective holes in the transaxle housing.
5.
With the transaxle assembly in place, install and tighten the transaxle to the engine block
bolts. Replace the two locating pins with the proper bolts.
6.
Remove the safety chains and transaxle jack from under the vehicle.
7.
Install the antirotational link, left engine mount, and splash shield.
8.
When installing the left drive shaft, hold the inner universal joint assembly at the housing
while aligning and inserting the spline into the transaxle housing.
9.
Place the outer splined shfat into the steering knuckle support.
10. Install the lower ball joint into the left steering knuckle support.
NOTE: The original or equivalent bolt must be used. No substitutes are allowed.
11. Torque the steering knuckle clamp bolt I
to manufacturers specifications.
12. Unwrap the speedometer pinion, adapter,
and cable and install into the transaxle
extension housing.
13. While supporting the right side inner
universal joint housing, push the drive
shaft into place.
14. Insert the outer end of the right drive
shaft into the right side steering knuckle.
Tighten the steering knuckle clamp bolt to

manufacturers specifications.
15. Install the lower ball joint stud into the steering knuckle and retain with the steering knuckle
clamp bolt.
Code No.
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09/21/16
Page #
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16. Install the front wheel hub nut and wheel nuts according to the sequence outlined in the
service manual.
17. Add lubricant to the proper level as recommended by the manufacturer.
18. Connect the gearshift operating lever and selector shaft.
19. Lower the vehicle to the floor
20. Torque the hub nut and wheel lug nuts to manufacturers specifications.
21. Repeat the gearshift linkage adjustment.
22. Adjust the clutch pedal clearance.
23. Connect the battery negative cable to the battery.
24. Remove the engine support fixture and install the #4 cylinder exhaust manifold bolt.
25. Remove fender covers.
26. Road test the vehicle for quiet operation, smooth upshifting, and downshifting.
FACTS TO REMEMBER:
1.
Some of the factors that contribute to a transmission slipping out of gear center around the
parts of a synchronizer assembly.
2.
A clicking noise in one gear range during vehicle operation indicates a damaged gear
tooth.
3.
When assembling a synchronizer assembly, align the indexing marks.
4.
During assembly always lubricate the gears inside diameter to provide initial lubrication
and ensure easy rotation.
5.
After pressing a bearing into a shaft, always check the gears turn freely on the shaft and
that the synchronizer blocker rings are free.
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
33
ASSIGNMENT SHEET LO2-1

INSPECTING STANDARD TRANSMISSION
OBJECTIVE
What you need
Tools to remove and replace a

standard transmission
What you will do
Inspect parts of a standard

transmission
How well
So that you can determine

which parts are damaged and
must be replaced.
If you feel able to meet this objective now, turn to the Self Check.
PURPOSE
Materials and
Equipment
Code No.
ALT723313b
Standard transmission are powered by the engine through one or

more drive couplings. This LE will show you how to inspect
transmission parts for damage in order to determine if they must be
replaced.
Vehicle
Shop manuals
Safety glasses
Hand tools set
Seal puller
Seal driver
Transmission gasket
Transmission seals
Can opener or oil spout
Shop towels
Jack stands
Floor jack
Drain pan
Gasket sealer
Creeper
Transmission fluid
Transmission jack
Gasket scraper
Fender covers
Blowgun
Air cornpressor
8/ 25/ 2003
09/21/16
Page #
34
INSPECTING STANDARD TRANSMISSION

STEP 1. Wash all bearings in clean solvent.
STEP 2. Dry bearings by using air blow gun and compressed air.
CAUTION:
Hold bearings while blowing with compressed air to prevent bearings from
spinning in their race.
STEP 3. Check bearings for roughness or pitting.

STEP 4. Clean and inspect the inside of the transmission case for cracks.
STEP 5. Clean and inspect all gears for broken teeth, wear or other damage.
STEP 6. Inspect synchronizer assemblies for grooving or excessive wear.
NOTE:
Any parts showing damage or wear must be replaced.
Code No.
ALT723313b
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09/21/16
Page #
35
Self-Check LO2-1
Inspect Standard Transmissions
Directions At this time, check your skills by reviewing the following criteria.
1. Bearings are cleaned and dried correctly.
2. Transmission parts are inspected for damage or excessive wear.
3. Parts to be replaced are determined.
4. 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.
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
36
JOB SHEET LO2-2

TRANSMISSION INSTALLATION PROCEDURE
1.
Have a colleague help you lift the transmission onto the transmission jack. Wrap the safety
chains around the transmission housing and transmission jack.
2.
After aligning the transmission jack and transmission with the clutch assembly, shift the
transmission into gear. Rotate the transmission output shaft so the transmission input shaft
aligns and engages with the clutch driven disc splines.
3.
Remove the safety chains from around the transmission housing and transmission jack.
Slide the transmission off the transmission jack and into place.
4.
Install and tighten the transmission mounting bolts to manufacturers specifications with a
torque wrench.
5.
Install the cross member and transmission mount.
6.
Remove the masking tape from the rear universal joint and align the indexing marks on the
rear universal joint yokes. Install the rear universal joint and be careful not to tighten the
mounting U bolts.
7.
Connect the speedometer cable.
8.
Install the shift levers at the side of the transmission cover plate
9.
Connect the backup light connector and the transmission control switch connector.
10. Remove the engine support stand.

11. Install transmission gear lubricant to the required level. Be sure to tighten the filler hole
plug.
12. Lower the vehicle, but leave the driving wheels free of the floor.
13. Connect an exhaust system pipe to the vehicle.
14. Start the engine and operate the transmission through the various gear ranges checking
for smooth shifting and quiet operation. If the transmission checks out satisfactorily, lower
the vehicle to the floor.
15. The vehicle should now be road tested for smooth, quiet transmission operation.
Code No.
ALT723313b
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09/21/16
Page #
37
FACTS TO REMEMBER:
1.
The parts on the four-speed transmission output shaft are the third and fourth synchronizer
assembly, third speed gear, second speed gear, first and second synchronizer assembly,
first speed gear, and the rear bearing assembly.
2.
The synchronizer assembly hub will have a longer hub at the front than at the rear.
3.
When assembling the synchronizer assembly, the synchronizer sleeve groove must be at
the opposite end of the synchronizer assembly to the long hub on the synchronizer hub.
4.
Synchronizer blocker ring notches must be always align with the synchronizer inserts.
5.
After the assembling the output shaft, a good service technician always checks his or her
work.
6.
Cluster assembly thrust washer tangs must always face away from the cluster gear
assembly.
7.
When installing the front bearing retainer. The lubrication drainage groove must align with
the transmission housing.
8.
When installing the transmission, shift into gear so the transmission input shaft can be
aligned with the clutch driven disc.
9.
Indexing marks must be aligned when installing the drive shaft to maintain alignment and
balance.
TRANSMISSION LUBRICANT LEVEL CHECK

Lubricant in a transmission reduces friction, wear, and heat. If the lubricant level is low, the
rotating gear teeth cannot throw enough oil onto the synchronizer assemblies and rotating
parts. Gear clashing problems and premature parts wear result from low lubricant levels.
When checking the lubricant be sure the transmission is at operating temperature. The
lubricant level should be at the lower edge of the filler plug hole. If the transmission is cold, the
lubricant level should be adjusted to approximately %to (12 mm to 19 mm) below the filler
plug hole.
These recommendations are important because when the lubricant is cold it contracts and
when hot it expands. If the transmission is filled and when hot it expands. If the transmission is
filled to the bottom of the filler plug hole when cold, heat will cause the lubricant to expand and,
consequently, overfill the transmission. The surplus fluid could flood the front transmission seal
and flow onto the clutch driven disc. Lubricant on the clutch driven disc causes clutch chatter
and grab.
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
38
OPERATION SHEET 2-1

REPLACING STANDARD TRANSMISSION
STEP 1. Replace the transmission
Heres how:
a.
Place transmission on transmission jack with input facing the clutch housing
b.
Raise transmission jack high enough to align input shaft clutch housing.
c.
Slowly and carefully roll transmission jack forward until the shaft goes into
transmission housing.
NOTE: Make sure clutch release bearing is in place.

d.
Move transmission slightly to the left or right, up or down, until alignment dowel pins
go through the bolt holes in the transmission housing.
e.
Remove alignment dowel pins and start attaching the bolts with your fingers.
f.
Start the bottom attaching bolts.
NOTE: Make sure bolts are started straight and not cross-threaded.
g.
Use socket and wrench and snug down transmission mounting bolts.
NOTE: Alternate from one bolt to the other. Make sure the transmission case has equal
pressure applied to it.
h.
Use torque wrench and torque to specifications.
Use the combination wrench to install the crossmember to the bolts.

j.
Use combination wrench to install transmission mounts to transmission and

crossmember
NOTE: If any exhaust system parts were removed, replace them at this time.
k.
Remove engine support jack and wooden blocks
I.
Install shift linkages
NOTE: Make sure the shift linkages do not bind and that they are properly attached
m.
Use pliers to connect speedometer cable.
n.
Reconnect all wires that were attached to the transmission.
NOTE: The wires and linkages should have been numbered with masking tape for ease
in
installation.
Code No.
ALT723313b
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09/21/16
Page #
39
o.
Use crescent wrench or combination wrench to install drain plug.
p.
Use crescent wrench or combination wrench to remove filler plug found on side
transmission case.
q.
Fill the transmission with proper lubricant.
NOTE: Check manual for type of lubricant to use and amount required to fill.
r.
Use crescent wrench or combination wrench to replace filler plug.
STEP 2. Install the drive shaft.

STEP 3. Use the jack to raise the vehicle and remove jack stands.
STEP 4. Lower the vehicle to the floor
STEP 5. Clean the work area of all oil spills.
STEP 6. Return tools and equipment to their proper storage area.
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
40
Self-Check LO2-2
Replace Standard Transmissions
Directions: At this time, check your skills by reviewing the following criteria.
1.
Transmission is installed correctly.
2.
Drive shaft is installed correctly.
3.
All tools and equipment are returned to their proper storage area.
4.
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.
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
41
QUALIFICATION
AUTOMOTIVE SERVICING NC III
MODULE
Test manual transmission performance
1.
2.
3.
4.
5.
Transmission is tested while the engine is running and transmission in neutral position.
Testing were conducted as per service manual.
Visual/ocular evaluation of transmission performance was conducted with emphasis on
performance of every shifting pattern, noise and operation.
Vehicle and shop work safety procedure is applied.
Personal safety requirement is observed.
RESOURCES:
Equipment
1. Car with manual transmission and

transaxle.
2. Testing instruments
3. Hand tools
4. Wrenches
5. Socket wrench set
5.
7.
8.
9.
10.
Rags
Soap
Fuel
Warning devices
Troubleshooting chart
REFERENCES:
1.
2.
3.
Manual Transmission and Power Trains by John H. White

The Automotive Power Train and Running Gear, Power Flow and Chassis Unit, by
Felizardo Y. Francisco, Cayetano R. Rivera
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
42
Learning Outcome #3: Test manual transmission performance

LEARNING ACTIVITIES
In the workshop using appropriate tools and

equipment and other instructional materials,
the trainees will test newly repaired manual
transmission.
1. Read: Steps in troubleshooting
defective transmission and power train
components.
2. Test : Newly repaired running manual

transmission.
Install the transmission into the vehicle

and check for defects using the
procedures in Job Sheet #LO3-1
3. Observe shop practices and safety.
Job Sheet #LO3-1 Testing Manual

Transmission
4. Report results in oral or written format
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
43
JOB SHEET LO3-1

TESTING MANUAL TRANSMISSION
OBJECTIVE
What you need
A troubleshooting chart and a vehicle with

defective transmission and power train
components
What will you do
Troubleshoot transmission and power train

problems and determine their causes
How well
So that you identify at least 75% of the causes

of noises and vibrations in the given
transmission and drive trains
If you feel able to meet this objective now, turn to the self check.
PURPOSE
Noises and vibrations are common in transmissions and drive trains.

Many of these can cause serious damage to the vehicle if not found
and corrected. A mechanic must be able to troubleshoot and isolate
the causes of these in order to make the correct repairs. In this Job
Sheet you will learn how to find and identify these causes.
Materials and
Equipment
Code No.
ALT723313b
Motor or shop manual
Troubleshooting checklist
Vehicle with defective transmission and power train components
8/ 25/ 2003
09/21/16
Page #
44
STEP 1. Check noises in the clutch.

Possible Cause
Correction
1.
2.
3.
4.
5.
6.
1.
2.
3.
4.
5.
6.
Dry clutch linkage

Worn release bearing.
Worn disc assembly
Worn release levers
Worn or dry pilot bushing.
Dry contact-pressure plate lugs in cover.
Lubricate where necessary

Replace release bearing
Replace disc assembly
Replace cover assembly
Lubricate or replace bushing
Lubricate very lightly
STEP 2. Check chatter in the clutch

Possible Cause
Correction
1.
2.
Worn or damaged disc assembly.

Grease or oil on disc facings.
1.
2.
3.
4.
5.
Improperly adjusted cover assembly.

Broken or loose engine mounts.
Misaligned clutch housing.
3.
4.
5.

Replace disc assembly cause of
contamination.
Replace cover assembly
Replace or tighten mounts
Align clutch housing and correct
STEP 3. Check why a clutch jumps out of gear

Possible Cause
Correction
1.
2.
3.
Gearshift linkage incorrectly adjusted.

Gearshift linkage bent or binding.
Clutch housing misaligned.
1.
2.
3.
4.
5.
Worn pilot bushing

Worn or damaged clutch shaft roller
bearings.
Worn, tapered gear teeth; synchronizer
parts worn.
Shifter forks, shift rails, or detent-interlock
parts worn, missing, etc.
Excessive end play of output shaft gear
train, countershaft gear or reverse idler
gear.
4.
5.
Adjust linkage
Correct bind, replace bent parts.
Check runout at rear face of clutch
housing.
Replace bushing.
Replace bearings.
6.
Inspect and replace as required.
7.
Inspect and replace as required
8.
Replace thrust washers, and snap rings

(output shaft gear train)
6.
7.
8.
STEP 4. Check why clutch is slipping.

Possible Cause
Correction
1.
2.
Insufficient pedal free play.

Burned, worn or oil-soaked facings.
1.
2.
3.
Weak or broken pressure springs.
3.
Code No.
ALT723313b
Adjust release fork rod.

Replace disc assembly and correct
cause of contamination.
Replace cover assembly.
8/ 25/ 2003
09/21/16
Page #
45
STEP 5. Check why gears clash when shifting from one forward gear to another.
Possible Cause
Correction
1.
2.
3.
Incorrect clutch adjustment Clutch linkage binding

Gear shift linkage incorrectly adjusted,
bent or binding.
Clutch housing misalignment.
1.
2.
3.
Damaged or worn transmission

components: shift forks, synchronizers,
shift rails and interlocks. Excessive end
play to worn thrust washers.
5.
4.
5.
4.
Adjust clutch
Lubricate or repair linkage as required
Adjust linkage, correct binds, replace
bent parts.
housing.
Inspect components. Repair or replace
as required.
STEP 6. Check the causes of transmission noises.

Possible Cause
Correction
1.
2.
3.
4.
5.
6.
7.
8.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Low fluid level

Wrong fluid
Dirt or chips in fluid
Plugged or restricted screen
Damaged screen to valve body gasket
Damaged or worn pump oil seals.
Loose converter to flywheel bolts.
Gearshift linkage bent, binding, or
adjusted wrong
Clutch housing aligned wrong.
9.
Check for leakage and refill

Replace with proper fluid
Drain and flush transmission
Clean or replace screen
Replace valve body gasket.
Replace pump oil seals.
Tighten flywheel bolts
Adjust linkage, correct binds, replace
bent parts.
Check runout at rear of housing clutch.
STEP 7. Check why a transmission is locked in one gear.

Possible Cause
Correction
1.
2.
1.
2.
Correct bind, replace bent components.

Tighten nuts, replace worn levers.
3.
Inspect and replace worn or damaged

parts
Inspect and replace damaged part.
3.
4.
Gearshift linkage binding or bent.

Transmission shifter lever attaching nuts
loose or levers are worn at shifter fork
shaft hole.
Shift rails worn or broken, shifter fork lock
plug missing or worn.
Broken gear teeth on countershaft gear,
clutch shaft, or reverse idler gear.
Code No.
ALT723313b
4.
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09/21/16
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46
STEP 8. Check why a transmission will not shift into a certain gears when all others are
working correctly.
Possible Cause
Correction
1.
2.
3.
4.
1.
2.
3.
4.
Gearshift linkage not adjusted correctly

Bent shift rod at transmission
Transmission shifter levers reversed
Worn or damaged shift rails, shift forks,
detent-interlock plugs, loose setscrew in
shifter fork, worn synchronizer parts.
Adjust linkage
Replace rod
Correctly position levers
Inspect and repair or replace parts as
required.
STEP 9. Check why a transmission shifts hard.

Possible Cause
Correction
1.
2.
3.
Incorrect clutch adjustment

Clutch linkage binding
Gearshift linkage incorrectly adjusted,
bent, or binding.
Bind in steering column, or column is
misaligned.
1.
2.
3.
Incorrect lubricant
Internal bind in transmissions - e.g. shift
rails, interlocks, shift forks, synchronizer
teeth.
Clutch housing misalignment.
5.
6.
4.
5.
6.
7.
4.
7.
Adjust clutch pedal free-play

Lubricate or repair linkage as required
Adjust linkage correct any bind.
Replace bent pads
Disconnect shift rods at column. Check
for bind/misalignment between tube and
jacket by shifting lever into all positions.
Correct as required.
Drain and refill transmission.
Remove transmission and inspect shift
mechanism. Repair as required.
housing.
STEP 10. Check why it is difficult to shift the gears.

Possible Cause
Correction
1.
2.
3.
4.
5.
Excessive pedal free play

Excessive deflection in linkage or firewall
Worn or damaged disc assembly
Improperly adjusted cover assembly
Clutch disc splines sticking.
1.
2.
3.
4.
5.
6.
7.
Worn or dry pilot bushing.

Clutch housing misaligned.
6.
7.
Code No.
ALT723313b
Adjust release fork rod.

Repair or replace linkage
replace cover assembly
Remove disc assembly splines or replace
disc.
lubricate or replace bushing
Align clutch housing and free up
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09/21/16
Page #
47
STEP 11. Check why lubricant is leaking in differential and drive axles.
Possible Cause
Correction
1.
2.
Lubricant level too high

Worn axle shaft oil seals
1.
2.
3.
4.
Cracked rear axle housing

Worn drive pinion oil seal
3.
4.
5.
Scored and worn companion flange
5.
6. Clogged vent
7. Loose carrier housing bolts or housing
cover screws
6.
7.
Drain excess lubricant

Replace worn oil seals with new ones.
Prepare new seals before replacement.
Repair or replace housing as required.
Replace worn drive pinion oil seal with a
new one.
Replace worn or scored companion
flange and oil seal.
Remove obstruction.
Tighten bolts or cover screws to
specifications and fill to correct level with
proper lubricant.
STEP 12. Check for cause of noise in rear wheel.

Possible Cause
Correction
1.
2.
Loose wheel
Spalled wheel bearing cup or cone
1.
2.
3.
Defective or brinelled wheel bearing
3.
4.
5.
Excessive axle shaft end-play

Bent or sprung axle shaft flange.
4.
5.
Tighten loose wheel nuts

Check rear wheel bearings. If spalled or
worn, replace.
Defective or brinelled bearings must be
replaced.
Readjust axle shaft end-play
Replace bent or sprung axle shaft.
STEP 13. Check for cause of noise in rear axle.

Possible Cause
Correction
1.
Insufficient lubricant
1.
2.
3.
Improper ring gear and pinion adjustment

Unmatched ring gear and pinion
2.
3.
4.
Worn teeth on ring gear or pinion.
4.
5.
6.
7.
8.
End-play in drive pinion bearings.

Side-play in differential bearings
Incorrect drive gear lash
Limited-slip differential moan and
chatter
5.
6.
7.
8.
Code No.
ALT723313b
Refil rear axle with crrect amount of the

proper lubricant. Also check for leaks and
correct as necessary.
Check ring gear and pinion tooth contact
Remove unmatched ring gear and pinion.
Replace with a new matched gear and
pinion set.
Check teeth on ring gear and pinion for
contact. If necessary, replace with new
matched set.
Adjust drive pinion bearing preload.
Adjust differential bearing preload
Correct drive gear lash
Drain and flush lubricant. Refill with
proper lubricant
8/ 25/ 2003
09/21/16
Page #
48
STEP 14. Check for cause of overheating.

Possible Cause
Correction
1.
2.
Lubricant level too low.

Incorrect grade of lubricant
1.
2.
3.
Bearings adjusted too tightly
3.
4.
Excessive wear in gears
4.
5.
Insufficient ring gear to-pinion clearance
5.
Refill rear axle

Drain, flush and refill rear axle with
correct amount of the proper lubricant
Readjust bearings.
Cheek gears for excessive wear or
scoring. Replace as necessary.
Readjust ring gear and pinion backlash
and check gears for possible scoring.
STEP 15. Check for cause of vibrations.

Possible Cause
Correction
1.
2.
3.
1.
2.
3.
Unbalanced or damaged drive shaft

Worn universal joints
Misaligned drive shaft at companion
flange.
Check drive for damage and balance.

Check u-joints and replace as needed
Adjust and align drive shaft
STEP 16. Check to see if differential gears and pinion are scored.
Possible Cause
Correction
1.
Insufficient lubrication
1.
2.
Improper grade of lubricant
2.
3.
Excessive spinning of one wheel.
3.
Code No.
ALT723313b
Replace scored gears. Scoring marks on

the pressure face of gear teeth or in the
bore are caused by instantaneous fusing
of the mating surface. Scored gears
should be replaced. Fill rear axle to
required capacity with proper lubricant.
Replace scored gears. Inspect all gears
and bearings for possible damage. Clean
and refill axle to required capacity with
proper lubricant.
Replace scored gears. Inspect all gears,
pinion bores and shaft for scoring, or
bearings for possible damage.
8/ 25/ 2003
09/21/16
Page #
49
STEP 17. Check tooth breakage on ring gear and pinion.

Possible Cause
Correction
1.
Overloading
1.
2.
Erratic clutch operation
2.
3.
Ice-spotted pavements
3.
4.
Improper adjustment
4.
Code No.
ALT723313b
Replace gears. Examine other gears and

bearings for possible damage. Avoid
future overloading.
Replace gears, and examine remaining
parts for possible damage. Avoid erratic
clutch operation.
Replace gears. Examine remaining parts
for possible damage. Replace parts as
required.
Replace gears. Examine other parts for
possible damage. Be sure ring gear and
pinion backlash is correct.
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09/21/16
Page #
50
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.
You will be rate based on the
overall evaluation on the right side.
OVERALL EVALUATION
Level
Achieved
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.
Yes
No
N/A
1.
Did you clean, lubricate and coat manual

transmission components with new gear oil as per manufacturers
manual?
2.
Have you clean transmission bearings
following the proper procedure?
3.
Did you follow the correct steps in installing

and mounting manual transmission?
4.
Did you properly test the

transmission performance meet in the required conditions?
Code No.
ALT723313b
manual
8/ 25/ 2003
09/21/16
Page #
51
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.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
52
Record of Achievement
Module: Assembling and Testing Manual Transmission
Learning Outcome #1 - Assemble manual transmission component
Performance Criteria:
1. Manual transmission component parts cleaned, lubricated and coated with new gear oil as per
manufacturers manual.
2. Parts reference marks were used in assembling.
3. Assembling of transmission component was performed as per steps and procedure.
4. Bolts and nuts were torqued according to specifications and in correct sequence.
5. Correct tools were used for assembling.
6. Vehicle, workshop and parts safety requirements were applied.
7. Oil properly filled.
COMMENTS:
Learner has satisfied the above performance criteria.

Learners signature: .
Trainers signature: ..
Date: .
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
53
Learning Outcome #2 - Install and mount manual transmission and associated parts
1.
2.
3.
4.
5.
6.
7.
Transmission gear oil is filled properly and in appropriate level.

Transmission jack is positioned in accordance with safety procedure.
Transmission assembly is mounted to the engine/vehicle in correct steps as per specification.
Attaching bolts were torqued according to specification and in correct sequence.
Transmission associated component were installed or mounted properly according to steps
and procedures.
Appropriate tools for the job were used.
Personal safety procedures were applied.
COMMENTS:

Date: .
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
54
Learning Outcome #3 - Test manual transmission performance
1. Transmission is tested while the engine is running and transmission in neutral position.
2. Testing were conducted as per service manual.
3. Visual/ocular evaluation of transmission performance was conducted with emphasis on
performance of every shifting pattern, noise and operation.
4. Vehicle and shop work safety procedure is applied.

5. Personal safety requirement is observed.
COMMENTS:

Date: .
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
55
EVIDENCE PLAN
1.
Assemble manual transmission components
2.
Install, mount manual transmission and associated

parts
3.
Test manual transmission performance
Portfolio
The evidence must show that the candidate
Interview
QuestioningDemonstration
Sector:
Unit of Competency:
OVERHAUL MANUAL TRANSMISSION
Module Title:
ASSEMBLING AND TESTING MANUALS TRANSMISSION
Ways in which evidences will be collected:
(tick the column)
Note: *Critical aspects of competency
Prepared by:
Date:
Instructor
Date:
Supervisor
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
56
Demonstration
Questions
The candidate should answer the following questions:
1.
2.
3.
Satisfactory Response
Yes
No
What are the steps in cleaning the transmission bearing and

associated components?
Explain the steps/procedure in installing and mounting manual
transmission and associated parts.
Did you meet the required condition in testing manual
transmission performance?
The candidates underpinning knowledge was:

Rating: _________
Feedback to candidate
The candidates overall performance was:

Rating: _________
Candidates signature:
Date:
Assessors signature:
Date:
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
57
Demonstration
Candidates name:
Assessors Name:
Competency Assessment Title:
Qualification:
Date of Assessment:
Tome of Assessment:
Instructions for Demonstration:
OVERHAUL MANUAL TRANSMISSION

Given the following material, tools and equipment, the candidate must be able to overhaul the
manual transmission.
a.
Car equipment with manual transmission/transaxle
b.
Hand tools
c.
Working table, stand
d.
Manual
OBSERVATION
During the demonstration of skills, did the candidate:
1.
2.
3.
4.
5.
6.
7.
8.
Clean, lubricate manual transmission component

parts.
Coat with nuts gear oil as per manufacturers
manual
Perform assembling manual transmission as per
steps and procedures.
Fill transmission gear oil properly and in
appropriate level.
Position transmission jack in accordance with
safety procedure.
Mount transmission assembly the engine/vehicle in
correct steps as per specification.
Install transmission associated component
according to steps and procedure.
Use appropriate tools and procedure for the job.
9. Apply personal safety procedure.

10. Torque bolts and nuts according to specifications
and in correct sequence.
11. Test transmission while the engine is running and
transmission in neutral position
12. Conduct visual/ocular evaluation of transmission
performance of every shifting pattern, noise and
operation.
Tick () to show if evidence is

demonstrated
Yes
No
ACTUAL
1.0 3.0
5.0
The candidates demonstration was:

Rating ______________
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
58
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
59
TECHNICAL TERMS
1. Transaxle
Power transmission device, attached to one end of the

transmission and driveshaft final drive and differential into a
single assembly
2. Overdrive
A device or transmission gear arrangement which cause the

output shaft to overdrive or rotate faster than the input shaft.
3. Steering Column shift
An arrangement in which the transmission shift lever is mounted

on the steering column.
4. Synchomesh
transmission
A transmission with a built-in device that automatically matches

the rotating speed automatically matches the rotating speed of
the transmission gears as they are about to mess there
eliminating the need for double clutching.
5. Transmission Oil
cooler
A small, sometimes finned, tube or tank, either mounted

separately or included as part of the engine radiator, which cools
the transmission fluid.
6. Transfer case
An auxiliary
7. Transmission
A metal case containing an assembly of shafts gears and related

parts. used to transmit power from the engine to the drive shaft
or final drive of an automatic vehicle; provide different gear
ratios as well as neutral and reverse; may be manual, automatic
or continuously variable.
8. Gears
Wheel with meshing teeth that transmit power or turning force

between shafts.
9. Bearing
A part that transmit a load to a support and in so doing absorbs

most of the friction of moving parts.
10. Gear Ratio
A number of revolution of a driving gear required to turn a driver

gear through one complete revolution.
11. Gear shift
A linkage type mechanism by which the gears of an automotive

transmission are engage and disengaged.
12. Synchronizer
A device in the transmission that synchronizes gear about to be

meshed so that no miss will occur.
13. Reverse
Iidler gear in a transmission, an additional gear that must

meshed to obtained reverse gear a gear use only in reverse.
That does not transmit power when transmission is in any other
position.
14. Ratio
The relationship in size or quantity of two or more objects. A gear

ratio is derived by dividing the number of teeth on the driver gear
by the number of teeth on the driving gear.
15. Shift lever
The lever used to shift gears in a transmission.
Code No.
ALT723313b
8/ 25/ 2003
09/21/16
Page #
60

Assembling and Testing Manual Transmission

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Overhaul Manual Transmission