KOLEJ VOKASIONAL MIRI

LORONG 10, JALAN JEE FOH, KROKOP

98000 MIRI, SARAWAK.

KERTAS KERJA
PROGRAM
KOD MODUL
TAJUK MODUL
TAHUN / SEMESTER

TEKNOLOGI AUTOMOTIF
MAT 501
4 WHEEL DRIVE TRAIN SYSTEM
TAHUN 1 SEMESTER 5 DIPLOMA VOKASIONAL

JAM KREDIT
JUMLAH JAM

MALAYSIA
3.0
5.0 JAM / SEMINGGU

KELAS/KULIAH
KOMPETENSI
STANDARD
PEMBELAJARAN
NAMA PELAJAR:

1. OVERHAUL 4 WHEEL DRIVE TRAIN SYSTEM

RUJUK DOKUMEN STANDARD KSKV

TARIKH:

TAJUK : PART TIME 4WD TRANSFER CASE DISASSEMBLY AND ASSEMBLY

OBJEKTIF :
Selepas aktiviti ini pelatih-pelatih mesti boleh :
1. Membuka dan memasang part time 4 wheel drive transfer case dengan teknik yang betul
2. Membuka dan memasang komponen transfer case adapter dengan teknik yang betul
3. Membuka transfer case plate dengan teknik yang betul
ARAHAN AM :
Anda dikehendaki membuka dan memasang part time 4 wheel drive transfer case, membuka dan
memasang komponen transfer case adapter dan membuka transfer case plate menggunakan teknik
yang betul. Masa yang diberikan adalah selama 2 jam. Sila patuhi langkah-langkah keselamatan

semasa melaksanakan tugas dan pastikan tempat kerja sentiasa kemas dan bersih semasa atau
selepas menjalankan tugas.
PERALATAN/PERKAKASAN/BAHAN :
BIL
1.
2.
3.
7.
8.

ITEM
4 wheel drive transfer case
Service manual
Peralatan tangan
Oil Seal
Takungan (tray)

Bil/Unit
1 unit
1 unit
1 set
1 set
2 unit

ARAHAN KERJA :
1. Sediakan bahan, peralatan dan kelengkapan yang sesuai.
2. Sangga kenderaan dan julang ia setinggi mengikut kesesuaian kerja
3. Membuka dan memasang part time 4 wheel drive transfer case dengan teknik yang betul
4. Membuka dan memasang komponen transfer case adapter dengan teknik yang betul
5. Membuka transfer case plate dengan teknik yang betul
GAMBAR RAJAH : PART TIME 4 WHEEL DRIVE TRANSFER CASE

LANGKAH KERJA
1.

BUTIRAN KERJA

H-L Shift Rail/Chain

NOTE: If the 2-4WD shift rail is at the 2WD position, the

Cover Removal

chain cover cannot be removed because interlock is actuated.

1.1 Shift the 2-4WD shift rail at the 4WD position.
1.2 Remove the chain cover, and then remove the H-L shift rail.

2.

Rear Output

2.1 Remove the rear output shaft, chain and front output shaft as a set.

Shaft/Chain/Front
Output Shaft Removal

3.

Adjustment Before

3.1 Place pieces of solder [approximately 10 mm (0.4 inch) in length

Assembly-

and 1.6 mm (0.06 inch) in diameter] in the transfer case housing

Spacer Selection for

as shown.

Adjustment Of

3.2 Install the countershaft gear into the transfer case.

Countershift Gear End

3.3 Install the transfer case plate and tighten the bolts.

Play

LANGKAH KERJA
4.

Oil Seal Installation

BUTIRAN KERJA
4.1 Use special tools to install the oil seal.
4.2 Apply MITSUBISHI genuine grease or equivalent to the lip of the
oil seal.

5.

Front Output
Shaft/Chain/Rear
Output Shaft
Installation

5.1 Engage the chain precisely with the sprocket of the rear
output shaft and the front output shaft.
5.2 Install the 2-4WD shift fork on the 2-4WD clutch sleeve.While
passing them beside the 2-4WD shift rail, install the front
output shaft, and chain and rear output shaft.

6.

Spring Pin

6.1 Align the 2-4WD shift lug with the 2-4WD shift rail spring pin hole.

Installation

6.2 Hammer in the spring valve so that the spring pin slit matches the
center of the shift rail shaft.

LANGKAH KERJA
7.

Interlock
Plunger/Chain Cover
Installation

BUTIRAN KERJA
7.1 Insert the interlock plunger into a position where it does not
interfere with 2-4WD shift rail.
CAUTION
Squeeze the sealant out evenly to apply it in an unbroken,
non-excessive quantity.
7.2 Apply sealant MITSUBISHI genuine sealant or equivalent to the
chain cover, and then install the chain cover.

8.

H-L Shift Rail/Spring

Pin Installation

8.1 Insert the H-L shift rail from the H-L shift rail hole, paying
attention to the direction of the shift rail.
8.2 Align the spring pin holes on the shift rail with the shift fork.Then
tap in the spring pin so that the slit of the spring pin is facing the
shaft center of the shift rail.

9.

Oil Seal Installation

9.2 Press into the dimensions shown in the illustration so that it is not
slanted.

LANGKAH KERJA
10. Spacer

Installation

BUTIRAN KERJA
10.1 Measure projection A of the rear output shaft bearing and depth B
of the second stage of the rear cover.
10.2 Subtract A from B and let the answer be C. Select a spacer so that
the subtracted value will be the standard value shown below.
Standard value: 0 0.08 mm (0 0.003 inch)

11. Rear

Cover

Installation

12. Control

Housing

Installation

11.1 Apply sealant Mitsubishi genuine sealant or equivalent to the

chain cover

12.1 Apply sealant Mitsubishi genuine sealant or equivalent to the

control housing

LANGKAH KERJA
13. H-L Shift

Rail Plug

BUTIRAN KERJA
13.2 Apply sealant 3M or equivalent to the threads.

and Plug Installation

14. Spacer

Installation

14.1 Install the previously selected spacer (see ADJUSTMENT

BEFORE ASSEMBLY).

15. Transfe

Case Plate

Installation

15.1 Face the notched section of the input gears in the direction shown
in the illustration

15.2 Apply MITSUBISHI genuine sealant or equivalent to the transfer

case plate

15.3 Install the transfer case plate together with the input gear.Slide the
input gear tooth aligned in Step 1 along the tooth space of the
countershaft gear

LANGKAH KERJA
16. Spring

Installation

BUTIRAN KERJA
16.1 Install the spring with its tapered end toward the ball

GAMBAR RAJAH : TRANSFER CASE ADAPTER

LANGKAH KERJA

BUTIRAN KERJA

17. Oil Seal

Installation

17.1 Use special tools to install the oil seal

18. Sealing

Cap

18.1 Press into the dimensions shown in the illustration so that it is not

Installation

slanted.
18.2Apply the sealant as shown in the illustration.

19. Parking

Sprag Spring

Installation

19.1Attach the end of the spring to the position shown in the illustration.

GAMBAR RAJAH : TRANSFER CASE PLATE

LANGKAH KERJA
20. Oil Seal

Installation

BUTIRAN KERJA
20.1 Use special tools to install the oil seal. Apply Mitsubishi genuine
or equivalent to the lip of the oil seal.
20.2 Use special tools to install the oil seal.Apply Mitsubishi
genuine grease or equivalent to the lip of the oil seal.

21. Bolt

Installation

21.1 Apply Mitsubishi genuine sealant or equivalent to the threads

PERATURAN PEMARKAHAN AMALI

PROGRAM DIPLOMA VOKASIONAL MALAYSIA
MTA 501: 4 WHEEL DRIVE TRAIN SYSTEM
1. Skala Markah:
0- Tidak menjalankan tugasan.
1- Menjalankan tugasan dan tidak mengikut kriteria yang ditetapkan.(1%-49%)
2- Menjalankan tugasan dan mengikut sebahagian kriteria yang ditetapkan.(50%-74%)
3- Menjalankan tugasan dan mengikut kriteria yang ditetapkan.(75%-100%)
2. Wajaran:
1- Perkara yang penting/ Tidak memerlukan kemahiran tinggi.
2- Perkara penting/ Perlu kemahiran tinggi.
3- Perkara sangat penting/ Mempengaruhi kefungsian.
3. Tandakan () di ruang markah yang disediakan

SKALA MARKAH:
Skala 0 = Calon tidak melakukan tugasan/ tidak mengikut kriteria yang ditetapkan
Skala 1 = Calon mengikut sebahagian daripada kriteria yang ditetapkan
Skala 2 = Calon mengikut kriteria ditetapkan
Skala 3 = Calon mengikut dan melebihi kriteria ditetapkan

BI
L

1.

WAJARAN
(1 3)

MARKAH
DIPEROLE
HI

PERATUS
MARKAH
DIPEROLEHI

PROSES KERJA -40%

Menyediakan peralatan dan bahan kerja

Melaksanakan kerja dengan tempoh

yang telah ditetapkan.

JUMLAH

2.

MARKAH
DIBERI

ASPEK DINILAI

/ 9 x 40

HASIL KERJA-40%
Membuka dan memasang part time
4wd transfer case dengan teknik yang
betul
Membuka dan memasang komponen
transfer case adapter dengan teknik

3
3

/ 27 x 40

betul
Membuka transfer case plate dengan
teknik yang betul
JUMLAH

3.

FAKTOR KRITIKAL -10%

Proses membuka, pemeriksaan dan
pemasangan ke atas komponen
menggunakan kaedah yang betul
mengikut manual servis pengeluar.
JUMLAH

4.

/ 9x 10
3
3

KESELAMATAN DAN NILAI - 10%

Sentiasa menjaga kebersihan tempat
kerja
Semua peralatan di simpan / di jaga
dengan baik

2
2

Sentiasa mengamalkan langkahkeselamatan semasa melakukan kerja.

Persediaan Diri

Berhemah dan berdisplin

Etika

Profesionalisma

2
JUMLAH

14

JUMLAH MARKAH KESELURUHAN

TANDA TANGAN
PEMERIKSA
NAMA PEMERIKSA
TARIKH
TERAMPIL / TIDAK
TERAMPIL
NAMA PENGESAH

TANDA TANGAN
PENGESAH

/ 42 x 10