AURT206670A

AUR30405 CERTIFICATE
INSPECT III
ANDIN AUTOMOTIVE
SERVICE TRANSMISSIONS
MECHANICAL (MANUAL)
TECHNOLOGY 1

AURT206670A
Inspect and service
transmissions (manual)

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Personal safety

• Safety shield
• Full body overalls
• Ear plugs or muffs
• Leather safety gloves
• Safety boots

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Workplace hazards

Heat Compressed air

• Burn your skin
• What else? ! • Blow dirt in your eyes
• What else?

Chemical substances
• Burn your eyes
• What else?

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Equipment safety

Do not work under vehicles

!
supported only by a trolley jack.

Trolley jack
! ALWAYS use safety stands.

! Do not exceed the safe

working load.
Safety stands

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Equipment safety
Four post hoist Two post hoist

! Follow manufacturer’s instructions

when operating vehicle hoists.

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Environmental issues

Waste oils
• recycle waste oils
• safe disposal of oily rags

Degreasing and parts washing

• bunded washing area
• large caustic degreaser
• small degreaser trough
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Material Safety Data Sheets

Must be provided by law.
For manual transmissions may cover:
• manual transmission fluids and oils
• additives
• caustic cleaning solutions
• hydrocarbon based cleaning solutions
• petroleum gels
• hand cleaners.

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Transmission functions

• Neutral position so
engine can start and
run without moving

• Range of gear ratios

• Engine braking

• Reverse gear.

Rear wheel drive transmission

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Types of gears

Spur gears

Helical gears

Hypoid gears

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Transmission components
Input shaft gear Main shaft
gear
Input shaft

Main shaft

Speedometer
Reverse idler drive
Counter shaft Cluster gear

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Torque

• The amount of force required to rotate an object

• The gears inside a transmission increase or decrease

the available engine torque.

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Multiplying torque

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Gear synchronizer

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Gear ratio
When a gear is selected - the speed of the input shaft
compared with the speed of the output shaft

Input shaft
1. How many teeth? Driven gear = 10
teeth

2. Driving gear teeth

Driven gear teeth
Output shaft
Driving gear = 20
3. 20 ÷ 10 teeth

4. Gear ratio = 2:1

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Compound gear ratios

Second simple
gear train

First simple
gear train

• Multiple simple gear trains in series

• Each set of gears generates an individual ratio
• Multiply individual ratios together to work out overall ratio.
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Compound gear ratios

Second set of gears

First set of gears
Number of teeth on
Number of teeth on driven gear = 30
driven gear = 24
Number of teeth on
Number of teeth on driver gear = 10
driver gear = 12
Formula =
Formula =
driven/ driver
driven / driver
30/10 = 3
24/12 = 2
Multiply both ratios together =
2x3
Overall ratio = 6:1

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Transfer case
Three functions:
1. Transfer power from two wheel to
four wheel drive.
2. Increase torque and improve
traction for “off-road” use.
3. Provide direct
drive for high
speed cruising.

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4WD transaxle

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Servicing transmissions

• Minor service - lubricant level check.

• Major service - lubricant replacement.

! Always use oil recommended by the

vehicle’s manufacturer.

If you do not use the correct oil, it could

cause serious damage to the gearbox. !
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Oil leaks

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Gear linkages

All moving parts must be checked and

lubricated during service.

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© Commonwealth of Australia 2011

ISBN: 978-1-876838-37-9

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© Commonwealth of Australia 2011 AURT206670A Inspect and service transmissions (manual)