Overhaul manual

transmissions

AURTTX008
Overhaul manual transmissions

Application
This unit describes the performance outcomes required to return a manual
transmission to original manufacturer tolerances and clearances. It involves
preparing for the task, dismantling and evaluating the transmission, carrying out the
overhaul procedures, reassembling and testing the transmission, and completing
workplace processes and documentation.

It applies to those working on manual transmissions in vehicles from all sectors of

the industry.

No licensing, legislative, regulatory or certification requirements apply to this unit at

the time of publication.

Pre-requisite Unit
NIL

Competency Field
Mechanical Miscellaneous

Unit Sector
Technical - Transmission

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Elements and Performance Criteria

ELEMENTS PERFORMANCE CRITERIA MAPPING
INFORMATION
(Describe the (Performance criteria describe the performance
essential needed to demonstrate achievement of the
outcomes) element)

1.1. Job requirements are determined from Page 2

workplace instructions

1.2. Dismantling information is sourced and Page 11

interpreted
1. Prepare to
1.3. Dismantling options are analysed and those Page 11
dismantle
most appropriate to the circumstances are
manual
selected
transmission
1.4. Hazards associated with the work are Page 2
identified and risks are managed

1.5. Dismantling tools and equipment are Page 13

selected and checked for serviceability

2.1. Transmission is dismantled in a logical Page 11

sequence according to manufacturer and
workplace procedures, and safety and
environmental requirements, and without
causing unnecessary damage to
components or systems

2. Dismantle and 2.2. Components are cleaned for evaluation Page 10

evaluate according to workplace procedures and
manual safety and environmental requirements
transmission
and 2.3. Components are measured and compared Page 16
components with manufacturer specifications and
serviceability is determined

Page 33
2.4. Component repair method is determined

2.5. Unserviceable parts are identified and Page 33

replacement parts sourced

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3.1. Overhaul information is sourced and Page 22-25

interpreted

3.2. Overhaul options are analysed and those Page 23

most appropriate to the circumstances are
selected

3.3. Overhaul tools and equipment are selected Page 13

3. Carry out
and checked for serviceability
overhaul
3.4. Components are machined, repaired and Page 30
replaced as required, and adjustments are
carried out according to manufacturer
specifications, workplace procedures, and
safety and environmental requirements, and
without causing damage to components or
systems

4.1. Transmission is assembled according to Page 30

manufacturer specifications, workplace
procedures, and safety and environmental
requirements

4.2. Tolerances and clearances are measured Page 37

against manufacturer specifications and
necessary adjustments are made
4. Assemble
transmission
4.3. Assembly of transmission is completed within Page 35
and
workplace timeframes and without causing
components
damage to other components or systems

4.4. Post-assembly testing is carried out Page 40

according to workplace procedures and
safety and environmental requirements, and
any problems detected as having been
introduced during the assembly process are
rectified

5.1. Final inspection is made to ensure work is to Page 40

workplace expectations and transmission is
presented ready for use or storage
5. Complete work
processes
5.2. Work area is cleaned, waste and non- Page 41
recyclable materials are disposed of, and
recyclable material is collected

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5.3. Tools and equipment are checked and Page 41

stored according to workplace procedures

5.4. Workplace documentation is processed Page 42

according to workplace procedures

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Knowledge Evidence
MAPPING
KNOWLEDGE OUTCOMES
INFORMATION

• Work health and safety (WHS) and occupational health

and safety (OHS) requirements relating to overhauling
manual transmissions, including procedures for using:

o specialised manual transmission overhaul tools, Page 10

equipment and machinery

o chemicals and toxic substances Page 8

o manual and mechanical lifting equipment Page 9

• Environmental requirements, including procedures for Page 10

trapping, storing and disposing of fluids released from
manual transmissions

• Types, characteristics and operating principles of manual Page 16

transmissions, including transaxles and conventional
transmissions

• Manual transmission overhaul procedures, including:

o methods for cleaning and preparing manual Page 23

transmissions for overhaul

o transmission dismantling procedures Page 23

o transmission component inspection, measuring and

evaluation procedures, including:

 non-destructive testing procedures, including dye Page 27

penetrant testing and magnetic particle testing

 assessing transmission case damage and alignment Page 30

to engine

 measuring tolerances and clearances of Page 31

components, including extension housing seal and
bushing, bearings, gear wear and damage,
synchroniser units and baulk rings, shift rails and forks,
detents and interlock systems, and input, main,
counter and output shafts

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o transmission component repair and adjustment

procedures, including:

 bearings and shims Page 34

 seals and bushings Page 34

 speedometer drive gears Page 34

o transmission assembly procedures, including procedures

for adjusting component tolerances, including:

 bearing preload Page 37

 shaft end float Page 38

 final drive bearing preload Page 38

• Post-overhaul testing procedures for manual transmissions. Page 40

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Table of Contents
1 Introduction ..................................................................................................... 1
2 Hazards or injuries at workplace .................................................................. 2
2.1 Work health and safety (WHS) ............................................................................... 2
2.2 Safety ......................................................................................................................... 2
2.2.1 Personal safety ...................................................................................................................4

2.2.2 Tools and equipment safety ............................................................................................5

2.2.3 Vehicle safety .....................................................................................................................7

2.2.4 Work area safety ................................................................................................................8

2.3 Chemicals and toxic substances........................................................................... 8

2.4 Manual and mechanical lifting equipment......................................................... 9
2.4.1 Hoists .....................................................................................................................................9

2.4.2 Jacking equipment ........................................................................................................ 10

2.5 Environmental requirements ................................................................................ 10

2.5.1 Procedures for trapping, storing and disposing of fluids released from manual
transmission handling...................................................................................................................... 10

3 Dismantling manual transmission ............................................................... 11

3.1 Dismantling information ........................................................................................ 11
3.1.1 RWD transmission disassembly procedure ................................................................. 11

3.1.2 FWD transmission disassembly procedure ................................................................. 12

3.2 Dismantling tools and equipment ....................................................................... 13

3.2.1 Transmission jack ............................................................................................................. 13

3.2.2 Flywheel wrench ............................................................................................................. 14

3.2.3 Transmission diagnostic tool.......................................................................................... 14

3.2.4 Spline alignment tool ..................................................................................................... 15

3.2.5 Pullers ................................................................................................................................. 15

4 Transmission system ...................................................................................... 16

4.1 Overview ................................................................................................................. 16
4.2 Manual transmission .............................................................................................. 16
4.3 Types, characteristics and operating principles of manual transmissions ..... 16
4.3.1 Drive train ............................................................................................................ 16
4.3.2 Gear ratio ............................................................................................................ 17
4.4 Types, characteristics and operating principles of transaxles ......................... 18

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4.5 Types, characteristics and operating principles of conventional transmissions

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4.5.1 First gear .............................................................................................................. 19
4.5.2 Second gear ....................................................................................................... 19
4.5.3 Third gear............................................................................................................. 19
4.5.4 Fourth gear .......................................................................................................... 20
4.5.5 Fifth gear.............................................................................................................. 20
4.5.6 Reverse gear ....................................................................................................... 20
4.6 Component failure diagnosis ............................................................................... 20

5 Overhauling manual transmission ............................................................. 23

5.1 Methods for cleaning and preparing manual transmissions for overhaul ..... 23
5.2 Transmission dismantling procedures .................................................................. 23
5.2.1 RWD transmission ................................................................................................ 23
5.2.2 FWD transmission ................................................................................................ 25
5.3 Transmission component inspection ................................................................... 27
5.3.1 Release bearing cleaning and inspection ..................................................... 27
5.3.2 Clutch release fork inspection .......................................................................... 28
5.3.3 Primary and secondary shaft inspection ........................................................ 28
5.3.4 FWD differential inspection ............................................................................... 29
5.4 Non-destructive testing procedures, including dye penetrant testing and
magnetic particle testing .............................................................................................. 29
5.4.1 Dye penetrant or liquid penetrant test ........................................................... 29
5.4.2 Magnetic particle testing.................................................................................. 30
5.5 Assessing transmission case damage and alignment to engine .................... 30
5.6 Measuring tolerances and clearances of components .................................. 31
5.6.1 Casing and housing ........................................................................................... 31
5.6.2 Shafts (input and output, counter) .................................................................. 32
5.6.3 Gears.................................................................................................................... 32
5.6.4 Bearings ............................................................................................................... 32
5.6.5 Shift rails and forks .............................................................................................. 32
5.6.6 Synchromesh units .............................................................................................. 32
5.6.7 Selector mechanism .......................................................................................... 33
5.6.8 End play of the shaft .......................................................................................... 33

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5.7 Transmission component repair and adjustment procedures ........................ 33

5.7.1 Transmission end clutch clearance............................................................................. 33

5.7.2 Cutch cable clearance adjustment........................................................................... 33

5.7.3 Hydraulic clutch clearance adjustment .................................................................... 34

5.7.4 Bearings and shims ......................................................................................................... 34

5.7.5 Seals and bushings ......................................................................................................... 34

5.7.6 Speedometer drive gears ............................................................................................. 34

5.8 Transmission assembly procedures ...................................................................... 35

5.8.1 RWD transmission assembly procedure ...................................................................... 35

5.8.2 FWD transmission installation procedure .................................................................... 36

5.9 Tolerance adjustments .......................................................................................... 37

5.9.1 Bearing preload .............................................................................................................. 37

5.9.2 Shaft end float ................................................................................................................. 38

5.9.3 Final drive bearing preload .......................................................................................... 38

5.10 Work completion procedures .......................................................................... 38

6 Post service procedures and documentation ........................................ 40

6.1 Final inspection....................................................................................................... 40
6.2 Workshop procedures ........................................................................................... 41
6.3 Documentation ...................................................................................................... 42

7 References .................................................................................................... 45

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1 Introduction
In this unit we can learn about the manual transmittion for both front wheel drive
and rear wheel drive. Transmission is the most important part in vehicle which
transmitte power from engine to wheels.

Nowadays the automobiles are more advanced and are coming with the modern
technologies, the more the vehicle’s technology is enhanced the complexity in the
faults will also grow high, the after sales platform should be to the highest level of
expertise to the fault and identify the root cause and to resolve the fault.

Hence, it is very important to a technician or supervisor whose knowledge is to the

extent of understanding in which system the fault exists and the ability to solve the
fault; this brings the ease of work with the necessary knowledge.

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2 Hazards or injuries at workplace

2.1 Work health and safety (WHS)

Figure 1: Work health and safety

Work health and safety (WHS) govern the safety, health and well-being of people
involved in work or employment. Irrespective of the nature of work, employees must
be able to carry out their responsibilities in a safe and secure work environment
which is free from hazards.

The objectives of WHS are to:

• ensure health, safety and welfare of employees and other people at work;

• protect the public from the health and safety risks of business activities;

• eliminate workplace risks at the source; and

• involve employers, employees and the organisations that represent them in the
formulation and implementation of health, safety and welfare standards.

2.2 Safety

Workplace injuries and hazards can be restricted at the early stage itself, by
effectively working towards safety management and workers commitment to make
the workplace safe.

Diagnosis and repair of vehicles and its components involves risks and hazards. Think
about the safety first. Following safe work practices is important while working with
any diagnosis and repair of the vehicle or any other components.

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Figure 2: Personal protective equipment

• Wear suitable PPE like safety boots, goggles, gloves and overalls.

• Do not carry heavy components or assemblies.

• Always use a transmission jack stand when removing a manual transmission.

• Store drained transmission fluids in a shelf in a lid container.

• Use proper equipment to drain hot fluid from transmission

• While cleaning transmissions use clean rags.

• Be careful not to crush your fingers or hands when installing transmission, as it is

very heavy.

• Wear safety glasses for eye protection, where appropriate. Use safety stands
whenever a procedure requires you to be under the vehicle.

• Ensure that the ignition switch is always in the off position, unless otherwise
required by the procedure. Set the hand brake when working on the vehicle.

• If you are working on an automatic transmission, set it in park unless otherwise

required by the procedure. Operate the engine only in a well-ventilated area to
avoid the danger of carbon monoxide.

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• To prevent serious bums, avoid contact with hot metal parts such as the radiator,
exhaust manifold, tail pipe, catalytic converter and muffler.

• To avoid injury, always remove rings, watches, loose hanging jewellery, and loose
clothing before beginning to work on a vehicle.

• Tie long hair behind the head. Keep hands and other objects clear of the radiator
fan blades.

• Electric cooling fans can start to operate at any time by an increase in

temperature.

• Avoid contacting the eyes or skin with acid, cooling system additives or brake
fluid. Immediately seek medical advice if these fluids are swallowed.

• Do not use petrol or highly flammable spirits when cleaning parts. All general
health and safety practices should be observed.

• OH&S requirements, including individual State/Territory regulatory requirements

and personal protection needs are observed throughout the work.

• Procedures and information such as workshop manuals and specifications, and

tooling required, are sourced.

• Methods appropriate to the circumstances are selected and prepared in

accordance with standard operating procedures.

• Resources required for transmission system inspection are sourced and support
equipment is identified and prepared.

The safety in the WHS is classified into 4 categories, namely:

• Personal safety

• Tools and Equipment safety

• Vehicle safety

• Work place safety

2.2.1 Personal safety

Personal protective equipment (PPE) is equipment designed to protect from specific

hazards and hazardous materials. It is considered to be the final protection system to
be used and it does not reduce or eliminate the hazard but only protects the person
wearing it.

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Classification of personal protective equipment:

 Eye and Face protection – The equipment must fit properly and be comfortable to
wear. A technician should wear all the time in order to protect the eyes from any
spillages and this should meet OSHA standard.

Examples – Safety glasses, face shields, chemical splash goggles

 Respiratory protective equipment – It prevents from inhaling hazardous chemicals,

asbestos, fumes, brake dusts etc.

Examples – Air purifying respirators, supplied air respirators

 Hearing protective devices – These devices help in noise reduction and also
provide comfort while working on the noisy machinery.

Examples – Ear muffs, hearing bands, ear plugs

 Head protection – It is important to wear head protection to prevent any impacts

and penetration of hazards while working under the vehicle.

Examples – Hard hats, safety helmets.

 Skin protection – Hazards like absorption of harmful substances, chemical or

thermal burns, electrical dangers, bruises, cuts, fractures can be prevented by
wearing skin protection PPE.

Examples – Safety gloves, heat resistance gloves, metal or leather mesh gloves.

 Protective clothing – Various protective clothing is available for particular hazards.

These provide protection against heat, chemical spills and fire sparks.

Examples – Uniforms, Overalls.

 Foot protection – Foot and leg injuries are caused by slippery surfaces, electrical
hazards, penetrating materials, falling, hot substances. These are prevented by
wearing foot protection equipment.

Examples – Safety boots, rubber boots.

2.2.2 Tools and equipment safety

An automotive technician must adhere to the following shop safety guidelines when
using tools and equipment.

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• Hand tool safety

Hand tools such as wrenches, screwdrivers, and hammers must be carefully used to
prevent any accidents. The following tips must be considered while using hand tools:

 keep the tools away from the oil and grease as these may turn slippery and may
cause injuries while working.

 Inspect the tools for the cracks or damages and never use the tool if found faulty.

 Use the appropriate tools for the purpose they are designed.

 Make sure the tool is of appropriate size and of professional quality.

 When using an air impact wrench, always use impact sockets.

 Never use a wrench or pliers as a hammer.

 Always be aware of striking an object with the full-face hammerhead.

 Be careful when using sharp or pointed tools.

 Do not place sharp tools or other sharp objects into your pockets.

 If a tool is supposed to be sharp, make sure it is sharp as dull tools can be more
dangerous than sharp tools.

• Power tool safety

Power tools are operated by an outside power source, such as electricity,

compressed air, or hydraulic pressure. Improper use may result in serious injury.
Always wear safety glasses when using power tools. Never try to use a tool beyond
its stated capacity.

• Electrical tool safety

Electrical tools are powered by electricity. Electrical equipment that is not properly
earthed or maintained can lead to electric shock, serious burns or even death.

 Always read and follow the operating procedures before using electrical
equipment’s.

 Ensure that the electrical tools are properly grounded before operating.

 Keep your hands, loose gloves, and loose clothing away from moving parts of
electrical tools.

 Check the wiring for insulation cracks, as well as bare wires, before using it.

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 Avoid contact with electrical tools using wet hands and water surrounding as it
leads to electrical shock. Also, when using electrical power tools, never stand on
a wet or damp floor.

 Before plugging in an electric tool, make sure its switch is in the off position.

 Always turn off the tool before unplugging the tool.

 Never leave a running power tool unattended.

 When using a bench or floor grinding wheel, check the machine and the
grinding wheels for signs of damage before using them. If the wheels are
damaged, they should be replaced before using the machine.

 Although the safety guards are designed to prevent injury, one should still wear
safety glasses and/or a face shield while using the machine.

 Make sure there are no people or parts around the machine before starting it.

 Keep hands and clothing away from the moving parts.

 Maintain a balanced posture while using the machine.

• Compressed air tool safety

Power tools that use compressed air are called pneumatic tools.

 Pneumatic tools must always be operated at the pressure recommended by the

manufacturer.

 Before using a pneumatic tool, check all the hose connections for leaks. Also,
check for airline damage.

 When using an air nozzle, always wear safety glasses or a face shield as the dirt
particles and metal pieces blown by high-pressure air can penetrate your skin or
get into your eyes.

 Never use compressed air to blow dirt from your clothes or hair or to clean the
floor or workbench.

 Never spin bearings with compressed air. If the bearing is damaged, one of the
steel balls or rollers might fly out and cause serious injury.

2.2.3 Vehicle safety

 Always be careful while lifting the vehicle on a lift or hoist. Place the hoist plates at
the jacking points only.

 Make sure the under body of the vehicle is not damaged while lifting.
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 Always use the appropriate jack to lift the vehicle and place the jack at the
jacking points only.

 Never hold the vehicle on the jack for longer time. Always use safety stands to
support the jack for a longer time.

 Apply the parking brake and shift the gear to Parking, before the vehicle is lifted
on the Hoist.

 Lock the wheels using the wheel stoppers and wheel chokes.

2.2.4 Work area safety

 The floor and benchtops of the work area must be kept clean, dry and orderly.

 Any oil, coolant, or grease on the floor can make it slippery and can result in
serious injuries.

 To clean up oil, use commercial oil absorbent.

 Keep the water off the floor as water is slippery on smooth floors, and electricity
flows well through water.

 Aisles and walkways should be kept clean and wide enough to easily move
through.

 Make sure the work areas around machines are large enough to safely operate
the machine.

 Keep an up-to-date list of emergency telephone numbers clearly posted next to

the telephone. These numbers should include a doctor, hospital, fire and police
departments.

 The work area should have a first-aid kit and eye flushing kits readily available.

2.3 Chemicals and toxic substances

Transmission fluid is most dangerous and when the fluid is drained, ensure it is saved
in respective container and recycling should be done.

And this chemical refers to its ability to damage an organ system (kidneys, liver),
disrupt a biochemical process (e.g., the blood-forming process) or disturb an
enzyme system at some site remote from the site of contact. Toxicity is a property of
each chemical that is determined by molecular structure. Any substance can be
harmful to living things.

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 Should not burn the transmission fluid, grease and other chemicals at any cause.

 Avoid pouring the fluid in land or water. Because when it mixes with water, it may
cause many dangerous problems for all living things.

2.4 Manual and mechanical lifting equipment

There are many types of lifting equipment. For transmissions, we use mostly two
types.

2.4.1 Hoists

Figure 3: Hoists

Before using the hoist, check that it has a valid and current service certificate. Do
not exceed the maximum lifting capacity as displayed on the hoist.

When using vehicle hoists, remember to:

• Align the vehicle with the centre of the hoist and drive slowly into position.

• Ensure that all locking devices are operational and in place.

• Ensure that the lifting arms are located to the vehicle jacking points.

• Wear eye protection, boots, overalls and gloves as appropriate.

• Check that there is sufficient ceiling clearance.

• Remove all tools and equipment from the area below the vehicle before lowering
the vehicle.

• Stand well clear when raising or lowering a vehicle.

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2.4.2 Jacking equipment

Figure 4: Vehicle jack

When using jacking equipment remember to:

• Wear overalls and boots.

• Check that the equipment is safe to operate.

• Locate the vehicle jacking points.

• Never work under a vehicle without axle stand in place.

• Ensure that the vehicle is on hardened level ground.

• Watch out for the protruding jacking handle.

2.5 Environmental requirements

2.5.1 Procedures for trapping, storing and disposing of fluids released

from manual transmission handling

It indicates the small metal parts that are shredded from the gears of the
transmission due to continues rotation and meshing with each gear.

Trapping fluid: Transmission fluids should be collected by using proper tools like funnel
and trays.

Storing fluids: Transmission fluids should be stored in spill proof containers and be
labelled to identify easily. It should not be mixed and stored with other fluids.

Disposing fluid: Used transmission fluids should be taken to your local used oil facility
for recycling. Many council facilities such as transfer stations, waste management
center’s or landfill sites accept used oil.

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3 Dismantling manual transmission

Figure 5: Exploded view of manual transmission

3.1 Dismantling information

3.1.1 RWD transmission disassembly procedure

1. Remove the release bearing housing, oil seal, input shaft shims and front bearing
ring from the front housing.

2. Remove the gear lever and extension housing from the transmission tail shaft
housing.

3. Remove the speedometer driven gear from the tail shaft housing.

4. Remove the retaining pin from the gear lever control socket and withdraw the
lever control socket from the gear selector shaft.

5. Remove the transmission through bolts from the transmission housing assemblies
and withdraw the tail shaft housing.

6. Attach a puller to the front bell housing and withdraw the front housing from the
centre housing. Secure the central housing and gear assembly into a vice.

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7. Remove the speedometer drive and snap rings from the main shaft.

8. Remove the 1st – 2nd , 3rd – 4th and reverse selector rod roll pins from the selector
shafts.

9. Remove the selector forks. Selector shafts detent springs, interlocks and detent
balls from the central housing.

10. Lock the transmission into lm gear and 3m gear to lock the rotation of the main
shaft. Remove the main shaft lock nut, thrust washer and reverse gear from the
main shaft.

11. Remove the main shaft, lay shaft and reverse idler gear shaft retaining plate
from the central housing and remove the reverse idler gear and idler shaft.

12. Tap the main and lay shafts with a soft faced hammer to remove both shafts
from the central housing.

13. To disassemble the main shaft remove the following components in sequence.

• Input shaft and needle roller bearings.

• 4th gear synchro baulk ring.

• Snap ring

• 3rd, 4th synchro hub assembly.

• 3rd gear synchro baulk ring and 3rd gear

• 1st gear, sleeve and synchro baulk ring.

• 1st, 2nd, synchro bulb.

• 2nd gear synchro baulk ring and 2nd gear.

Clean all transmission components, clean gasket material from the trnasmsiion
housings and prepare all components for inspection.

3.1.2 FWD transmission disassembly procedure

To gain access to transmission components in a front wheel drive vehicles the

transmission must be dismantled completely.

Once disassembled, all components must be thoroughtly cleaned and inspected for
damage, where evidence of damage to components exists, replace as necessary.

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1. Ensure that the transmission is securely mounted onto a transmission stand or on

a work bench.

2. Remove the 5th gear end housing, attach a primary shaft lock tool to the shaft
to the transmission stand or workbench.

3. Select 1st and 3rd gear to lock the transmission shafts so that they do not rotate
and remove the primary and secondary shaft lock nuts.

4. Remove the reverse light switch, reverse idler shaft lock bolt, interlock guide bolt,
detent springs and ball assemblies from the transmission housings.

5. Remove the primary shaft 5th gear assembly and remove the transmission rear
housing securing bolts. Remove the rear housing from the front housing.

6. Remove the reverse idler shaft and reverse gear from the front housing.

7. Remove all the selector fork roll pins from the selector shafts.

8. Lift the selector fork and selector shaft assemblies from the transmission.

9. Remove the primary shaft front bearing locking plate, grasp both the primary
and secondary shafts and lift from the transmission front housing.

10. Lift the differential carrier assembly from the housing.

3.2 Dismantling tools and equipment

• Transmission jack

• Flywheel wrench.

• Transmission diagnostic tool.

• Spline alignment tool.

• Pullers (hydraulic)

3.2.1 Transmission jack

These are specialty jacks used to raise and lower a vehicle’s transmission from the
bottom of the vehicle. They are similar to a floor jack but have a large cradle with tie
downs to secure the transmission and a way to tilt the transmission cradle so it can
match the angle of the engine it will be bolted to. This allows the mechanic to raises
the transmission into place for securing to the engine.

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Figure 6: Transmission jack

3.2.2 Flywheel wrench

Figure 7: Flywheel wrench

Flywheel wrench is a special wrench used to turn the flywheel and rotate the
engine. It also holds the flywheel or flex plate when torqueing the flywheel or
harmonic balancer bolts.

3.2.3 Transmission diagnostic tool

This tool helps to avoid the transmission problems become a big hassle. As the most
common trouble codes come from the transmission of your vehicle, with a
transmission diagnostic tool, it will send you a fault code if any. All you need to do is
to fix an error code.

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Figure 8: Transmission diagnostic tool

3.2.4 Spline alignment tool

Figure 9: Spline alignment tool

This tool is used for alignement purpose and replicate the shaft and splines of the
vehicle’s drive shaft. They are made of high quality polypropylene injected plastics
and ensure perfect alignment of the clutch.

3.2.5 Pullers

Figure 10: Puller

Unique combination of a hydraulic jaw and a strong back puller is used in various
applications. Hydraulic spindle facilitates easy and quick dismounting, effortless
generation of force.

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4 Transmission system

4.1 Overview

The manual transmission is a system of gears that transfer the engine’s power to the
drive wheels of the car. The transmission receives torque from the engine through its
input shaft, when the clutch is engaged. This torque is then transferred through a set
of gears that either multiply it or transfer it directly. The resultant torque turns the
transmission’s output shaft, which is indirectly connected to the drive wheels.

4.2 Manual transmission

The transmission changes the ratio of the engine speed and torque to the wheels by
connecting gears in various combinations. The transmission allows the gear ratio
between the engine and the drive wheels to change as the vehicle speeds up and
slows down. If a gear with 10 teeth drives a gear with 20 teeth, the drive would have
2:1 ratio. As the driving gear will need to complete 2 revolutions to cause the drive
gear to rotate once.

The transmission is connected to the engine through the clutch. Therefore, the input
shaft of the transmission rotates at the same revolutions per minute as the engine.
Due to the number of rotating shafts and gears, transmission use a wide range of
bearings. Common bearings found in transmissions include:

• Open and sealed ball bearings

• Roller bearings

• Tapered roller bearings

• Needle roller bearings (plain, caged and sealed)

• Bronze bushes (plain and porous)

4.3 Types, characteristics and operating principles of manual

transmissions

4.3.1 Drive train

A drive train transmits the power developed in the engine to the driving wheels of a
vehicle. The two types generally used are front wheel drive and rear wheel drive. In
front wheel drive vehicles, the final drive and the differential gears are included in
the transmission housing. This unit is called Transaxle.

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Figure 11: Manual transmission drive train

4.3.2 Gear ratio

Figure 12: Manual transmission gear ratio

Gear ratio express the number of turns the drive gear makes compared to one turn
of the driven gear it meshes with. Gears are wheels with teeth that mesh together.

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This can happen either directly, as in a transmission where the wheels touch each
other or indirectly, as in a camshaft drive where a belt is used to make one gear turn
another.

The gear ratio is dependent on the size of the two gear wheels working together.

Gear ratio rules

• The larger wheel will always rotate slower than the smaller wheel.

• The smaller wheel has to turn faster to keep up with the larger wheel.

4.4 Types, characteristics and operating principles of transaxles

Transaxle transmission use fully synchronized, constant mesh helical gears for all
forward speeds and use spur or sliding gears for the reverse gears.

Transaxle have two separate shafts; a primary shaft and secondary shaft. The engine
torque is supplied to the primary shaft, which in turn multiplies or reduces the torque
by gearing to the secondary shaft.

The primary shaft is commonly located above and parallel to the secondary shaft.
The main gear will free wheel around the secondary shaft unless they are locked to
the shaft by the synchroniser.

A pinion gear is machined onto the end of the secondary shaft and is in constant
mesh with the differential ring gear. The ring gear is fastened to the differential case.
This case holds the differential assembly which consists of side gears and spider
gears.

When the secondary shaft rotates the pinion gear, the differential ring gear to
rotate. This torque rotates the other differential gears, which in turn rotate the
vehicles drive axles and wheels.

4.5 Types, characteristics and operating principles of

conventional transmissions

Power flow in front wheel drive transaxles is similar to conventional rear wheel drive
transmissions, with the only difference being that the secondary shaft is directly
connected to the differential.

Most transaxles use the two-shaft system with synchromesh gears.

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Overhaul manual transmissions

Figure 13: Conventional transmission

4.5.1 First gear

Engine torque enters the transmission through the primary shaft; the first/second
synchronizer sleeve has been selected towards first gear (located on the output
shaft) and has locked the first/second gear to the secondary shaft.

This allows engine torque to travel from the primary shaft across the selected gears
and along to the pinion gear that is in constant mesh with the ring gear. From here,
engine torque travels down towards the differential to be delivered to the driving
road wheels.

4.5.2 Second gear

Second gear is accomplished by the movement of the first/second synchroniser

towards the free-wheeling second gear on the secondary shaft. Consequently,
engine torque travels along the primary shaft to the second gear and across the
new fixed second gear on the output shaft and finally to the ring gear and drive
shafts.

4.5.3 Third gear

Third/fourth gear synchroniser hub on the primary shaft is moved towards the engine.
This locks the freewheeling third gear to the primary shaft and drives the third gear
on the secondary shaft. The power flow is now through the locked 3rd gear on the
primary shaft through to the 3rd gear on the secondary shaft through to the pinion
and ring gear.

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Overhaul manual transmissions

4.5.4 Fourth gear

Movement rearward by the third/fourth gear synchroniser sleeve engages drive to

the 4th gear on the primary shaft. This drive now travels across to the secondary
shaft, down then length of the shaft to the pinion and ring gear assembly and out
toward the driveshaft and road wheels.

4.5.5 Fifth gear

The fifth gear synchroniser is moved towards the engine end of the transmission,
which in turn locks the free-wheeling helical gear to the primary shaft. This allows
engine torque to travel up the primary shaft across the meshed fifth gears and down
to the end of the secondary shaft, where the pinion is in mesh with the ring gear and
driveshaft. This results in an overdriving effect.

4.5.6 Reverse gear

To select reverse gear, the reverse idler gear is moved towards the engine end of
the transmission, which enables the spur gears on the reverse idler to mesh with both
the primary shaft and the secondary shaft. Introducing this, reverse idler gear rotates
the secondary shaft in the opposite direction than the primary shaft; this reverse
rotation is transferred to the pinion and driveshaft resulting in reverse motion.

4.6 Component failure diagnosis

Trouble Possible Cause Service Information

Shift lever does not Shift lever ball unit is stiff Repair or replace
operate smoothly or
cannot be operated at Shift control rod joint is stiff
all
Shift control rod is bend Replace bend rod

Lack of lubrication on shift Clean an lubricate with

linkage pivot recommended grease

Gearshift gate incorrectly Adjust linkage

adjusted

Excessive shift lever Shift control rod brushing is Replace

play worn

Weak spring in the shift leverl

ball assembly

The bushing in shift lever ball

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Overhaul manual transmissions

unit is worn

Hard shifting Selector shaft is bent Replace

Transmission selector Lubicate

mechanism is not sufficiently
lubricated

Insufficient oil Top up

Incorrect oil quality Drain and refill with

recommended lubrication

Selector fork and selector Replace

shafts are worn

Synchroniser ring is worn Replace

Worn cone surface of gear

Incorrect contact between

synchroniser baulk ring and
cone surface

Excessive primary shaft Readjust

preload

Excessive play in axial Replace worn component

direction of each gear

Bearings worn Adjust or replace

Synchroniser shift plates are Replace

fatigued

Noise Insufficient oil Top up

Deterioration of oil quality Drain and refile with

recommended lubricant

Worn sliding surfaces on gear Adjust or replace

shafts

Worn sliding surface on gear Replace

Excessive backlash

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Overhaul manual transmissions

Surface of gear is damaged

Foreign matter in transmission Repair or Relace

Differential gear is damaged

Ring riverts are loose

Bearings worn or out of Repair or adjust

adjustment

Gear clash Excessive enigne idle speed Adjust engine idle rpm

Inadequate clutch pedal Check clutch adjustment

reserve resulting in excessive
spin time Inadequate clutch
diengagement

Excessive disc run out Replace

Flywheel housing Realign

misalignment

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5 Overhauling manual transmission

5.1 Methods for cleaning and preparing manual transmissions for

overhaul

Cleaning the transmission before removing can show whether the sections have any
damage and any damage on the housing. Hence, it reduces the risk of breaking
the case.

By cleaning the outer area of the transmission with any oil can provide a proper grip
to hold the transmission.

While overhauling the transmission, it is important to keep the gear assembly and
other internal components clean from dust by cleaning the outer portion of the
transmission.

Use a degreaser to clean the outside of the pan and brake cleaner to clean the
inside and the gasket mating surfaces.

5.2 Transmission dismantling procedures

In transmission there are two types, they are:

• RWD transmission

• FWD transmission

5.2.1 RWD transmission

Figure 14: RWD transmission

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Overhaul manual transmissions

While dismantling the rear wheel transmission, it is important that a technician should
select the appropriate manufacturer’s repair manual when carrying out the
transmission repairs to ensure that the correct torque settings, pre load adjustments
and special tools are used.

It is also important to ensure that each of the following transmission related

components are operating correctly and are not the source of the fault.

• Clutch

• Clutch linkages

• Selector linkages

• Driveline

• Differential

Removal procedure

• Disconnect the negative terminal form the battery.

• From inside the vehicle, remove the gear lever boot and lever.

• Raise and support the vehicle.

• Position a clean drain tray under the drain plug. Clean around the area of the fill
and drain plugs.

• Remove the drain and fill plugs and allow the transmission to drain.

• Mark the differential pinion flange and then rear driveshaft flange so that they
can be installed in their original positions.

• It may be necessary to remove hand brake cables or an exhaust section to allow

the transmission to be removed.

• Disconnect the speedometer cable from the transmission.

• Disconnect wiring and harnesses from the transmission.

• Disconnect the starter cable at the starter terminal, remove the starter motor
retaining bolts. Remove the starter assembly.

• When the lubrication is completely drained, clean the drain plugs and refit to the
transmission.

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Overhaul manual transmissions

• Inspect the fluid that collects in the drain tray. Look for metal in the oil. Metal
shows up as shiny, metal particles or flakes. An excessive amount of metal could
mean internal damage to transmission components.

• Support the transmission assembly with a transmission jack.

• Remove the transmission cross member.

• Remove the transmission bell housing bolts.

• Move the transmission rearward until the input shaft clears the flywheel, and
clutch assembly then lower the jack and remove the transmission.

Clutch release bearing and lever removal

• Slide the clutch fork out from under the pivot bolt/or unclip from the ball stud and
remove the lever and bearing assembly.

• Remove the retaining clips from the release bearing and from the clutch fork.

• For units, which have a separate release bearing and hub, refer to the
manufacturer’s specifications for recommended release bearing removal
procedure.

5.2.2 FWD transmission

Figure 15: Front wheel drive (FWD) transmission

Removal procedure

• Disconnect the negative terminal from the battery.

• Raise the front end of the vehicle and support it with safety positioned under the
jacking points of the vehicle or raise the vehicle on a two post hoist.

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Overhaul manual transmissions

• Position a clean drain tray under the transmission drain plug. Clean around the
area of the fill and drain plugs.

• Remove the drain and fill plugs and allow the transmission oil to drain.

• Disconnect the speedometer cable from the transmission.

• Release the clutch cable adjuster and remove the clutch inner cable from the
clutch release fork.

• Remove the electrical wiring from the bell housing bolt clips. Remove both front
wheels.

• Remove the undercover and side covers.

• Disconnect both lower suspension arms from the wheel hub assembly.

• Disconnect the tie rod ends from the wheel hub assembly.

• Pull out the drive shaft horizontally from the transaxle to prevent damage to oil
seal lip.

• It may be necessary for some vehicles to attach an engine support bracket or

lifting tackle on the rear engine lifting bracket and lift the engine to remove
weight off the transmission mountings. Note: a floor jack with a wooden pad may
be used to support engine oil pan.

• Separate the transmission control rod or gear change rod.

• Remove gearshift stabilizer bar from the manual transaxle.

• When the lubricant is completely drained clean the drain plugs and refit to the
transmission.

• Inspect the fluid that collects in the drain pan. Look for metal in the oil. Metal
shows up as shiny, metal particles or flakes. An excessive amount of metal may
indicate internal damage to transmission components.

• Disconnect the starter cable at the starter terminal, remove the starter motor
retaining bolts. Remove the starter assembly.

• Position a transmission jack to support the transmission.

• Remove the remaining transmission mounts.

• Remove the transmission to engine mounting bolts.

• Remove the transmission bell housing bolts.

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Overhaul manual transmissions

• Lowering the transmission on to a jack

• Man, oeuvre the transmission jack and slide the transmission away from the
engine, ensuring that the transmission remains horizontal. This allows the input shaft
to slide away from the clutch assembly without distortion.

• Lower the transmission jack and remove the transmission from under the vehicle.

5.3 Transmission component inspection

5.3.1 Release bearing cleaning and inspection

• Wipe all oil and dirt off the release bearing. The bearing is pre-lubricated and
should not be immersed in solvent.

• Inspect the release bearing hub bore for burrs, which may cause the assembly to
drag on the transmission bearing retainer. Any such burrs should be removed. If
burrs are found inspect the transmission input shaft bearing retainer for evidence
of scoring. Any scoring should be removed.

• Hold the bearing inner race and rotate the outer race while applying pressure to
it. If the bearing rotation is rough or noisy, replace the release bearing.

• Inspecting a release bearing

• Fill the groove in the bearing hub bore with the specified grease.

• Prior to release bearing installation, apply a light film of the specified grease on
both sides of the release lever fork where it contacts the release bearing hub and
hub assembly. This lubricates the two contacting surfaces and reduces wear and
prevents noise (squeaking clutch fork).

• Care must be exercised when applying lubricants to avoid excessive grease from
contaminating the clutch plate linings.

Most release bearing failures are caused by incorrect clutch pedal adjustments. If
the clutch linkage does not have enough free travel, the release bearing will
constantly touch the release fingers and will spin whenever the engine is running. If
the bearing is not correctly installed on the hub, failure may occur.

Release bearing failure can be caused by the release lever contact points being out
of alignment. Misalignment between the engine and the transmission can cause
release bearing failure. Other symptoms of misalignment are: transmission jumping
out of gear, driveline vibration, excessive clutch spin time resulting in gear clash, and
excessive transmission gear wear.

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Overhaul manual transmissions

5.3.2 Clutch release fork inspection

RWD

Clean and inspect the clutch release fork for signs of cracking, worn release bearing
supports and damaged pivot points. If evidence of these failures is present, replace
the clutch release fork.

FWD

Check for evidence of wear in the transmission housing where the release lever is
supported. If wear is evident, the transmission housing should be repaired or
replaced.

Check for wear on the lever shaft. Ensure that the shaft rotates freely in the
transmission front housing.

Casing and Housing

The casting should be inspected for cracks and damages. A case with worn bearing
bores should be replaced. Other damages such as damaged threads may be
repairable. Any burns on the mounting surface should be removed as these will
affect alignment of the parts.

5.3.3 Primary and secondary shaft inspection

Prior to disassembly, both the primary and secondary shaft gear clearances must be
checked using a feeler gauge placed between the gears, gear sleeve, thrust
washer or bearing surface.

Clearances that are outside of manufacturer's specifications indicate a worn gear,

gear sleeve, thrust washer or bearing surface. The shaft will need to be dismantled
for further inspection.

The primary shaft clearance checks are made between the following gears, thrust
washers or bearing surfaces:

• 3rd gear and thrust washer

• 4th gear and thrust washer

• 5th gear and gear sleeve

The secondary shaft clearance checks are made between the following gears,
thrust washers or bearing sleeves:

• 1st gear and the differential drive gear

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Overhaul manual transmissions

• 2nd gear and thrust washer

• 3rd gear and thrust washer

• 4th gear and thrust washer.

5.3.4 FWD differential inspection

If any of the differential components indicate excessive wear or damage, the

component must be replaced. The components are

• Ring gear

• Bearings and thrust washers

• Side gears and spiders’ gears

• Carrier and housing

• Cross pin

• Roll pin

5.4 Non-destructive testing procedures, including dye penetrant

testing and magnetic particle testing

5.4.1 Dye penetrant or liquid penetrant test

Figure 16: Liquid penetration test

Before starting the process, cleaning is important ranging from grinding and wire
brushing to merely wiping the part with a rag moistened with the cleaner/ remover.

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Overhaul manual transmissions

The surface needs to be free of dirt, rust, scale, paint, oil, and grease, and be
smooth enough to wipe off the penetrant without leaving residue.

Apply the penetrant by spraying or applying it with brush giving a soak time of
maximum 30 minutes not longer than that so it does not dry. All penetrant should be
removed with clean, dry, lint-free rags until thoroughly clean.

The transmission should be rubbed vigorously until the penetrant is not visible on the
dry rags. Next, cleaner/ remover should be sprayed on another clean, dry, lint-free
rag and used to vigorously rub the part again until there is no penetrant visible on
the rag.

Then apply or spray light coating of developer on the part being examined. The
dwell time for developer is typically 10 to 60 minutes. Then, examine the part within
the time frame designated. If there is a crack or a minute flaw in the housing, then
the penetrant bleeds out which must be wiped out.

5.4.2 Magnetic particle testing

Figure 17: Magnetic particle testing

It is a non-destructive testing method and used to detect surface and slightly

subsurface flaws in most ferromagnetic materials such as iron, nickel, and cobalt,
and some of their alloys.

The process begins by running a magnetic current through the component. This will
create a “flux leakage field” at the site of the damage. The second step involves
spreading metal particles over the component. If there are any flaws on or near the
surface, the flux leakage field will draw the particles to the damage site. This
provides a visible indication of the approximate size and shape of the flaw.

5.5 Assessing transmission case damage and alignment to engine

• First be sure that the crank flange is clean/rust free. Bolt up the flywheel and
torque the bolts to spec.

• Set up your dial indicator perpendicular to the flywheel clutch surface. This can
be done by attaching the magnetic base to the oil pan or engine block.

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Overhaul manual transmissions

• Be sure to zero out your indicator and mark your starting point. Then slowly crank
the engine by hand for one full revolution (360*) to be sure you come back to a
zero reading at your starting point. Do this one more revolution to ensure
repeatability and that your dial indicator is mounted securely.

• Once you have your starting point established make another rotation and note
for any low (negative) readings. If you have any negative readings, mark that
spot and that will be your new zero starting point. If you have no negative
readings move on to the next step.

• Now that you have verified your zero-starting point, make a couple revolutions
and note any high spots. You should end up with no more than .005” TIR. As
always, the lower number the better.

• If you end up with more than .005” TIR, there is a possibility that your flywheel is
warped, damaged or needs to be resurfaced. At this point it may also be
necessary to check the crank flange for run out as well as to be sure that it does
not have any damage.

• Once you have your flywheel runout within spec, you are ready to move onto
checking the bell housing alignment.

Precautions to be taken while aligning

• Raise the transmission up into the transmission tunnel and align it with the clutch.

• Align the clutch and cover assembly using the special tool and tightening bolts to
specific torque.

• Make sure that the release bearing sleeve end of the clutch fork is in place and
slide the sleeve onto the main shaft.

• Make sure there is no wire or cables that are in between the transmission and the
engine.

• Using long and lengthy bolts that can guide with the engine housing which can
align the transmission.

• Also use the dowel pins as guide for a proper fit.

5.6 Measuring tolerances and clearances of components

5.6.1 Casing and housing

The casting should be inspected for cracks and damages. A case with worn bearing
bores should be replaced. Other damages such as damaged threads may be

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Overhaul manual transmissions

repairable. Any burns on the mounting surface should be removed as these will
affect alignment of the parts.

5.6.2 Shafts (input and output, counter)

Inspect shafts for excessive wear and spline or tooth damage. Their bearing surface
should be examined for possible wear or damage from defective roller bearings.

The same should be done for countershaft the spigot on the main shaft of rear wheel
drive transmission and the shaft of trans axel that carry needle rollers for the constant
mesh gear. Long shaft such as main shaft should also be checked for runout on V
block using dial gauge.

5.6.3 Gears

Check for burrs and chipped teeth on all gears. Using feeler gauge, check the end
play of countershaft gears and constant mesh gears. Adjust by fitting selective thrust
washer or snap rings as required. The bores of gears such as the constant mesh gears
and cluster gear should be checked to see that the bearing surface has not
become worn or damaged by the roller bearings

5.6.4 Bearings

After being thoroughly cleaned, bearings should be examined for the condition of
their raceways and external surfaces, the amount of cage wear, the increase in
internal clearance and degradation of tolerances. These should be carefully
checked, in addition to examination for possible damage or other abnormalities, in
order to determine the possibility for its reuse.

5.6.5 Shift rails and forks

Check for smooth slide movement of fork on the rail. Check the fork and rails for any
bends, cracks or excessive wear. Check the ball and spring for wear and tension,
since this will affect the gear shifting.

5.6.6 Synchromesh units

Synchroniser should be checked in following ways:

• Examine the splines of the synchroniser sleeve and hub and check the sleeve for
free movement.

• Examine the baulk rings for wear and damage to the teeth and insert slots.

• Check gap between baulk ring and gear with feeler gauge.

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Overhaul manual transmissions

• Check each baulk ring by holding it hard and turning it against its mating cone on
the constant mesh gear.

• Examine the ends of the inserts and bead for excessive wear.

• Check for the springs for installed positioned.

5.6.7 Selector mechanism

• Check wear of the selector forks where they are in contact with the synchromesh
sleeves.

• Check the dents balls and parts of the interlock device for wear or damage

• Check the dent and inter lock springs for any distortion.

• Check the selector rails for condition particularly the edge of the detent grooves
which can become worn from the action of the dent balls.

5.6.8 End play of the shaft

Transmission main shaft can be done by inserting a feeler gauge between the gear
and the shoulder on the shaft. This can also be done between two gears or between
a gear and a bearing.

Constant mesh gear is free to rotate on the shaft, but usually have a specific end
float. Excessive end float can cause jumping out of gear or poor synchroniser action;
that kind of gears are retained on the shaft by snap ring and its end float can be
adjusted by thin or thick snap ring

5.7 Transmission component repair and adjustment procedures

5.7.1 Transmission end clutch clearance

Once the correct pedal free play and height have been achieved, whether cable
or hydraulically operated, it is necessary to ensure that there is clearance between
the release bearing and the diaphragm on the clutch pressure plate.

5.7.2 Cutch cable clearance adjustment

The clutch outer cable is fixed between the bulkhead end and the transmission end.
Typically, either the outer or inner cables will provide an adjustment facility
comprising of an adjustment nut and a locking nut. By releasing the locking nut and
adjusting nut, the clearance can be adjusted to specification.

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Overhaul manual transmissions

5.7.3 Hydraulic clutch clearance adjustment

The hydraulic clutch clearance adjustment facility is generally located on the

pushrod, which is fitted between the clutch slave cylinder and clutch fork. The
adjustment is achieved by adjusting the ball nut on the end of the pushrod, which
extends or contracts the length of the push rod.

5.7.4 Bearings and shims

Bearings should be examined for the condition of their raceways and external
surfaces, the amount of cage wear, the increase in internal clearance and
degradation of tolerances. These should be carefully checked, in addition to
examination for possible damage or other abnormalities, in order to determine the
possibility for its reuse.

The differential, primary and secondary shafts must have a bearing clearance. This
clearance is achieved by either adding or removing shims between the main
bearing of each shaft and the differential carrier main bearing. To determine the
correct shim thickness, place 3 or 4 short pieces of solder between the main bearing
of each shaft and the differential carrier main bearing.

5.7.5 Seals and bushings

Seals are used because to avoid the leaks in the transmission. Wherever specified,
sealants will be applied. When transmission overhauling is done, it is mandatory that
old seal should be replaced with new one.

These bushings may contain an oil hole that must match up with the oil supply
passage in the housing. This is true of many bushings in transmission. Never deprive a
spinning shaft of its lubrication. Bushings are made of brass or soft metal so they wear
before the slip yolk.

5.7.6 Speedometer drive gears

Mechanical speedometers measure the speed of a car by being linked

mechanically with the gearbox output shaft. Since this shaft lies 'downstream' of the
gearbox, the speed with which it rotates is independent of gear changes and so
gives a true measure of the road speed.

Inside the gearbox, the output shaft contains a gear wheel which rotates with the
shaft. Linked to this gear wheel, and driven by it, is a small pinion gear, the
speedometer chive pinion, which links in turn to the speedometer cable that runs up
to the speedometer itself.

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Overhaul manual transmissions

5.8 Transmission assembly procedures

5.8.1 RWD transmission assembly procedure

The re-assembly procedure is carried out in the reverse order of the disassembly
procedure described previously.

However, on re-assembly, particular attention must be paid to the rotating and

sliding components of the transmission to ensure long service life. Each component
must be assembled using the manufacturer's recommended lubricant, clearances
and torque settings.

1. Each synchroniser hub and sleeve assembly must be installed onto the main
shaft with its installation marking facing forward. The hub and sleeve shift plate
retaining springs must be installed so that the ends of the springs arc 120' apart
to ensure even spring tension is maintained.

2. Each gear must be lubricated and assembled onto the main shaft with new
snap rings ensuring that each gear rotates freely on the main shaft and gear
clearance is within the manufacturer's specifications.

3. When assembling the main shaft and lay shaft into the central housing, the
correct bearing to housing clearance is achieved by using the correct size shim.

4. The correct reverse idler gear clearance is achieved by using the correct size
shim between the idler gear and the thrust washer when it is installed.

5. Reverse gear end float is adjusted to the recommended clearance by using the
correct size shims.

6. Ensure that the main shaft lock nut is torqued to the manufacturer's
recommended torque setting and that the lock nut is pined onto the main shaft.

7. Sealant is applied sparingly to each of the transmission housings on assembly to

prevent damage to the transmission internal bearings and gears. Applying
excessive amounts of sealant can cause premature failure of transmission
components.

8. The input shaft and lay shaft front bearings are installed using the correct
installation tool.

9. The input shaft front housing and shims are seated correctly and the end float is
adjusted with specification.

10. Ensure that the gear lever is installed checking that all gears can be selected
prior to refitting the transmission to the vehicle.

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Overhaul manual transmissions

11. Ensure that the release bearing and hub assembly is correctly installed on to the
clutch release fork before installing the transmission.

12. Ensure that the bell housing of the transmission and the cylinder block mating
surfaces are clean and free from obstruction.

13. Position the transmission on to the transmission jack.

14. Raise the transmission and move it forward towards the engine until the input
shaft splines enter the clutch hub splines and the bell housing is positioned
against the engine block.

15. Install the transmission securing bolts and lightly secure evenly to the engine
block.

16. Connect the wiring to the reverse light switch and the speedometer cable.

17. Raise the transmission and install the cross member. Torque the bell housing and
cross member bolts to specification.

18. Reconnect the exhaust system.

19. Remove the transmission jack.

20. Install the drive shaft to the transmission output shaft.

21. Connect the rear driveshaft flange of the driveshaft to the differential pinion
flange ensuring that the mating marks are in alignment.

5.8.2 FWD transmission installation procedure

1. Ensure that the release bearing and hub assembly is correctly installed on to the
clutch release fork before installing the transmission.

2. Ensure that the bell housing of the transmission and the cylinder block mating
surfaces are clean and free from obstruction.

3. Using a transmission jack install the transaxle assembly by carefully aligning the
input shaft through the clutch plate spline and locate the bell housing onto the
engine guide bushings. Insert and lightly secure the bell housing bolts evenly to
ensure that the transmission is aligned correctly to the engine.

4. Install the lower transmission mount and engine cross member. Ensure mountings
are not twisted. Lower the engine and torque the mounting bolts and as the bell
housing bolts to the recommended torque settings.

5. Install the top engine mounting to the transmission and secure to the body.
Torque to specification.

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Overhaul manual transmissions

6. Install the starter motor and connect the starter motor wiring.

7. Install right hand drive shaft into the transmission. Slide the shaft horizontally into
the differential, supporting it at the inner driveshaft joint to prevent damage to
the oil seal lip. Ensure that the shaft is inserted fully into the transmission until the
circlip has engaged into the differential side gear. Attempt to lightly extract the
shaft to confirm clip has been located correctly.

8. Reconnect the lower ball joint, tie rod arm, brake calliper, side covers and road
wheel. Note: torque lower arm ball joint bolts and road wheel nuts to
manufacturer's specification.

9. Reconnect the stabiliser bar to the lower suspension arm control link. Tighten nuts
to specification.

10. Reconnect the gearshift stabiliser and gear selector rod to the transmission.

11. Reconnect the wiring harness clips, clutch cable mounting brackets and
connect the clutch cable to the release lever. Check clutch cable adjustment.

12. Reconnect the left hand driveshaft, ball joint, tie rod end, brake calliper and
road wheel and torque to specifications.

13. Refit the speedometer driven gear and connect the speedometer cable.

14. Top up the transmission with lubricant as required. Note: check drain plugs for
security and refit the lower engine cover.

15. Connect the negative battery cable and lower the vehicle to the floor.

16. Consult the manufacturer's repair manual to carry out clutch pedal height and
clearance adjustments.

5.9 Tolerance adjustments

5.9.1 Bearing preload

Bearings apart from being mounted on the shafts and housings have to be
preloaded properly for their proper functioning. Preloading is the methodology by
which we remove the internal clearance in the bearing by applying a permanent
thrust load to it.

In other terms we can say that we push the bearing to such an extent that it has to
move only in the groove (raceway) and cannot move axially in either direction. By
preloading, we tend to eliminate all the unnecessary clearances, which induces a
rigidity to the bearings and thus to the system, the bearing supports.

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Overhaul manual transmissions

Figure 18: Bearing preload

5.9.2 Shaft end float

The end float allows room for the formation of an oil film, misalignment, and thermal
expansion of the bearing components. End float is the total distance the shaft can
move between the two thrust bearings and is sometimes called thrust bearing
clearance.

With the help of a dial indicator, the end float can be measured. It should be
located as close as possible to the shaft. Axial proximity probes should be used to
measure the gap along with dial indicator. By pulling the shaft by hand, the shaft
movement can be measured in the dial indicator. It gives the measurement or size
of shim that can be used in the shaft to reduce play if required.

5.9.3 Final drive bearing preload

Excessive preloading also causes the bearing to get loaded extremely, causing
changes in the power requirement required to drive the system. A very high amount
of torque is necessarily required to overcome this tightness in the bearing and thus
increasing the energy or power demand for driving the system.

Various methodologies for the preloading of the bearings can be found. These
methods of preloading are as important as the design and selection of the bearings.

5.10 Work completion procedures

1. Check for the sensors that had to be installed on the transmission housing.

2. Inspect the linkages and the gear cables for routing.

3. Check for shift cable housings for proper installation.

4. Inspect for oil level.

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Overhaul manual transmissions

5. Check for oil seal installation position.

6. Check for shift mechanism for correct operation in all gears.

7. Wherever specified apply sealant and gasket.

Final inspection procedure

• Recheck for the throw out bearing and the fork for operation of the clutch.

• Check for the torque on all oil pan bolts and rear cover on the transaxle.

• Check for the end float on shafts.

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6 Post service procedures and documentation

Any industry that uses heavy vehicles, faces the risk of workers being injured while
fitting tyres. Problems frequently arise during work involving industrial type split rims,
as used on earth moving machinery, trucks, forklifts and rural use vehicles, with both
bolts together and lock ring type rims.

Over inflation is a common contributor, usually due to use of an unregulated

compressed air supply; in other words, using an air outlet on a workshop or shed
compressor without a pressure regulator and pressure gauge, or bypassing the air
pressure regulator, and/or inflating the tyre/tube higher than the manufacturer's
recommendations.

Some other factors which may contribute to an injury include:

• miss-matching of split rim assemblies (involving all the elements of a rim including
the lock rings).

• retainers not being reassembled as matching sets when more than one rim is
being refitted with new tyres.

• rims being fitted with a new tyre/tube when they are worn, corroded or damaged
beyond their serviceable life (according to manufacturers' standards and
recommendations).

6.1 Final inspection

• Check for position of wheel nuts for any movement or looseness.

• Check for cracked or broken nuts due to over tightening.

• Ensure there is no leakage ports on the tyres and puncture on surfaces.

• Make sure there is no wobbling of tyres when the wheel is spinning.

• Visually check for distortion of the rims.

• Check for worm components of suspension which might cause tyre vibration.

• Check for proper seal and any damage to sidewall which might cause deflation.

Workers have been seriously injured by blasted parts of the tyre/rim assembly or by
the force of the sudden release of air pressure which has thrown them to the hard
surface floor. In some cases, this has caused permanent damage to hearing and
eyesight.

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Tyre pyrolysis can also cause a tyre to fail. This happens when a tyre has been
damaged internally after the vehicle has had contact with electrical power lines. In
many cases the tyre damage cannot be detected by visual inspection alone, and
the tyres explode many hours or days after the contact has occurred.

A basic preventative measure is to use a remote tyre filling hose fitted with a
pressure gauge when inflating tyres. This allows the tyre fitter to stand at a safe
distance out of the danger zone while monitoring the tyre inflation pressure.

6.2 Workshop procedures

Once the automotive systems are inspected and repaired, follow the below house-
keeping rules:

• Ensure the work area is cleaned and there is no waste lying on the floor.

• Clean and wipe all the oil spills on the floor to avoid slips, trips and falls.

• Do not leave the tools on the workshop floor.

• Clean the tools and equipment after completion of the task.

• Inspect the tools for physical damages and tagout any faulty tools and report to
the supervisor.

Tagout: The tagout is a safety practice to reduce the risk of technicians using tools
and equipment which are found unsafe or that are in the process of being serviced.
The tagged-out tool avoids the accidental usage of the faulty tools.

Figure 19: Tagout of faulty equipment

• The tools must be stored back in the designated place.

• Precision measuring equipment like dial gauges, Vernier calipers, screw gauges,
etc. and specialist diagnostic tools such as scan tools and multimeter should be

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stored in the moisture free manufacturer provided containers in line with the
manufacturer’s procedure.

• Adhere to the safe environmental procedures for cleaning and disposing of non-
recyclable materials.

• The recyclable materials must be disposed to the authorized dealer.

6.3 Documentation

The documentation procedure in the system is very important after service and
before service or diagnosis.

 Repair Order (RO)

A repair order (RO) is written for every vehicle brought into the shop for service.
ROs are also called as service or work orders. ROs contain information about the
customer, the vehicle, the customer’s concern or request, an estimate of the cost
for the services, and the time the services should be completed.

ROs are legal documents that are used for many other purposes, such as payroll
and general record keeping. Legally, a RO protects the shop and the customer.
Although every shop may enter different information onto the original RO, most
ROs contain the following information:

• Complete customer information

• Complete vehicle identification

• The service history of the vehicle

• The customer’s complaint

• The preliminary diagnosis of the problem

• An estimate of the amount of time required for the service

• An estimate of the costs of the parts involved in the service

• The time the services should be completed

• The name or other identification of the technician assigned to perform the

services

• The actual services performed with their cost

• The parts replaced during the services

• Recommendations for future services

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• The total cost of the services

Figure 20: Sample repair order

 Diagnostics report

The diagnosis report is a report of diagnosis generated or manually prepared by

the technicians which consist of the following information:

• Complete vehicle information

• The service history of the vehicle

• Concern being diagnosed

• The diagnosis tool and equipment used

• The diagnosed fault codes generated

• the live data, the freeze frame data for the diagnosis done

• the technician’s observations

• the procedure involved to resolve the generated concern.

• The conclusion and summary of the diagnosis.

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This data helps the technician in understanding and registering the diagnosis,
making the customer understand the repairs and diagnosis done on the vehicle.
This also helps as a quick reference for the workshop if any complaint arises. And
as per the law, the reports have to be procured in the workshop for further
assistance.

Figure 21: Sample diagnostic report

Importance of documenting diagnostic process

• The technician can keep track of the process e.g. tests were done and their
results.

• The technician can see the build-up of information which will help them
eventually recognize the fault.

• The business can communicate accurately with the customer from the start of
the diagnostic procedure until the repair is completed and paid for.

• The business can obtain authority to repair at the appropriate stages as the
procedure is worked through.

• There is an accurate record if there is any dispute over the work done.

• There is a service record that helps as a reference for future jobs.

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7 References
Erjavec, J. Automotive Technology: A Systems Approach. [Cengage]. Retrieved
from https://cengage.vitalsource.com/#/books/9781337794404/

May and Simpson, Automotive mechanics: 10th Edition, McGraw-Hill Education.

CDX Automotive, Light Vehicle: Jones and Bartlett Learning.

* All images are taken from google and clipart

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