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AUTO-1290 Manual Transmissions and Differential Axles Prerequisite: None This course emphasizes power trains, including the theory and shop practice of automotive, commercial, and agriculture vehicles. Manual transmission units and differential axles used in automobile, commercial, and agricultural vehicles are explained. Students may supply shop work, but it is not mandatory. Offered fall semester only. (3/30/45/0/0/5)



The student will be able to: A. Develop clean work habits, attitudes and skills related to manual transmissions and differential axle servicing. [GE Goal: 5] B. Assess information concerning the vocational opportunities offered in the area of manual transmissions and differential axle servicing. [GE Goal: 5] C. Work effectively with others. [GE Goal: 5] D. Perform repairs under conditions similar to those in the automotive service industry. E. Demonstrate knowledge of correct nomenclature of tools, lab techniques and equipment usage, resulting in an intelligent and effective application of skills related to manual transmissions and differential axle servicing. [GE Goal: 2] F. Analyze, diagnose and determine necessary repairs required to repair modern manual transmissions and differential axle servicing. [GE Goal: 2] G. Develop the technical and academic knowledge necessary to expand on lifelong learning as the automotive industry continually updates. [GE Goal: 5] H. Research shop manuals and Internet sites for correct repair procedures and write a descriptive work order upon completion of repairs. [GE Goals: 1 & 3]



A. Textbook 1. James D. Halderman. Automotive Technology Principles, Diagnosis

MANUAL TRANSMISSIONS AND DIFFERENTIAL AXLES AUTO-1290 and Service. 3rd Edition. ISBN 978-0-13-175477-5 B. Required References: 1. Motors Repair Manuals 2. Chilton Repair Manuals 3. Mitchell Repair Manuals 4. Manufacturers Shop Manuals C. Visual Aides: 1. Films 2. Video tapes, CD, & DVD 3. Demonstration by instructor 4. Field trips to industry 5. Charts



A. Approximate Breakdown 1. Tools 2. Special purpose tools 3. Measuring tools 4. Fastening devices and tube fittings 5. Clutch assembly 6. Manual transmissions 7. Differential axles 8. Drive shaft and U-joints/half shaft and C.V. joints 9. Four-wheel drive/All-wheel drive components



A. Specific Instruction


MANUAL TRANSMISSIONS AND DIFFERENTIAL AXLES AUTO-1290 1. Shop safety a) Safe behavior in the shop b) Power equipment in operation c) Shop tour 2. Tools-Correct Use and Proper Names a) Screwdrivers b) Wrenches c) Hammers d) Chisels and punches e) Files f) Drill bits g) Drills h) Reamers i) Saws and blades j) Taps and dies k) Cleaning tools l) Pliers 3. Special Purpose Tools a) Manual Transmission /Drive Train Tools (1) Bearing pullers (2) Bearing separators (3) Gear pullers (4) Dial indicator (5) Clutch alignment (6) U-Joint press


MANUAL TRANSMISSIONS AND DIFFERENTIAL AXLES AUTO-1290 (7) Slide hammer (8) Half shaft puller (9) C.V. joint boot pliers (10)Pinion depth/ differential set-up gauge b) Measuring Tools (1) Feeler gauges (2) Micrometers (3) Caliper (4) Dial indicator (5) Torque wrench (inch pound, foot pound) c) Fastening Devices (1) Bolt and head sizes (types of thread and classification) (2) Washers (flat, locking, star, etc.) (3) Cotter pins, snap rings, retainer rings 4. Standard Transmissions and Clutches a) Torque multiplication b) Shift mechanisms c) 2 speed d) 3 speed e) 4 speed f) 5 speed g) With overdrive h) Clutches (1) Mechanical linkage (2) Hydraulic


MANUAL TRANSMISSIONS AND DIFFERENTIAL AXLES AUTO-1290 (3) Cable 5. Differential Axles a) Construction b) Axle types c) Differentials d) Adjustments e) Anti-slip differentials f) Hypoid gears g) Spiral gears h) Spur gears i) Gear ratio j) Planetary gear differentials k) Lubrication l) Gear 6. Propeller shafts a) Universal joints b) Slip joints c) Hotchkiss drive d) Torque drive e) Constant velocity joints f) Shaft alignment g) Shaft vibrations 7. Four-Wheel Drive/All-Wheel Drive Components a) Locking/automatic hubs b) Part time





A. General Drive Train Diagnosis 1. Complete work order to include customer information, vehicle identifying information customer concern, related service history cause, and correction. 2. Identify and interpret drive train concern; determine necessary action. 3. Research applicable vehicle and service information, such as drive train system operation, vehicle service history, service precautions, and technical service bulletins 4. Locate and interpret vehicle and major component identification numbers. 5. Diagnose fluid loss, level, and condition concerns; determine necessary action. 6. Drain and fill manual transmission/transaxle and final drive unit. B. Clutch Diagnosis and Repair 1. Diagnose clutch noise, binding, slippage, pulsation, and chatter problems; determine needed action. 2. Inspect clutch pedal linkage, cables, automatic adjuster mechanisms, brackets, bushings, pivots, and springs; perform necessary action. 3. Inspect hydraulic clutch slave and master cylinders, lines, and hoses; determine necessary action. 4. Inspect and replace clutch pressure plate assembly, clutch disc, release (throw-out) bearing and linkage, and pilot bearing/bushing (as applicable). 5. Inspect flywheel and ring gear for wear and cracks; determine necessary action. 6. Inspect engine block, core plugs, rear main engine oil seal, clutch (bell) housing, transmission/transaxle case mating surfaces, and alignment dowels; determine necessary action. C. Transmission/Transaxle Diagnosis and Repair 6

MANUAL TRANSMISSIONS AND DIFFERENTIAL AXLES AUTO-1290 1. Remove and reinstall transmission/transaxle. 2. Disassemble, clean, and reassemble transmission/transaxle components. 3. Inspect transmission/transaxle case, extension housing, case mating surfaces, bores, and vents; perform necessary action. 4. Diagnose hard shifting, jumping out of gear, concerns; determine necessary action. 5. Inspect, adjust, and reinstall shift linkages, brackets, bushings, cables, pivots, and levers. 6. Inspect and reinstall powertrain mounts. 7. Inspect and replace gaskets, seals, and sealants; inspect sealing surfaces. 8. Inspect, adjust, and install shift cover, forks, levers, grommets, shafts, sleeves, detent mechanism, interlocks, and springs. 9. Measure endplay or preload (shim or spacer selection procedure) on transmission/transaxle shafts; perform necessary action. 10. Inspect and reinstall synchronizer hub, sleeve, keys (inserts), springs, and blocking rings. 11. Inspect lubrication devices (oil pump or slingers); perform necessary action. 12. Inspect, test, and replace transmission/transaxle sensors and switches. D. Drive Shaft and Half Shaft, Universal and Constant-Velocity (CV) Joint Diagnosis and Repair 1. Diagnosis constant-velocity (CV) joint noise and vibration concerns; determine necessary action. 2. Diagnose universal joint noise and vibration concerns; perform necessary action. 3. Remove and replace front wheel drive (FWD) front wheel bearing. 4. Inspect, service, and replace shafts, yokes, boots, and C.V. joints. 5. Check shaft balance, and phasing; measure shaft runout; measure and adjust driveline angles. 7

MANUAL TRANSMISSIONS AND DIFFERENTIAL AXLES AUTO-1290 E. Drive Axle Diagnosis and Repair 1. Diagnose noise and vibration concerns; determine necessary action. 2. Diagnose fluid leakage concerns; determine necessary action. 3. Inspect and replace companion flange and pinion seal; measure companion flange runout. 4. Inspect ring gear and measure runout; determine necessary action. 5. Remove, inspect and reinstall drive pinion and ring gear, spacers, sleeves, and bearings. 6. Measure and adjust drive pinion depth. 7. Measure and adjust drive pinion bearing preload. 8. Measure and adjust side bearing preload and ring and pinion gear total backlash and backlash variation on a differential carrier assembly (threaded cup or shim types) 9. Check ring and pinion tooth contact patterns; perform necessary action. 10. Disassemble, inspect, measure, and adjust or replace differential pinion gears (spiders), shaft gears, side bearings, thrust washers, and case. 11. Reassemble and reinstall differential case assembly; measure runout; determine necessary action. F. Limited Slip Differential Diagnosis and Repair 1. Diagnose noise, slippage, and chatter concerns; determine necessary action. 2. Clean and inspect differential housing; refill with correct lubricant and/or additive. 3. Inspect and reinstall limited slip differential components. 4. Measure rotating torque; determine necessary action. G. Drive Axle Shaft 1. Diagnose drive axle shafts, bearings, and seals for noise, vibration, and fluid leakage concerns; determine necessary action.


MANUAL TRANSMISSIONS AND DIFFERENTIAL AXLES AUTO-1290 2. Inspect and replace drive axle shaft wheel studs. 3. Remove and replace drive axle shafts. 4. Inspect and replace drive axle shaft seals, bearings, and retainers. 5. Measure drive axle flange runout and shaft end play; determine necessary action. H. Four-wheel Drive/All-wheel Drive Component Diagnosis and Repair 1. Diagnose noise, vibration, and unusual steering concerns; determine necessary action. 2. Inspect, adjust, and repair shifting controls (mechanical, electrical, and vacuum), bushings, mounts, levers, and brackets. 3. Remove and reinstall transfer case. 4. Disassemble, service, and reassemble transfer case and components. 5. Inspect front-wheel bearings and locking hubs; perform necessary action. 6. Check drive assembly seals and vents; check lube level.



A. Method of instruction includes individual and group demonstrations. B. Work in the lab and classroom correlated. The student is first told and shown why and how a mechanism works. He/she then goes to the lab verifies what was seen and heard in lecture. All repair, overhaul and other service work is likewise preceded by classroom lecture and demonstration. There is little time lapse between classroom presentation and related lab work; the student applies the theory before it has had a chance to grow stale in the mind.


A. Regular attendance is a must because performance in the lab under actual working conditions is stressed B. Quality of work C. Quantity of work D. Effort and attitude to include: 1. Cooperation with group and instructor 9

MANUAL TRANSMISSIONS AND DIFFERENTIAL AXLES AUTO-1290 2. Care and use of equipment 3. Organization and pride in work. 4. General courtesy and respect for rule and general situation in the lab. 5. Observation of safety factors 6. Respect for other students and their work. 7. Thriftiness in use of materials and equipment E. Tests are given at frequent intervals. Two types of tests are given - practical in lab and written in classroom. F. Final grade will be determined by the following criteria: 1. Quality and quantity of work 2. Effort and attitude 3. Testing - practical and written



Academic integrity forms a fundamental bond of trust between colleagues, peers, teachers, and students, and it underlies all genuine learning. At WNCC, there is no tolerance for plagiarism or academic dishonesty in any form, including unacknowledged "borrowing" of proprietary material, copying answers or papers, or passing off someone else's work as one's own. Such acts are reported to the appropriate authorities A breach of ethics or act of dishonesty can result in: failure of a paper or exam within a course failure of an entire course (blatant plagiarism, cheating on a test or quiz) academic suspension or expulsion from the college



Western Nebraska Community College is committed to providing equal access to educational opportunities. If you believe that you qualify under the Americans with Disabilities Act (ADA), please contact the Director of Counseling (308-6356090) as soon as possible to begin a process of documentation review and determination for appropriate accommodation or adaptive strategies. 4-25-11



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