AUT 5011 - Manual Drive Trains & Axles

A. General

1. Research vehicle service information including fluid type, vehicle service history, service precautions, and technical service bulletins, and recalls including vehicles equipped with advanced driver assistance systems (ADAS).
2. Identify manual drive train and axles components and configurations.
3. Retrieve and record DTC’s, OBD monitor status, and freeze frame data; clear codes and data when directed.
4. Check fluid condition; check for leaks; determine needed action.
5. Drain and refill manual transmission/transaxle; use proper fluid type per manufacturer specification.
6. Diagnose drive train concerns; determine needed action.

B. Clutch

1. Check and adjust clutch master cylinder fluid level; check for leaks; sue proper fluid type per manufacturer specification.
2. Diagnose clutch noise, binding, slippage, pulsation, and chatter; determine needed action.
3. Inspect clutch pedal linkage, cables, automatic adjuster mechanisms, brackets, bushings, pivots, and springs; determine needed action.
4. Inspect and/or replace clutch pressure plate assembly, clutch disc, release (throw-out) bearing, linkage, and pilot bear/bushing (as applicable).
5. Bleed clutch hydraulic system.
6. Inspect flywheel and ring gear for wear and cracks, and discoloration; determine needed action.
7. Measure flywheel runout and crankshaft end play; determine needed action.
8. Describe the operation and service of a system that uses a dual mass flywheel.

C. Transmission/Transaxle

1. Describe the operational characteristics of an electronically controlled manual transmission/transaxle.
2. Inspect, adjust, lubricate, and/or replace shift linkages, brackets, bushings, cables, pivots, and levers.

D. Drive Shaft and Half Shaft, Universal and Constant-Velocity (CV) Joint (Front, Rear, All-wheel, and Four-wheel drive)

1. Inspect, remove, and/or replace bearings, hubs, and seals.
2. Inspect and/or service/replace shafts, yokes, boots, and universal/CV joints.
3. Check for leaks at drive assembly and transfer case seals; check vents; check fluid level; use proper fluid type per manufacturer specification.
4. Diagnose constant-velocity (CV) joint and vibration concerns; determine needed action.
5. Diagnose universal joint noise and vibration concerns; determine needed action.
6. Check shaft balance and phasing; measure shaft runout; measure and adjust driveline angles; determine needed action.

E. Differential and Drive Axels

 E1 Ring and Pinion Gears and Differential Case Assembly

1. Inspect differential housing; check for leaks; inspect housing vent.
2. Check and adjust differential housing fluid level; use proper fluid type per manufacturer’s specification.
3. Drain and refill differential housing; use proper fluid type per manufacturer’s specification.
4. Inspect and replace companion flange and/or pinion seal; measure companion flange runout.
5. Demonstrate knowledge of drive pinion and ring gear service and set up including depth, preload, backlash and gear tooth contact.

E2 Drive Axles

1. Inspect and replace drive axle wheel studs.
2. Remove and replace drive axle shafts.
3. Inspect and replace drive axle shaft seals, bearings, and retainers.
4. Measure drive axle flange runout and shaft end play; determine needed action.

F. Four-wheel Drive/All-wheel Drive

1. Identify concerns related to variations in tire circumference and/or final drive ratios.
2. Inspect, adjust, and repair shifting controls (mechanical, electrical, and vacuum), bushings, mounts, levers, and brackets.
3. Inspect axle locking mechanisms; determine needed action(s).
4. Check for leaks at drive assembly and transfer case seals; check vents; check fluid level; use proper fluid type per manufacturer specifications.