DPE 5010 - Drive Trains

Safety

• Identify and practice general shop safety rules and procedures.
• Utilizing safe procedures for handling of tools and equipment.
• Identifying and using proper placement of floor jacks and jack stands.
• Identifying and using proper procedures for safe lift operation.
• Utilizing proper ventilation procedures for working within the lab/shop area.
• Identifying marked safety areas.
• Identifying the location and the types of fire extinguishers and other fire safety equipment.
• Demonstrating knowledge of the procedures for using fire extinguishers and other fire safety equipment.
• Identifying the location and use of eye wash stations.
• Identifying the location of the posted evacuation routes.
• Complying with the required use of safety glasses, ear protection, gloves, and shoes during lab/shop activities.
• Identifying and wearing appropriate clothing for lab/shop activities.
• Securing hair and removing jewelry for lab/shop activities.
• Demonstrating awareness of the safety aspects of supplemental restraint systems (SRS), electronic brake control systems, and hybrid vehicle high voltage circuits.
• Demonstrating awareness of the safety aspects of high voltage circuits (such as high intensity discharge (HID) lamps, ignition systems, injection systems, etc.).
• Locating and demonstrating knowledge of material safety data sheets (MSDS).

Tools and Equipment

• Identify tools and their usage in automotive applications.
• Identifying standard and metric designation.
• Demonstrating safe handling and use of appropriate tools.
• Demonstrating proper cleaning, storage, and maintenance of tools and equipment.
• Demonstrating proper use of precision measuring tools Examples: micrometer, dial-indicator, dial-caliper.

Clutch

• Identify causes of clutch noise, binding, slippage, pulsation, vibration, grabbing, dragging, and chatter problems; determine needed action.
• Inspect and adjust clutch linkage, cables, levers, brackets, bushings, pivots, springs, and clutch safety switch (includes push and pull-type assemblies); check pedal height and travel; perform needed action.
• Inspect, adjust, repair, and replace hydraulic clutch slave and master cylinders, lines, and hoses; bleed system.
• Inspect, adjust, lubricate, or replace release (throw-out) bearing, sleeve, bushings, springs, housing, levers, release fork, fork pads, rollers, shafts, and seals.
• Inspect, adjust, and replace single-disc clutch pressure plate and clutch disc.
• Inspect, adjust, and replace two-plate clutch pressure plate, clutch discs, intermediate plate, and drive pins/lugs.
• Inspect and/or replace clutch brake assembly; inspect input shaft and bearing retainer; perform needed action.
• Inspect, adjust, and replace self-adjusting/continuous-adjusting clutch mechanisms.
• Inspect and replace pilot bearing.
• Remove and reinstall flywheel, inspect mounting area on crankshaft, rear main oil seal, and measure crankshaft end play; determine needed action.
• Inspect flywheel, starter ring gear and measure flywheel face and pilot bore runout; determine needed action.

Transmission

• Identify causes of transmission noise, shifting concerns, lockup, jumping-out-of-gear, overheating, and vibration problems; determine needed action.
• Inspect, test, repair, or replace air shift controls, lines, hoses, valves, regulators, filters, and cylinder assemblies.
• Inspect and replace transmission mounts, insulators, and mounting bolts.
• Inspect for leakage and replace transmission cover plates, gaskets, seals, and cap bolts; inspect seal surfaces and vents; repair as needed.
• Check transmission fluid level and condition; determine needed service; add proper type of lubricant.
• Inspect, adjust, and replace transmission shift lever, cover, rails, forks, levers, bushings, sleeves, detents, interlocks, springs, and lock bolts/safety wires.
• Remove and reinstall transmission.
• Inspect input shaft, gear, spacers, bearings, retainers, and slingers; determine needed action.
• Inspect transmission oil filters, coolers and related components; replace as needed.
• Inspect speedometer components; determine needed action.
• Inspect and adjust power take-off (P.T.O.) assemblies, controls, and shafts; determine needed action.
• Inspect and test function of reverse light, neutral start, and warning device circuits; determine needed action. Inspect and test transmission temperature gauge, wiring harnesses and sensor/sending unit; determine needed action.
• Inspect and test operation of automated mechanical transmission and manual electronic shift controls, shift, range and splitter solenoids, shift motors, indicators, speed and range sensors, electronic/transmission control units (ECU/TCU), neutral/in gear and reverse switches, and wiring harnesses; determine needed action.
• Inspect and test operation of automated mechanical transmission electronic shift selectors, air and electrical switches, displays and indicators, wiring harnesses, and air lines; determine needed action
• Use appropriate electronic service tool(s) and procedures to diagnose automated mechanical transmission problems; check and record diagnostic codes, clear codes, and interpret digital multimeter (DMM) readings; determine needed action.
• Inspect and test operation of automatic transmission electronic shift controls, shift solenoids, shift motors, indicators, speed and range sensors, electronic/transmission control units (ECU/TCU), neutral/in gear and reverse switches, and wiring harnesses.
• Inspect and test operation of automatic transmission electronic shift selectors, switches, displays, indicators, and wiring harnesses.
• Use appropriate electronic service tool(s) and procedures to diagnose automatic transmission problems; check and record diagnostic codes, clear codes, and interpret digital multimeter (DMM) readings; determine needed action.

Driveshaft and Universal Joint

• Identify causes of driveshaft and universal joint noise and vibration problems; determine needed action.
• Inspect, service, or replace driveshaft, slip joints, yokes, drive flanges, and universal joints, driveshaft boots and seals, and retaining hardware; check phasing of all shafts.
• Inspect driveshaft center support bearings and mounts; determine needed action.
• Measure driveline angles; determine needed action.

Drive Axle

• Identify causes of drive axle(s) drive unit noise and overheating problems; determine needed action.
• Check and repair fluid leaks; inspect and replace drive axle housing cover plates, gaskets, sealants, vents, magnetic plugs, and seals.
• Check drive axle fluid level and condition; determine needed service; add proper type of lubricant.
• Remove and replace differential carrier assembly.
• Inspect and replace differential case assembly including spider gears, cross shaft, side gears, thrust washers, case halves, and bearings.
• Inspect and replace components of locking differential case assembly.
• Inspect differential carrier housing and caps, side bearing bores, and pilot (spigot, pocket) bearing bore; determine needed action.
• Measure ring gear runout; determine needed action.
• Inspect and replace ring and drive pinion gears, spacers, sleeves, bearing cages, and bearings.
• Measure and adjust drive pinion bearing preload.
• Measure and adjust drive pinion depth.
• Measure and adjust side bearing preload and ring gear backlash.
• Check and interpret ring gear and pinion tooth contact pattern; determine needed action.
• Inspect, adjust, or replace ring gear thrust block/screw.
• Inspect power divider (inter-axle differential) assembly; determine needed action.
• Inspect, adjust, repair, or replace air operated power divider (inter-axle differential) lockout assembly including diaphragms, seals, springs, yokes, pins, lines, hoses, fittings, and controls.
• Inspect, repair, or replace drive axle lubrication system: pump, troughs, collectors, slingers, tubes, and filters.
• Inspect and replace drive axle shafts.
• Remove and replace wheel assembly; check rear wheel seal and axle flange gasket for leaks; perform needed action.
• Identify causes of drive axle wheel bearing noise and check for damage; perform needed action.
• Inspect and test drive axle temperature gauge, wiring harnesses, and sending unit/sensor; determine needed action.
• Clean, inspect, lubricate and replace wheel bearings; replace seals and wear rings; inspect and replace retaining hardware; adjust drive axle wheel bearings. Verify end play with dial indicator method.