MANUAL DRIVE TRAIN AND AXLES
For every task in Manual Drive Train and Axles, the following
safety requirement must be strictly enforced:
Comply with personal and environmental safety practices
associated with clothing; eye protection; hand tools; power
equipment; proper ventilation; and the handling, storage, and
disposal of chemicals/materials in accordance with local, state, and
federal safety and environmental regulations.
III. MANUAL DRIVE TRAIN AND AXLES
A. General Drive Train Diagnosis
1. Identify and interpret drive train concern;
determine necessary action. P-1
2. Research applicable
vehicle and service information, such as drive train system
operation, vehicle service history, service precautions, and
technical service bulletins. P-1
3. Locate and interpret
vehicle and major component identification numbers (VIN, vehicle
certification labels, calibration decals). P-1
4. Diagnose
fluid usage, level, and condition concerns; determine necessary
action. P-1
5. Drain and fill manual transmission/transaxle
and final drive unit. P-2
B. Clutch Diagnosis and
Repair
1. Diagnose clutch noise, binding, slippage,
pulsation, and chatter; determine necessary action. P-1
2.
Inspect clutch pedal linkage, cables, automatic adjuster mechanisms,
brackets, bushings, pivots, and springs; perform necessary action.
P-1
3. Inspect hydraulic clutch slave and master cylinders,
lines, and hoses; determine necessary action. P-1
4. Inspect
release (throw-out) bearing, lever, and pivot; determine necessary
action. P-1
5. Inspect and replace clutch pressure plate
assembly and clutch disc. P-1
6. Bleed clutch hydraulic
system. P-1
7. Inspect, remove or replace pilot bearing or
bushing (as applicable). P-1
8. Inspect flywheel and ring
gear for wear and cracks, determine necessary action. P-1
9.
Inspect engine block, clutch (bell) housing, transmission/transaxle
case mating surfaces, and alignment dowels; determine necessary
action. P-3
10. Measure flywheel runout and crankshaft
endplay; determine necessary action. P-3
III. MANUAL
DRIVE TRAIN AND AXLES
C.
Transmission/Transaxle Diagnosis and Repair
1.
Remove and reinstall transmission/transaxle. P-1
2.
Disassemble, clean, and reassemble transmission/transaxle
components. P-2
3. Inspect transmission/transaxle case,
extension housing, case mating surfaces, bores, bushings, and vents;
perform necessary action. P-3
4. Diagnose noise, hard
shifting, jumping out of gear, and fluid leakage concerns; determine
necessary action. P-2
5. Inspect, adjust, and reinstall shift
linkages, brackets, bushings, cables, pivots, and levers.
P-2
6. Inspect and reinstall powertrain mounts. P-3
7.
Inspect and replace gaskets, seals, and sealants; inspect sealing
surfaces. P-2
8. Remove and replace transaxle final drive.
P-3
9. Inspect, adjust, and reinstall shift cover, forks,
levers, grommets, shafts, sleeves, detent mechanism, interlocks, and
springs. P-2
10. Measure endplay or preload (shim or spacer
selection procedure) on transmission/transaxle shafts; perform
necessary action. P-1
11. Inspect and reinstall synchronizer
hub, sleeve, keys (inserts), springs, and blocking rings.
P-2
12. Inspect and reinstall speedometer drive gear, driven
gear, vehicle speed sensor (VSS), and retainers. P-2
13.
Diagnose transaxle final drive assembly noise and vibration
concerns; determine necessary action. P-3
14. Remove,
inspect, measure, adjust, and reinstall transaxle final drive pinion
gears (spiders), shaft, side gears, side bearings, thrust washers,
and case assembly. P-2
15. Inspect lubrication devices (oil
pump or slingers); perform necessary action. P-3
16. Inspect,
test, and replace transmission/transaxle sensors and switches.
P-1
III. MANUAL DRIVE TRAIN AND AXLES
D. Drive Shaft and Half Shaft, Universal
and Constant-Velocity (CV) Joint Diagnosis and Repair
1. Diagnose constant-velocity (CV) joint noise and
vibration concerns; determine necessary action. P-1
2.
Diagnose universal joint noise and vibration concerns; perform
necessary action. P-1
3. Replace front wheel drive (FWD)
front wheel bearing. P-2
4. Inspect, service, and replace
shafts, yokes, boots, and CV joints. P-1
5. Inspect, service,
and replace shaft center support bearings. P-3
6. Check shaft
balance; measure shaft runout; measure and adjust driveline angles.
P-2
III. MANUAL DRIVE TRAIN AND AXLES
E. Drive Axle Diagnosis and Repair
1. Ring and Pinion Gears and Differential Case
Assembly
1. Diagnose noise and vibration concerns; determine
necessary action. P-2
2. Diagnose fluid leakage concerns;
determine necessary action. P-2
3. Inspect and replace
companion flange and pinion seal; measure companion flange runout.
P-2
4. Inspect ring gear and measure runout; determine
necessary action. P-2
5. Remove, inspect, and reinstall drive
pinion and ring gear, spacers, sleeves, and bearings. P-2
6.
Measure and adjust drive pinion depth. P-2
7. Measure and
adjust drive pinion bearing preload. P-1
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). P-2
9. Check ring and pinion tooth
contact patterns; perform necessary action. P-1
10.
Disassemble, inspect, measure, and adjust or replace differential
pinion gears (spiders), shaft, side gears, side bearings, thrust
washers, and case. P-2
11. Reassemble and reinstall differential case assembly; measure
runout; determine necessary action. P-2
2. Limited Slip Differential
1. Diagnose noise, slippage,
and chatter concerns; determine necessary action. P-3
2.
Inspect and flush differential housing; refill with correct
lubricant. P-2
3. Inspect and reinstall clutch (cone or
plate) components. P-3
4. Measure rotating torque; determine
necessary action. P-3
3. Drive Axle Shaft
1. Diagnose
drive axle shafts, bearings, and seals for noise, vibration, and
fluid leakage concerns; determine necessary action. P-2
2.
Inspect and replace drive axle shaft wheel studs. P-3
3.
Remove and replace drive axle shafts. P-1
4. Inspect and
replace drive axle shaft seals, bearings, and retainers.
P-2
5. Measure drive axle flange runout and shaft endplay;
determine necessary action. P-2
III. MANUAL DRIVE
TRAIN AND AXLES
F. Four-wheel
Drive/All-wheel Drive Component Diagnosis and Repair
1. Diagnose noise, vibration, and unusual steering
concerns; determine necessary action. P-3
2. Inspect, adjust,
and repair shifting controls (mechanical, electrical, and vacuum),
bushings, mounts, levers, and brackets. P-3
3. Remove and
reinstall transfer case. P-3
4. Disassemble, service, and
reassemble transfer case and components. P-3
5. Inspect
front-wheel bearings and locking hubs; perform necessary action.
P-3
6. Check drive assembly seals and vents; check lube
level. P-3
7. Diagnose test, adjust, and replace
electrical/electronic components of four-wheel drive systems.
P-3
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