AURLTX101 Diagnose and repair light vehicle manual transmissions

Student Assessment Agreement

Make sure you read through the assessments in this booklet before you fill out and sign the agreement below.
If there is anything that you are unsure of, consult your assessor prior to signing this agreement.
Have you read the assessment requirements for this unit?  Yes  No
Do you understand the requirements of the assessments for this unit?  Yes  No
Do you agree to the way in which you are being assessed?  Yes  No
Do you have any specific needs that should be considered?  Yes  No
If so, explain these in the space below.
Do you understand your rights to re-assessment?  Yes  No
Do you understand your right to appeal the decisions made in an assessment?  Yes  No

Student name Sahil Maan

Student number 20231095

Student signature Sahil Maan

Date 6/7/24

Qualification Code and

AUR30620: Certificate III in Light Vehicle Mechanical Technology
Title

AURLTX101 Diagnose and repair light vehicle manual

Unit Code and Title
transmissions

Assessor name

Assessor signature

Date

Assessment Task Cover Sheet

Student Declaration
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 AURLTX101 Diagnose and repair light vehicle manual transmissions

To be filled out and submitted with assessment responses

 I declare that this task is all my own work and I have not cheated or plagiarised the work or colluded with any
other student(s).
 I understand that if I If I am found to have plagiarised, cheated or colluded, action will be taken against me
according to the process explained to me.
 I have correctly referenced all resources and reference texts throughout these assessment tasks.
Student name Sahil Maan

Student ID number 20231095

Student signature Sahil Maan

Date 6/7/24

Assessor declaration
 I hereby certify that this student has been assessed by me and that the assessment has been carried out
according to the required assessment procedures.

Assessor name

Assessor signature

Date

Assessment outcome S NS DNS Resubmission Y N

Feedback

Student result response

 My performance in this assessment task has been discussed and explained to me.
 I would like to appeal this assessment decision.
Sahil Maan
Student signature

6/7/24
Date

A copy of this page must be supplied to the office and kept in the student’s file with the evidence

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 AURLTX101 Diagnose and repair light vehicle manual transmissions

Assessment 1 – Questioning – Written Assessment

Student Name Sahil Maan Student ID Number 20231095

Unit Start Date Unit End Date

Assessment Due Date Date Submitted 6/7/24

This cover sheet is to be completed by the student and assessor and used as a record to determine student
competency in this assessment task

The assessment process and tasks were fully explained. Yes / No

I am aware of which evidence will be collected and how. Yes / No

I am aware of my right to appeal an assessment decision. Yes / No

I am aware that I can locate The RTO Complaints and Appeals Policy and Procedure on their Yes / No
website at (insert website address)

I have discussed any additional educational support or reasonable adjustments I require in order to
undertake this assessment with the Student Support Services Officer and Trainer / Assessor, (if Yes / No
applicable). e.g. Student Handbook and Access and Equity Policy (insert website address)

I have access to all required resources? Yes / No

Cheating & Plagiarism Declaration

Student Declaration: In accordance with The RTO Plagiarism Policy, I hereby acknowledge by signing this
declaration that I have not cheated or plagiarised any work regarding the assessment tasks undertaken in this unit
of competency except where the work has been correctly acknowledged.
NOTE: Student must sign this prior to submitting their assessments to the assessor

_6_____ / ___7___ /
Signature Sahil Maan Date:
20_4_____

Satisfactory or Not Yet Satisfactory

Assessment Results
(Please circle the assessment result for this task)

Feedback to Student - Please provide general feedback on the Student’s performance

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 AURLTX101 Diagnose and repair light vehicle manual transmissions

Student Declaration: - I verify that the work completed Assessor Declaration: - I verify that I have adequately
is my own and that I was adequately informed of the explained and negotiated the assessment tasks with the
assessment process prior to commencing this student prior to commencing assessment.
assessment task.

Student Name: Sahil Maan Assessor’s Name:

Student Signature Sahil Maan Date 6/7/24 Assessor Signature Date

Student Guide for Written Knowledge Assessment

Overview of This is a written assessment task you will be assess on your knowledge of diagnosing and
Assessment repairing light vehicle manual transmissions.
The topics that will be covered in the assessment are:
1. Prepare to diagnose and repair light vehicle manual transmissions
2. Diagnose manual transmissions
3. Repair manual transmissions
4. Complete work processes
This assessment will ensure that the elements, performance criteria, performance evidence
and knowledge evidence required, and conditions are adhered to demonstrate competency
in this unit assessment task.
5. Read the assessment carefully before commencing.
6. Your Assessor will use the assessment criteria in this document and will provide
feedback / comment.
7. You MUST answer all the questions in the assessment tasks in your own words and
own handwriting.
8. This is an “Open Book” assessment, and students can use the resources listed in
the “Resources Required” section below.

Task/s to be To complete this written assessment, you will need to answer the 88 questions comprising
assessed of Multiple Choice, True and False, Fill-in the Gap and Short Answer questions.

Time allowed On average, the Assessment should take 4 – 6 hours to complete.

Location This theory assessment will be completed in a classroom under the supervision of a
trainer/assessor.

Decision making To receive a ‘satisfactory’ outcome for this assessment students MUST successfully answer
rules all questions. If a student achieves less than 100%, they can reattempt the assessment
after further study has taken place. Students who cannot achieve a minimum of 100% you
will not have satisfactorily completed this assessment
Your assessor will be looking for the following in this assessment task: -
 Work health and safety (WHS) and occupational health and safety (OHS)
requirements relating to diagnosing and repairing light vehicle manual
transmissions, including procedures for lifting, supporting and manual handling light
vehicle manual transmissions

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 Environmental requirements, including procedures for trapping, storing and

disposing of fluids released from transmissions
 Operating principles light vehicle manual transmissions, including:
o Gear types
o Gear ratios and torque reduction and multiplication
o Simple gear trains
o Compound gear trains
o Lubricant types
 Application, purpose and operation of light vehicle manual transmissions and
components, including:
o Power flows, including:
 Longitudinal manual transmissions
 Transaxles
 Transfer cases
o Synchromesh operation
o Gearshift mechanisms
o Transfer cases, including:
 Part-time four-wheel drives
 Full-time four-wheel drives
 All-wheel drives
 Diagnostic testing procedures for light vehicle manual transmissions, including:
o Abnormal noise diagnosis
o Shift diagnosis
 Repair procedures for light vehicle manual transmissions, including procedures for
removing, replacing and adjusting them
 Post-repair testing procedures for light vehicle manual transmissions.

Assessment Assessors MUST satisfy NVR/AQTF assessor requirements.

conditions
Competency is to be assessed in the workplace or a simulated environment that accurately
reflects performance in a real workplace setting.
Assessment MUST include direct observation of tasks.
Where assessment of competency includes third-party evidence, individuals MUST provide
evidence that links them to the light vehicle manual transmissions that they have worked on,
e.g. repair orders.
Assessors MUST verify performance evidence through questioning on skills and knowledge
to ensure correct interpretation and application.
The following resources MUST be made available:
 Automotive repair workplace or simulated workplace
 Workplace instructions
 Manufacturer light vehicle manual transmission specifications
 Two different light vehicles with faults in the manual transmission components
specified in the performance evidence
 Diagnostic equipment for light vehicle manual transmissions
 Tools, equipment and materials appropriate for repairing light vehicle manual
transmissions.

Resources required Learning Resources available to students include:

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 AURLTX101 Diagnose and repair light vehicle manual transmissions

 Automotive Technology (A System Approach) 6th Edition – Chapters 5, 6, 7, 8, 41,

42 and 43
 Websites
 Trainer Handouts

Results/Re-  The Assessor will grade the assessment and record the result on the front page of
assessment this document (S) – Satisfactory if all observable behaviours are correct and (NS)
not satisfactory if any areas are left incorrect
 Feedback will be provided on either result
 Where a student receives a ‘NS – Not Satisfactory’ result, the assessor will discuss
the area of the non-compliant observable behaviour and an opportunity given for re-
assessment. This may be through direct observation or a different method of
assessment e.g. verbal/oral questioning, problem solving exercise.
 If the outcome is again not satisfactory the student result will be deemed (NYC) not
yet competent. Additional feedback will be given, and a time agreed upon for further
assessment after additional training and skills practice has taken place, this
information will be recorded, dated and signed in the re-assessment area on the
last page of this document
 Where all the assessment tasks have been graded (S) Satisfactory, the student will
be deemed C – Competent for the practical component and the result recorded and
signed in the area indicated on the last page of this document

Reasonable If the participant is unable to undertake the written assessment as designed, an interview
Adjustment (verbal questioning) may be used as an alternate approach.

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 AURLTX101 Diagnose and repair light vehicle manual transmissions

Assessment 1 – Questioning

Written Assessment

1. Identify five (5) important items of personal safety when working on manual transmissions in an automotive
workplace?

1 Hearing protection
Skin protection
2

3 Skin protection
Footwear
4

5 Clothing

2. List three (3) precautions when jacking a vehicle on the floor.

1 Rotating driveline components Hot exhaust system

2 Hot gear oil

3 Rotating driveline components Hot exhaust system

3. Why should safety stands be placed under a raised vehicle?

Transmission oils should be correctly stored, labelled and removed by a licensed contractor.

4. What precautions should be observed if a vehicle is to be raised on a hoist?

1 Stable Ground: Ensure the hoist is on stable ground and rated for the weight of the vehicle.

2 Positioning: Center the vehicle properly on the hoist to maintain balance.

3 Chocks: Use wheel chocks to prevent any movement of wheels that remain on the ground.

4 Lifting Points: Lift the vehicle using manufacturer-recommended lifting points to avoid damage.

5 Clearance: Make sure there's sufficient overhead clearance for the vehicle.

Multiple choice. Circle all the correct answer

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 AURLTX101 Diagnose and repair light vehicle manual transmissions

5. When using lifting equipment, what does SWL stand for?

A. Safe weight lift.

B. Safe working load.
C. Safe working limit.
D. Secure working load.

Fill in the Gaps

6. Complete the following statement about safely manually lifting something like a transmission using the
following words.

Words: Back, Body, Close, Condition, Forward, Grasp, Heavy, Knees, Legs, Move, Object, Part, Pinch,
Straight, Travel, Wood

1. Place your feet close to the object. Position your feet so you will be able to maintain a good balance.
2. Keep your back and elbows as straight as possible. Bend your knees until your hands reach the best place to
get a strong grip on the object.
3. If the part is in a cardboard box, make sure the box is in good condition. Old, damp, or poorly sealed boxes
will tear and the contents will fall out.
4. Firmly grasp the object or container. Never try to change your grip as you move the load.
5. Keep the object close to your body and lift it up by straightening your legs. Use your leg muscles, not your
back muscles.
6. If you must change your direction of travel, never twist your body. Turn your whole body, including your feet.
7. When placing the object on a shelf or counter, do not bend forward. Place the edge of the load on the shelf
and slide it forward. Be careful not to pinch your fingers.
8. When setting down a load, bend your knees and keep your back straight. Never bend forward. This strains the
back muscles.
9. When lowering something close to the floor, set the object on blocks of wood to protect your fingers.

7. What precautions are needed when draining the fluid from a manual transmission?
Ensure the vehicle is properly supported on jack stands.
Wear appropriate protective gear (gloves, eye protection).
Use a suitable container to collect the fluid.
Allow the transmission to cool if it has been running to avoid burns.

8. How should waste transmission oils be stored and disposed?

Sealed containers labeled appropriately.
Stored in a designated area away from heat sources.
Disposed of according to local environmental regulations.

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Multiple choice. Circle all the correct answer

9. When changing the manual transmission oil, what should you use to catch the oil waste oil?

A. Drain pan.
B. Mop bucket.
C. Storm water drain.
D. Funnel.

10. When handling, trapping, storing and disposing of manual transmission/transaxle new or waste oils, which
document should you use to find this information?
Safety Data Sheet (SDS)

11. What are the three (3) different types of gears in a manual transmission/transaxle?

1 Spur gears

2 Helical gears

3 Synchromesh gears

Multiple choice. Circle all the correct answer

12. Gears can _____.

A. Transfer speed and torque.

B. Decrease speed and increase torque.
C. Increase speed and decrease torque.
D. All answers are correct.

Multiple choice. Circle all the correct answer

13. Which of the following is NOT a function of gears?

A. Multiply torque while increasing speed.

B. Multiply speed while decreasing torque.
C. Multiply torque while decreasing speed.
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D. Transfer torque leave speed unchanged.

Multiple choice. Circle all the correct answer

14. To reduce gear whine, manufacturers use _____ gears.

A. Spur.
B. Helical.
C. Ellipsoidal.
D. Parabolic.

Multiple choice. Circle all the correct answer

15. A(n) _____ gear is used to transfer motion without changing rotational direction.

A. Differential.
B. Spur.
C. Counter.
D. Idler.

Multiple choice. Circle all the correct answer

16. In a five-speed manual transmission/transaxle, an idler gear is used for _____ gear.

A. First and second and third.

B. Direct drive [fourth gear].
C. Overdrive [fifth gear].
D. Reverse.

Multiple choice. Circle all the correct answer

17. When a large gear drives a smaller gear, the output speed _____.

A. Decreases and torque decreases.

B. Decreases and torque increases.
C. Increases and torque increases.
D. Increases and torque decreases.

Multiple choice. Circle all the correct answer

18. When a small gear drives a larger gear, the output speed _____.

A. Decreases and torque decreases.

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B. Decreases and torque increases.

C. Increases and torque increases.
D. Increases and torque decreases.

Multiple choice. Circle all the correct answer

19. When an idler gear is placed between the driving and driven gear, the driven gear _____.

A. Rotates in the same direction as the driving gear.

B. Rotates in the direction opposite to the driving gear.
C. Remains stationary.
D. Rotates faster.

Multiple choice. Circle all the correct answer

20. Which of the following gear ratios generates the highest torque or power output?

A. 0.85:1.
B. 2.67:1.
C. 5.23:1.
D. 11.12:1.

Multiple choice. Circle all the correct answer

21. A gear ratio of 0.80:1 is a(n) _____ ratio

A. Reduction.
B. Overdrive.
C. Direct drive.
D. Geometric.

True or False question

22. The higher gear ratios allow for higher vehicle speeds and more torque.

✘ True or False

True or False question

23. The lower gear ratios provide less torque and reduce vehicle speed.

✘ True or False
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 AURLTX101 Diagnose and repair light vehicle manual transmissions

True or False question

24. A 1:1 ratio is called direct drive.

✘ True or False

True or False question

25. A 2.85:1 ratio represents a gear reduction.

✘ True or False

True or False question

26. If the engine is running at 3,000 rpm and the wheels are spinning at 500 rpm the overall gear ratio is six (6) to
one.

True or ✘ False

27. Why are overdrive gear ratios used in most modern transmissions?
Overdrive gear ratios reduce engine rpm at cruising speeds, improving fuel efficiency and reducing engine wear.

Fill in the Gaps

28. Complete the following statement about transmission gearsets using the following words.

Words: Axle, Calculated, Final, First, Fourth, Gears, Increased, Large, Meshes, Multoplying, Ratio, Second,
Shaft, Torque, Transmission,

Power is moved through the transmission via four gears (two sets of two gears). Speed and torque are altered in
steps. To explain how this works, let us assign numbers to each of the gears. The small gear on the input shaft has
twenty teeth. The gear it meshes with has forty. This provides a gear ratio of 2:1. The output of this gearset moves
along the shaft of the forty-tooth gear and rotates other gears. The gear involved with first gear has fifteen teeth. This
gear rotates with the same speed and with the same power as the forty-tooth gear. However, the fifteen-tooth gear is
meshed with a large gear with thirty-five teeth. The gear ratio of the fifteen-tooth and the thirty-five-tooth gearset is
2.33:1. However, the ratio of the entire gearset (both sets of two gears) is 4.67:1. The driveline’s gear ratios are further
multiplied by the gear ratio of the ring and pinion gears in the drive axle assembly. Typical final ratios are between
2.5 and 4.5:1. The final (overall) drive gear ratio is calculated by multiplying the transmission gear ratio by the final
drive ratio. If a transmission is in first gear with a ratio of 3.63:1 and has a final drive ratio of 3.52:1, the overall gear
ratio is 12.78:1. If fourth gear has a ratio of 1:1, using the same final drive ratio, the overall gear ratio is 3.52:1. The

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overall gear ratio is calculated by multiplying the ratio of the first set of gears by the ratio of the final (3.63 times 3.52
equals 12.78).

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29. Calculate this gear ratio, divide the driven (output) gear of the first set by the drive (input) gear of the first set.
Do the same for the second set of gears, and then multiply the answer from the first by the second. The result
is equal to the gear ratio of the entire gearset.

Driven (24) Driven (30) 60

X =
Drive (12) Drive (1)

30. What does the term “constant mesh” mean?

Constant mesh refers to a transmission design where all gears are in constant contact, but only selected gears are
engaged to transmit power.

Multiple choice. Circle all the correct answer

31. Manual transmission/transaxle lubricants in use today include ______.

A. Automatic transmission fluids.

B. Engine oils.
C. Multiple viscosity gear oils.
D. All answers are correct.

32. What is the purpose of the transmission/transaxle in a light vehicle?

To transfer power from the engine to the wheels at varying speeds and torque levels.

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33. Identify the nineteen [19] internal components of a manual transmission below.

1 Input shaft 11 Clutch hub

2 Output shaft 12 Clutch release mechanism

3 Gears (various types: spur, helical, 13 Clutch shaft

synchromesh)

4 Synchronizers (also known as synchros) 14 Counter shaft

5 Shift forks 15 Main shaft

6 Shift rails 16 Reverse idler gear

7 Bearings (various types: ball, roller) 17 Dog gears (for engagement)

8 Thrust washers 18 Differential gears (if part of the transmission

design)

9 Gear shafts 19 Oil pump (for lubrication, in some designs)

10 Selector mechanism

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34. Draw the power-flow for 1st, 2nd, 3rd, 4th, 5th gears and reverse gear on the manual transmission images below
and describe the path of the power through for each gear selection.

1st Gear
 Power flows from the engine through the input shaft.

 The input shaft drives the first gear on the main shaft.

 From the first gear, power is transmitted to the counter shaft.

 The counter shaft drives the output shaft through the first gear on the output shaft.

 This configuration provides the highest torque but lowest speed output.

2nd Gear

 Power continues to flow from the engine through the input shaft.

 The input shaft drives the second gear on the main shaft.

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 From the second gear, power is transmitted to the counter shaft.

 The counter shaft drives the output shaft through the second gear on the output shaft.

3rd Gear
 The input shaft drives the third gear on the main shaft.

 Power is transmitted to the counter shaft through the third gear.

 The output shaft is driven by the third gear on the output shaft.

 This gear provides a higher speed with less torque than 1st and 2nd gears.

 The input shaft drives the third gear on the main shaft.

4th Gear

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 The input shaft drives the fourth gear on the main shaft.

 Power is transmitted to the counter shaft through the fourth gear.

 The output shaft is driven by the fourth gear on the output shaft.

 This gear provides even higher speed with lower torque compared to lower gears.

5th Gear
 The input shaft drives the fifth gear on the main shaft.

 Power is transmitted directly to the output shaft through the fifth gear on the output shaft.

Reverse Gear
 To engage reverse, a reverse idler gear is used.

 The input shaft drives the reverse idler gear.

 The reverse idler gear meshes with a gear on the counter shaft.
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 Power is transmitted to the output shaft in the opposite direction, allowing the vehicle to move backwards.

35. What movement occurs inside a transmission when the vehicle is stopped, the engine is running, and the
transmission is in neutral?
 Input Shaft: The input shaft is connected directly to the engine through the clutch (if manual transmission) or
torque converter (if automatic transmission). It continues to rotate at engine speed.

 Output Shaft: The output shaft, which is connected to the wheels through the driveshaft and differential,
remains stationary because the vehicle is not moving.

 Gears and Shafts: Inside the transmission, gears (such as the main shaft and counter shaft) are typically in
motion due to the rotating input shaft. However, since the transmission is in neutral, these gears are not engaged
with any gear on the output shaft.

 Bearings and Lubrication: Bearings within the transmission allow the rotating parts to spin freely. Lubrication
ensures that these components operate smoothly and without excessive wear.

 Synchronizers: In a manual transmission, synchronizers are not engaged in neutral. They remain in a neutral
position, ready to engage when a gear is selected.

36. Draw the power-flow for 1st, 2nd, 3rd, 4th, 5th gears and reverse gear on the manual transaxle images below.
1st Gear
 Power flows from the engine through the input shaft.
 The input shaft drives the first gear on the main shaft.
 From the first gear, power is transmitted to the differential through the final drive gear.
 The differential then distributes power to the axles and ultimately to the wheels.

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2nd Gear
 Power continues to flow from the engine through the input shaft.
 The input shaft drives the second gear on the main shaft.
 Power is transmitted to the differential through the final drive gear.
 The differential distributes power to the axles and wheels.

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3rd Gear
 The input shaft drives the third gear on the main shaft.
 Power is transmitted to the differential through the final drive gear.
 The differential distributes power to the axles and wheels.

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4th Gear
 The input shaft drives the fourth gear on the main shaft.
 Power is transmitted to the differential through the final drive gear.
 The differential distributes power to the axles and wheels.

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5th Gear
 The input shaft drives the fifth gear on the main shaft.
 Power is transmitted to the differential through the final drive gear.
 The differential distributes power to the axles and wheels.

Reverse
 To engage reverse, a reverse idler gear is used.
 The input shaft drives the reverse idler gear.
 The reverse idler gear meshes with a gear on the main shaft in the opposite direction.
 Power is transmitted to the differential through the final drive gear.
 The differential distributes power to the axles and wheels, causing the vehicle to move backward.

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Fill in the Gaps

37. Complete the following statement about transaxle power flow using the following words.

Words: Differential, Gear, Output, Rotate, Selected, Shaft, Shift, Synchronizer

When first gear is selected, the first/second gear synchronizer engages with first gear. Because the synchronizer hub
is splined to the output shaft, first gear on the input shaft drives its mating gear (first gear) on the output shaft. This
causes the output shaft to rotate at the ratio of first gear and to drive the differential ring gear at that same ratio

38. Draw the power-flow for two-wheel drive (high range), four-wheel drive (high range) and four-wheel drive (low
range) on the transfer case images below.
Two-wheel drive (high)
 Power flows directly from the transmission to the rear wheels through the transfer case.
 Front differential and driveshaft are disengaged.

Four-wheel drive (high)

 Power flows from the transmission to the transfer case.
 Transfer case directs power to both the front and rear axles.
 Front and rear driveshafts are engaged.

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Four-wheel drive (low)

 Similar to high range, but with lower gear ratio.
 Provides increased torque for off-road conditions.
 Slower speeds and more power to all wheels.

39. Describe the path of the power through for each gear selection of the transfer case below.

Two-wheel drive, high range

Two-wheel drive, high range: Power flows directly from the transmission to the rear wheels through the
transfer case, bypassing the front axle.

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Four-wheel drive, high range

Four-wheel drive, high range: Power is split from the transmission to the transfer case, which then sends
power to both the front and rear axles.

Four-wheel drive, low range

Four-wheel drive, low range: Similar to high range but with a lower gear ratio, providing increased torque and
slower speeds for off-road conditions.

40. Name the five [5] part of a synchronizer assembly below.

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1  Synchronizer Hub: This component

is splined to the output shaft and rotates
with it.

2  Synchronizer Sleeve: Also known as

the blocker ring, it engages with the gear
to be selected and helps to synchronize
its speed with the output shaft.

3  Blocking Ring: A friction ring that

prevents the gear from engaging until
speeds are synchronized.

4  Shifting Keys or Plates: These are

mechanisms that facilitate the movement
of the synchronizer sleeve.

5  Detent Ball and Spring: These

components help to hold the
synchronizer in place once a gear is
engaged.

True or False question

41. In a conventional transmission, the speed gears freewheel around the mainshaft until they are locked to it by
the synchronizer.

✘ True or False

True or False question

42. During a gear shift, the blocking ring is pushed into the speed gear cone by the shifter plates or keys.

True or ✘ False

True or False question

43. The blocking ring eliminates friction between the cone-shaped surface on the speed gear and the
synchronizer assembly.

✘ True or False

Multiple choice. Circle all the correct answer

44. When fourth gear is selected on a five-speed manual transmission, the synchronizer couples the ______.

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A. Fourth speed gear to the mainshaft.

B. Clutch [input] gear to the mainshaft.
C. Both “fourth speed gear to the mainshaft” and “clutch [input] gear to the mainshaft”.
D. Neither “fourth speed gear to the mainshaft” nor “clutch [input] gear to the mainshaft”.

Multiple choice. Circle all the correct answer

45. Which of the following is not part of a synchronizer assembly?

A. Blocking ring.
B. Synchronizer hub.
C. Shifting plates or keys.
D. Interlock pin.

46. What is the function of a synchronizer?

Answer: The function of a synchronizer is to equalize the speed between the gear and the output shaft before
engagement, allowing smooth gear shifts without grinding.

47. Name the seven [7] parts of a gearshift mechanism assembly for a manual transmission below.

1  Shift lever.

2  Shift linkage.

3  Shift rails.

4  Shift forks.

5  Shift rods.

6  Selector mechanism.

7  Detent mechanism.

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48. Explain the role of shift rails and shift forks in the operation of transmissions and transaxles.
Answer: Shift rails guide the movement of shift forks, which in turn engage and disengage the gears on the
mainshaft or counter shaft of the transmission. They ensure that the correct gears are selected based on the
driver's input via the gearshift lever.

Multiple choice. Circle all the correct answer

49. When the 1-2 shift rail is moved into first gear, the 3-4 and 5-R shift rails are prevented from moving by the
______.

A. Detent ball and spring.

B. Shifter plate.
C. Shift fork.
D. Interlock pin.

True or False question

50. Cables are used to connect the shift lever to the transmission.

True or ✘ False

True or False question

51. Rods are used to connect the shift lever to the transmission.

✘ True or False

52. Nearly all part-time 4WD systems have a transfer case that not only allows for 2WD or 4WD, but also offers?
Answer: Typically, part-time 4WD systems offer a low range for increased torque and slower speeds during off-
road use.

True or False question

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53. In a part-time four-wheel drive systems, 4WD [4 HI or 4 LO] should not be selected when the vehicle is
traveling on dry surfaces.
✘ True or False

Multiple choice. Circle all the correct answer

54. Which of the following components is (are) NOT found in a transfer case?

A. Drive chain.
B. Shifter forks.
C. Blocking rings.
D. Planetary gearset.

Multiple choice. Circle all the correct answer

55. Full-time four-wheel drive _____.

A. Is never disconnected.
B. Must be disconnected by a technician.
C. Is disconnected during off-road use only.
D. Is used with manual transmissions only.

Multiple choice. Circle all the correct answer

56. A 4WD vehicle may be shifted into four-wheel drive _____.

A. Only while stopped.

B. Only while moving.
C. At any time.
D. Only according to the owner's manual instructions.

Multiple choice. Circle all the correct answer

57. _____ are often used to link the input and output shafts in a transfer case and serve as a link that does not
influence gear ratios.

A. Drive chains.
B. Sprockets.
C. Locking hubs.
D. Pin and rocker joints.

Multiple choice. Circle all the correct answer

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58. Which of the following components is NOT part of a viscous clutch assembly?

A. Sealed drum.
B. Hydraulic piston.
C. Externally splined steel plates.
D. Internally splined steel plates.

Multiple choice. Circle all the correct answer

59. In a viscous clutch, when the silicone fluid is heated, it ______.

A. Becomes a very thin fluid.

B. Boils to a vapour.
C. Thickens to a solid mass.
D. Stiffens.

Multiple choice. Circle all the correct answer

60. In an automatic AWD vehicle, normally one axle receives all the torque; when slippage occurs, 50 percent of
the torque can be sent to the other axle by _____ means.

A. Hydraulic.
B. Mechanical.
C. Electrical.
D. All answers are correct.

True or False question

61. If a noise stops with the engine at idle and the clutch disengaged, the noise is probably coming from the
inside of the transmission.
✘ True or False

Multiple choice. Circle all the correct answer

62. A clicking noise during transmission/transaxle operation may be an indication of ______.

A. Worn main shaft (input shaft) bearings.

B. Faulty synchronizer operation.
C. Failed oil seals.
D. Worn, broken, or chipped gear teeth.

True or False question

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63. A rough growling noise occurs when the engine is running, the transmission is in neutral, the clutch is
engaged, and the vehicle is not moving. The input shaft bearing may be faulty.
✘ True or False

Multiple choice. Circle all the correct answer

64. Gold-coloured particles in the transmission fluid are an indication of worn ______.

A. Blocking rings.
B. Gear teeth.
C. Roller bearings.
D. Shifter forks.

Multiple choice. Circle all the correct answer

65. A growling noise that occurs when the transaxle is in neutral, the vehicle is not moving, the engine is running,
and the clutch is engaged is most likely caused by ______.

A. Clutch pilot bearing.

B. Differential carrier bearing.
C. Output shaft bearing.
D. Input shaft bearing.

True or False question

66. A rough growling noise occurs when the vehicle is moving and the transmission is in forward or reverse
gears. The noise is not heard when the transmission is in neutral. The output or mainshaft bearings may be
faulty.
✘ True or False

67. What do shiny metallic particles in the oil indicate?

Answer: Shiny metallic particles in the oil usually indicate metal-to-metal wear, possibly from gears or bearings.

68. Identify three (3) causes of unusual noises from within a manual transmission.

1  Worn gear teeth.

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2  Faulty bearings (input shaft, output shaft, or mainshaft).

3  Synchronizer issues (worn or damaged).

True or False question

69. A plugged transmission vent may cause a seal to leak.
✘ True or False

70. List eight (8) the areas of potential transmission fluid leakage.

1  Output shaft seal.

2  Input shaft seal.

3  Rear extension housing seal.

4  Shift shaft seals.

5  Vent.

6  Pan gasket.

7  Cooler lines.

8  Transmission cooler

Multiple choice. Circle all the correct answer

71. An excessively low lubricant level will most likely cause ______.

A. Gear clash.
B. Hard shifting.
C. Gear lockup or seizure.
D. Gear jump-out.

True or False question

72. Manual transmission/transaxle internal shift linkage should be adjusted if a shift linkage problem is identified.
✘ True or False

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True or False question

73. Jumping out of gear is often caused by loose, worn, or out-of-adjustment shift linkage.
✘ True or False

Multiple choice. Circle all the correct answer

74. Using a lubricant that is thicker than service manual specifications can lead to ______.

A. Gear jump-out.
B. Hard shifting.
C. Gear lockup.
D. Gear slippage.

Multiple choice. Circle all the correct answer

75. A poorly adjusted shift linkage can cause which of the following problems?

A. Gear clash.
B. Hard shifting.
C. Jumping out of gear.
D. All answers are correct.

True or False question

76. Broken or worn engine and transaxle mounts can cause a transaxle to have shifting problems.
✘ True or False

Multiple choice. Circle all the correct answer

77. Which of the following will NOT cause gear clash?

A. Incorrect lubricant.
B. Incorrect clutch adjustment.
C. Worn countergear bearings.
D. Worn synchronizer blocking rings.

Multiple choice. Circle all the correct answer

78. The owner of an FWD car complains that the vehicle jumps out of second and fourth gears when he
accelerates hard. What could the fault be?

A. There could be insufficient clearance between the shifter boot and the shifter.

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B. One of the engine mounts could be broken.

C. Both “There could be insufficient clearance between the shifter boot and the shifter” and “One of the
engine mounts could be broken”.
D. Neither “There could be insufficient clearance between the shifter boot and the shifter” and “One of the
engine mounts could be broken”.

True or False question

79. Prior to disassembling a manual transmission, measure the input and output shaft end play with a dial
indicator.
✘ True or False

True or False question

80. End play and preload are usually set by placing shims under the bearing caps.
✘ True or False

Multiple choice. Circle all the correct answer

81. An engine support fixture is used to hold the engine in place while removing a ______.

A. FWD transaxle.
B. RWD transmission.
C. Both “FWD transaxle” and “RWD transmission”.
D. Neither “FWD transaxle” nor “RWD transmission”.

True or False question

82. On some vehicles, the engine and transmission must be removed as a unit.

✘ True or False

83. List three (3) components that may need to be removed from the vehicle before the transmission/transaxle
can be removed.

1  Driveshafts.

2  Starter motor.

3  Exhaust system components.

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84. Explain the four [4] procedure to replace the rear extension housing seal on an RWD manual transmission.

1  Support the vehicle securely on jack stands.

2  Drain the transmission fluid.

3  Remove the driveshaft.

4  Remove the old seal using a suitable seal removal tool, install a new seal using a seal driver tool,
and reassemble in reverse order.

Fill in the Gaps

85. Complete the following statement about linkage adjustment using the following words.

Words: Adjustments, Linkage, Provision, Service

Transmissions with internal linkage have no provision for adjustments. However, external linkages can be adjusted.
Linkages are adjusted at the factory but worn parts may make adjustments necessary. Also, after a transmission has
been reassembled, adjustments may be necessary. To begin the adjustment procedure, raise the car and support it
on jack stands. Then follow the procedure given in the service information.

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86. Consider the various post repair checks that you would make during a road test on the vehicle manual
transmissions?
 Shifting Operation: Ensure smooth shifting through all gears without any grinding or resistance.
 Clutch Engagement: Verify that the clutch engages smoothly and fully disengages when the pedal is
pressed.
 Noise Levels: Listen for any abnormal noises such as whining, grinding, or clicking during acceleration,
deceleration, and gear changes.
 Vibration: Check for excessive vibration, especially during acceleration or when maintaining steady speeds.
 Gear Engagement: Confirm that each gear engages properly and stays engaged without slipping out.
 Transmission Fluid Leaks: Inspect for any signs of transmission fluid leaks underneath the vehicle after the
road test.
 Performance: Evaluate the overall performance of the transmission in terms of responsiveness and power
delivery.
 Road Handling: Ensure that the vehicle handles well in various driving conditions (e.g., turns, inclines,
declines).

Multiple choice. Circle all the correct answer

87. Which source of information will give you the most detail about diagnosing and repairing light vehicle manual
transmissions on the vehicle you are working on?

A. Workshop manual.
B. Owner’s manual.
C. Google.
D. Textbooks.

88. Why is it very important that the Job Card is completed correctly?
 Documentation: It serves as an official record of the work performed, including details of repairs, parts
replaced, and services conducted.
 Reference: It provides information for future servicing or repairs, ensuring that subsequent technicians have a
clear understanding of the vehicle's history.
 Billing and Warranty: Accurate completion ensures correct billing for services rendered and validates
warranty coverage for parts and labor.
 Customer Communication: It helps in communicating the scope of work done to the customer, ensuring
transparency and satisfaction.

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