Assembling and Testing Manual Transmission

COMPETENCY BASED LEARNING MATERIAL
Sector:
AUTOMOTIVE
Qualification:
Automotive Servicing NC II
Unit of Competency:
Overhaul Manual Transmission
Module Title:
ASSEMBLING AND TESTING MANUAL TRANSMISSION

Technical Education and Skills Development Authority
East Service Road, South Superhighway, Taguig, Metro Manila
AUTOMOTIVE
INDUSTRY SECTOR
NATIONAL CERTIFICATE LEVEL II

QUALIFICATION LEVEL
COMPETENCY-BASED LEARNING MATERIALS

No. Unit of Competency Module Title Code
1. Service Starting System  Servicing Starting System ALT723307
2. Service Charging System  Servicing Charging System ALT723308
3. Service Engine Mechanical  Servicing Cooling System ALT723309a
System  Servicing Lubricating System ALT723309b
 Servicing Gasoline Fuel System ALT723309c
 Servicing Air Induction System ALT723309d
 Servicing Diesel Fuel Injector ALT723309e
4. Service Clutch System  Servicing Clutch System ALT723310
5. Service Differential and Front  Servicing Differential and Front ALT723311
Axle Axle
6. Service Manual Steering System  Servicing Manual Steering ALT723312
System
7. Overhaul Manual  Pulling-out, Disassembling and ALT723313a
Transmission Checking Manual Transmission
 Assembling and Testing ALT723313b
Manual Transmission
8. Service Brake System  Identifying and Explaining ALT723314a
Hydraulic Brake System
Operations and Functions
 Servicing Brakes ALT723314b
 Overhauling Brake Systems ALT723314c
9. Service Suspension System  Servicing Suspension System ALT723315
HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL
Welcome to the module in Assembling and Testing Manual Transmission. This module
contains training materials and activities for you to complete.
The unit of competency "Overhaul Manual Transmission" contains knowledge, skills and
attitudes required for Automotive Servicing. It is one of the specialized modules at National
Certificate level (NC III).
You are required to go through a series of learning activities in order to complete each
learning outcome of the module. In each learning outcome are Information Sheets and
Resources Sheets (Reference Materials for further reading to help you better understand the
required activities). Follow these activities on your own and answer the self-check at the end of
each learning outcome. You may remove a blank answer sheet at the end of each module (or
get one from your facilitator/trainer) to write your answers for each self-check. If you have
questions, don’t hesitate to ask your facilitator for assistance.
Recognition of Prior Learning (RPL)
You may already have some or most of the knowledge and skills covered in this learner's
guide because you have:
 been working for some time
 already completed training in this area.
If you can demonstrate to your trainer that you are competent in a particular skill or skills,
talk to him/her about having them formally recognized so you don't have to do the same training
again. If you have a qualification or Certificate of Competency from previous trainings, show it
to your trainer. If the skills you acquired are still current and relevant to the unit/s of competency
they may become part of the evidence you can present for RPL. If you are not sure about the
currency of your skills, discuss this with your trainer.
At the end of this module is a Learner’s Diary. Use this diary to record important dates, jobs
undertaken and other workplace events that will assist you in providing further details to your
trainer or assessor. A Record of Achievement is also provided for your trainer to complete
once you complete the module.
This module was prepared to help you achieve the required competency, in Assembling and
Testing Manual Transmission. This will be the source of information for you to acquire
knowledge and skills in this particular trade independently and at your own pace, with minimum
supervision or help from your instructor.
 Talk to your trainer and agree on how you will both organize the Training of this unit.
Read through the module carefully. It is divided into sections, which cover all the skills,
and knowledge you need to successfully complete this module.
 Work through all the information and complete the activities in each section. Read
information sheets and complete the self-check. Suggested references are included to
supplement the materials provided in this module.
 Most probably your trainer will also be your supervisor or manager. He/she is there to
support you and show you the correct way to do things.
 Your trainer will tell you about the important things you need to consider when you are
completing activities and it is important that you listen and take notes.
 You will be given plenty of opportunity to ask questions and practice on the job. Make
sure you practice your new skills during regular work shifts. This way you will improve
both your speed and memory and also your confidence.
 Talk to more experience workmates and ask for their guidance.
 Use the self-check questions at the end of each section to test your own progress.
 When you are ready, ask your trainer to watch you perform the activities outlined in this
module.
 As you work through the activities, ask for written feedback on your progress. Your
trainer keeps feedback/ pre-assessment reports for this reason. When you have
successfully completed each element, ask your trainer to mark on the reports that you
are ready for assessment.
 When you have completed this module (or several modules), and feel confident that you
have had sufficient practice, your trainer will arrange an appointment with registered
assessor to assess you. The results of your assessment will be recorded in your
competency Achievement Record.
QUALIFICATION : AUTOMOTIVE SERVICING NC II
UNIT OF COMPETENCY : Overhaul Manual Transmission
MODULE : Assembling and Testing Manual Transmission
INTRODUCTION:
This module deals with assembling manual transmission component, installing and
mounting transmission assembly. It also deals with the testing of manual transmission
output.
LEARNING OUTCOMES:
At the end of this module you will be able to:
1. Assemble manual transmission component;

2. Install and mount manual transmission and associated parts; and
3. Test manual transmission performance.
ASSESSMENT CRITERIA:
1. Manual transmission component parts cleaned, lubricated and coated with new
gear oil as per manufacturer’s manual.
2. Parts reference marks were used in assembling.
3. Assembling of transmission component was performed as per steps and procedure.
4. Bolts and nuts were torqued according to specifications and in correct sequence.
5. Correct tools were used for assembling.
6. Vehicle, workshop and parts safety requirements were applied.
7. Oil properly filled.
8. Transmission gear oil is filled properly and in appropriate level.
9. Transmission jack is positioned in accordance with safety procedure.
10. Transmission assembly is mounted to the engine/vehicle in correct steps as per
specification.
11. Attaching bolts were torqued according to specification and in correct sequence.
12. Transmission associated component were installed or mounted properly according
to steps and procedures.
13. Appropriate tools for the job were used.
14. Personal safety procedures were applied.
15. Transmission is tested while the engine is running and transmission in neutral
position.
16. Testing were conducted as per service manual.
17. Visual/ocular evaluation of transmission performance was conducted with emphasis
on performance of every shifting pattern, noise and operation.
18. Vehicle and shop work safety procedure is applied.
19. Personal safety requirement is observed.
PREREQUISITE:
Before you take this module you must complete first the modules: Set Up Work Area,
Equipment as well as the Core and Common Competencies of Automotive Service
Technician (NCII).
Code No. Date: Developed Date: Revised Page #

Assembling and Testing Manual Transmission
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LEARNING OUTCOME #1 : Assemble manual transmission component
1. Manual transmission component parts cleaned, lubricated and coated with new gear oil
as per manufacturer’s manual.
RESOURCES:
Equipment Supplies and Materials

1. Car equipped with manual transmission/ 12. Rags
transaxle 13. Soap
2. Hand tools
3. Working table 14. Spare bolt
4. Transaxle 15. Clear glass
5. Snap ring pliers 16. Apron/gloves
6. Punch 17. Clear pan/solvent
7. Press
18. Mechanic’s wire
8. Wrenches
9. Socket set 19. Transmission gear oil
10. Dial gauge
11. Manual
REFERENCES:
1. Manual Transmission and Power Trains by John H. White, pp 453-460

2. The Automotive Power Train and Running Gear, Power Flow and Chassis Unit by
Felizardo Y Francisco, Cayetano R. Rivera
3. Basic Auto Repair Manual Tools and Equipment

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Learning Outcome #1: Assemble manual transmission components
LEARNING ACTIVITIES SPECIAL INSTRUCTIONS
1. In the workshop with appropriate

equipment and other instructional
materials, the trainees will perform the
correct procedure in assembling manual
transmission components.
1.1 Read Information Sheet LO1-1 “Manual  Analyze the function of the transmission
Transmission Components” and its components.
1.2 Follow the procedures in Operation  Follow safety precautions.

Sheet LO1-1 “Removing the Gearbox”
1.3 Perform Job Sheet LO1-1 "Assembling  Mark parts of manual transmission in
Manual Transmission Components” detailed position and assemble following
the procedure. Follow the safety notes.
1.4 Assemble different transmission brands
following Job Sheets LO1-2, LO1-3  Ask your instructor to evaluate your work
and LO1-4 in the workshop and after performing the assembly.
observe shop practices and safety.

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INFORMATION SHEET LO1-1
Manual Transmission Components
TRANSMISSION:
Cars need transmissions

because of the physics of the
gasoline engine. First, any engine
has a redline -- a maximum rpm
value above which the engine cannot
go without exploding. Second, the
engines have narrow rpm ranges
where horsepower and torque are at
their maximum. For example, an
engine might produce its maximum
horsepower at 5,500 rpm. The
transmission allows the gear ratio
between the engine and the drive
wheels to change as the car speeds
up and slows down.
Photo courtesy DaimlerChrysler

You shift gears so the engine can stay below the redline and near the rpm band of its best
performance.
The name transmission refers to the series of parts used to transmit the engine torque
(turning effort) from the flywheel to the vehicle’s driving wheels.
The transmission usually consists of four major components:
 Clutch
- friction, fluid, or
electromagnetic
types
 Gearbox
- manual or
automatic
 Drive shaft
- propeller or
drive shaft and
universal joints CONVENTIONAL COMPONENT LAYOUT
 Final drive assembly
- provides a suitable top gear ratio;

- transmits drive to road wheels;
- provides differential action between driving wheels when the vehicle is cornering
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ENGINE AND TRANSMISSION POSITION
Location of engine and transmission

assemblies in the vehicle, vary with different
makes and models. This makes it essential
that you refer to the maker’s instruction
manuals to a certain in a correct and safe
method of removal and replacement of these
assemblies.
 Engine and transmission position in the ENGINE IN THE FRONT – REAR WHEEL DRIVE
vehicle may be:
- Traditional front engine and rear wheel
drive.
- Front engine with front and rear wheel

drive.
ENGINE IN THE FRONT – FRONT AND REAR

WHEEL DRIVE
- Front engine and front wheel drive
ENGINE IN THE FRONT – FRONT WHEEL

DRIVE
- Rear engine and rear wheel drive
ENGINE IN THE REAR – REAR WHEEL DRIVE

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DIFFERENTIAL:
The differential mechanism is fitted in final drive units to apply equal torque to each drive wheel,
yet allow them to turn at different speeds when the vehicle is turning or cornering.
 Conventional differential mechanisms are used on the majority of motor vehicles.

- This type will only move the vehicle when traction on each driving wheel is equal.
 Limited-slip differentials perform the same functions as the conventional type differentials,
but in addition, transfer the driving force to the wheel with traction, should the opposite
wheel begin to slip.
When serving a vehicle fitted with a limited-slip

differential, never run the engine while the
transmission is in gear and one rear wheel is raised,
The driving force to the wheel on the ground may
cause the vehicle to move. This is most dangerous if
the vehicle has other wheels removed.
Portable ‘on car’ type wheels balances are not

recommended for use on the rear wheels of cars
equipped with a limited-slip differential. However, this
type of balancer may be used by removing the wheel
opposite to the one being balanced, with the
complete assembly raised up. If a wheel is removed,
replace at least two wheel nuts to prevent the brake
DO NOT RUN THE ENGINE
drum from coming off.

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OPERATION SHEET LO1-1
Removing the Gearbox
The gearbox must be removed from the vehicle for proper inspection and servicing.
Draining oil
 Avoid scalds from the hot oil when:

- draining the gearbox and the final
drive housing;
- disconnecting oil pipes and lines;
- disconnecting oil coolers
 Ensure that the wheels are chocked before

disconnecting drive and propeller shafts in
the vehicle:
- has a transmission parking brake;
- is fitted with an automatic gearbox
and is engaged in the parked position;
- has a manual shift gearbox which
is engaged in forward or reverse drive. AVOID SCALDS WHEN DRAINING
Removing the gearbox
When removing and replacing gearboxes
 Plug the opening in the gearbox extension

housing, after removal of the drive shaft, to
prevent oil spillage.
 Support the engine assembly before

removing the transmission mountings.
- Do not let the engine hang on the
remaining support mountings.
 Do not manually lift or support the weight of

Support the engine
heavy transmission components during
removal or replacement. REMOVING THE GEARBOX
- Use a transmission trolley or a garage
jack in conjunction with a suitable
transmission cradle attachment.
Servicing and repair of these components often necessitates their removal from the vehicle,
To eliminate possible hazards when implementing this work, make reference to vehicle maker’s
manuals, as the procedures will vary with the different transmission and power flow systems
and layouts.
General safety precautions are to be observed.

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 Do not let the gearbox assembly hang on
engine without support, as it:
- may fall causing injury or damage
- can distort the clutch disc assembly.
 Use proper work stands or fixtures to

secure heavy transmission units when
carrying out repairs.
- Do not support it in a bench vice by
drain plugs or flanges, etc.
USE A TRANSMISSION PULLEY

Clutch
When dismantling certain types of clutch

pressure plate assemblies, care must be taken
to relieve the force of the pressure plate coil
springs before removing the retaining eye-bolt
adjusting nuts, otherwise the compressed
springs will cause parts to fly.
 Mark the clutch cover and pressure plate to

ensure reassembly in the same relative
position.
 Place the assembly on the bed of a press
with the pressure plate resting on wooden
blocks.
 Place a wooden block on top of the clutch
cover. RESTRAIN THE PRESSURE PLATE SPRINGS
 Carefully operate the press and compress
the clutch springs.
- remove the retaining eye-bolt nuts.
 Slowly release the force of the press so
that the cover will rise upwards as the
springs extend.
- Lift off the cover and remove the clutch
springs.
- The eye-bolts and levers can now be
removed.
DISMANTLE CLUTCH
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SYNCHRONIZER ASSEMBLY
Before disassembling the synchronizer assembly to examine the parts, file a scribe mark
across the front face of the third and fourth synchronizer sleeve and hub. These marks should
be aligned when assembling the synchronizer assembly to maintain mating parts if the same
parts are used.
Parts to be examined are:
 The snap ring holding the synchronizer assembly in place on the intermediate shaft. The
snap ring could be misplaced or have a sloppy fit.
 Synchronizer blocker rings. Refer to the section on examining the synchronizer blocker
ring.
 Synchronizer hub. There should be no rotary looseness between the synchronizer hub
and the intermediate shaft. If looseness exists, experiment with a new synchronizer huh
and check for a loose fit. If the looseness is removed, the synchronizer assembly must
be replaced.
 Worn synchronizer shift inserts and insert springs. These worn parts will permit the
synchronizer sleeve to slide back and forth on the synchronizer hub.
The synchronizer hub parts cannot normally be purchased separately. Therefore, the
synchronizer hub, sleeve, inserts, and springs must be purchased as an assembly. The only
parts of the synchronizer assembly that can be purchased separately from the sleeve and hub
are the synchronizer blocker rings. The snap ring retaining the synchronizer assembly on the
intermediate shaft can also be purchased separately.
Gear Teeth
A chipped or damaged gear tooth makes a clicking sound. This problem is easy to locate;
simply check all gear teeth for damage. If one gear tooth on the input shaft is damaged, the
whole input shaft assembly must be replaced. Since the damaged input shaft gear meshes with
a gear on the intermediate shaft, that mating gear should also be examined very closely. If both
gears are damaged, both must be replaced to remove the clicking noise. If the mating gear is
damaged, it must be replaced or of will reduce the new driving gear to its damaged state.
This completes the methods of examining and inspecting the most common causes of
manual shift transaxle problems. The next service procedures are assembling the transaxle
subassemblies and transaxle, followed by installing the transaxle assembly into the vehicle.

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JOB SHEET LO1-1
Assembling Manual Transmission Components”
TRANSAXLE SUBASSEMBLY ASSEMBLY PROCEDURE
1. Insert the third and fourth synchronizer

hub into the third and fourth synchronizer
sleeve and align the file marks.
NOTE: This alignment should also index

the inserts with the scalloped (small
curve) teeth placed 120 degrees apart on
the inside diameter of the synchronizer
sleeve.
NOTE: If the synchronizer blocker rings

are not replaced, they should be matched
with their respective gears. This whole
alignment and matching process helps to
ensure smooth gear shifting. A smooth
shifting transaxle might be the operator’s The Synchronizer inserts should align with the
only means of justifying the cost of the synchronizer sleeve scallops.
service work.
2. Assemble all three synchronizer

assemblies following the steps outlined
previously.
The synchronizer sleeve and hub must be aligned so that inserts index with the scallops.

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3. Install the antispin pin and first gear
thrust washer on the intermediate shaft.
4. Organize the parts on the workbench,
This ensures the proper location of gears,
thrust washers, and snap rings to be
installed onto the intermediate shaft.
5. Before installing each gear, lubricate the
inside diameter with lubricating oil to
ensure initial lubrication and make sure
that the gear turns freely with minimum of
0.003” (0.076mm) clearance between the
gears measured with a feeler gage.
Use the adapter and a hydraulic press to press on
the tight race of the intermediate shaft rear
bearing.
Safety Note:
When pressing bearings on or off a shaft, always cover the pressing operation with a safety
collar to restrict flying shrapnel in the event the bearing explodes.
6. Locate the special pressing arbor in contact with the rear bearing’s inner (tight) race. Using
a hydraulic press, drive the bearing assembly into place. After the rear bearing is seated,
check the fourth speed gear for free rotation.
7. After installing the rear bearing outer snap ring and intermediate shaft snap ring, check all
gears for free rotation.
Safety Note:
Check all synchronizer blocker rings to be sure that they rotate freely and do not bind on
adjacent cone clutches.
8. Remember that if the input shaft gear assembly or its bearing are replaced, the input shaft
select shim thickness must be recalculated. Refer to the service manual for this procedure.
9. With the input shaft in place, the intermediate shaft assembly and shift forks can be
installed into the transaxle housing.
10. Lubricate the reverse idler gear assembly and install in the transaxle housing. Seat the roll
pin into the roll pin notch.
11. With the shift rail and bearing retainer plate inside the transaxle housing, the parts for the
fifth gear can be organized on the workbench.
12. Install the input shaft fifth gear and snap ring, synchronizer, and shift fork and rail into the
transaxle housing.

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13. Shift the transaxle into neutral gear. With
the fifth speed shift pin (located in the
shift fork, insert into the shift fork and rail.
With the fifth fork and rail adjusted to the
other transaxle shift forks and rails, invert
the fifth speed shift pin and tighten into
place.
14. After installing the fifth gear strut retainer

plate and snap ring, install the rear end
cover with new sealant. Tighten all rear
end cover plate bolts and the fill plug.
The shift pin is located in the shift fork.
15. With new sealant on the contact surfaces, install the selector shaft housing. Be sure to
insert the bolts in their proper location.
16. Lubricate the new extension housing 0-ring and install the differential assembly, extension
housing, and bolts. Bolts should be torqued to manufacturer’s specifications.
17. Align and install the differential bearing retainer and torque the bolts to manufacturer’s
specifications.
18. Apply new sealer to the differential cover installing bolts and studs in proper locations.
Now the transaxle is ready to be installed.

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SUBASSEMBLIES ASSEMBLY PROCEDURE
1. Coat the inside diameter of the cluster gear assembly with petroleum jelly and insert the
dummy shaft.
2. Place the counter shaft needle bearings between the dummy shaft and the inside diameter
of the cluster gear assembly.
3. When the needle bearings are all in place, install at either end the bearing thrust washers
and the original or replacement cluster assembly thrust washers.
4. Place pilot end (front) of transmission output shaft upward.
Layout of the transmission output shaft
5. Lubricate the third speed gear and place on the output shaft with the cone clutch facing up.
6. Install the third gear synchronizer blocker ring so the cone clutch sits on the third gear
cone clutch.
Service Tip:
The synchronizer sleeve has a large, deep groove located on the outside diameter at the
rear of the synchronizer assembly. The synchronizer hub has a longer front hub than rear.
When building up the synchronizer assembly align the file marks on the sleeve and hub and
place the sleeve groove at the opposite end of the synchronizer hub from the long front hub.
7. Install the third and fourth synchronizer assembly with the longer front inner hub facing up.
The synchronizer sleeve should be facing downward,

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8. Be sure the notches on the synchronizer blocker rings align with the inserts of the
synchronizer assembly.
9. Install the third and fourth synchronizer assembly snap ring. Tap the snap ring with a
hammer and punch to ensure it is seated.
10. Turn the rear of the output shaft upward to install the remaining output shaft parts.
11. Lubricate the inside diameter of the second speed gear and slide on the output shaft with
the cone clutch facing up.
12. Install the synchronizer blocker ring so the cone clutches meet.
13. Install the first and second synchronizer assemblies so the large, deep shift fork groove is
facing downward.
14. Install the first and second synchronizer snap ring making sure it is seated the output shaft
groove.
15. The first gear synchronizer blocker ring can be installed and the inserts aligned.
16. Lubricate the inside diameter of the first speed gear and install with the steel thrust washer
and the spring washer.
17. Using a hydraulic press install the rear bearing onto the output shaft. Install the rear
bearing snap ring.
18. Install the speedometer drive gear and retaining clip.
19. With the output shaft assembled, test your assembly work
a. Check that all gears on the output shaft rotate freely.

b. Check that the synchronizer blocker rings are not jammed on the gear cone clutches
c. Make sure all snap rings are seated into place
20. Place petroleum jelly into the socket at the rear of the transmission input shaft and install
the roller bearings.

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TRANSMISSION ASSEMBLY PROCEDURE
1. Place thrust rings and washers at either

end of cluster gear assembly.
Installing the rear transmission bearing on the

transmission output shaft
NOTE: Petroleum jelly or heavy grease can be used to hold these parts in place during
assembly.
2. Insert the cluster gear assembly, thrust

rings, washers, and dummy shaft through
the rear opening of the transmission
housing. Be sure the thrust washer tangs
face away from the cluster assembly and
the tangs index with the grooves inside
the transmission housing.
3. Align the cluster assembly with the holes

in the transmission housing and insert the
counter shaft and woodruff key from the
rear.
4. Using a plastic hammer, tap the counter

shaft and woodruff key into place in the
transmission housing while removing the
dummy shaft.
Roller bearings being installed in the transmission

input shaft using petroleum jelly or heavy grease
to hold rollers in place.
5. Lubricate the reverse idler gear inside diameter and install the reverse idler gear, shaft,
and woodruff key from the rear of the housing.

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6. With snap ring pliers, expand the extension housing snap ring and slide the extension
housing over the output shaft assembly. Be sure the snap ring seats in the rear bearing
outer groove.
7. Place the fourth gear synchronizer blocker ring into place on the third and fourth
synchronizer assembly. Be sure the notches of the synchronizer blocker ring align with the
synchronizer inserts.
8. Place the transmission input shaft on the pilot (front) of the output shaft.
Service Tip:
Piece petroleum jelly on the rear surface of the transmission housing to hold the extension
housing gasket in place.
9. Feed the input shaft, output shaft assembly, and extension housing through the rear
opening of the transmission housing.
10. The reverse idler might have to be moved back and forth on the shaft to accommodate the
assembly operation.
11. Align the extension housing bolt holes and install the extension housing bolts. Do not
tighten these bolts until the front transmission bearing is installed.
12. Install the large outer front bearing snap ring over the outer bearing race.
13. Slide the front transmission bearing onto the transmission input shaft and seat into place.
14. Install the small front transmission bearing snap ring.
15. Align the front bearing retainer and gasket to the transmission housing.
Be sure the lubricant drainage groove aligns with the transmission housing. Install the front
bearing retainer bolts.
16. Tighten extension housing to transmission housing bolts.
17. Move all synchronizer sleeves to the neutral position.
18. Place the transmission cover gasket in place.
19. Shift the forks on the cover plate to the neutral position.
20. Install the cover plate with the shift forks seating into the synchronizer sleeves and tighten
all bolts.
21. The transmission should be shifted through all gear ranges before installing into the
vehicle.

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JOB SHEET LO1-2
ASSEMBLING A WARNER T-10
1. Before reassembling bearings and

spacers in countergear, inspect teeth
closely for excessive wear, chips or
cracks; replace it if worn, damaged.
2. While you’re at it, check spacers,

countergear roller bearings for wear.
Inspect countershaft, reverse idler;
replace them if necessary.
2. Use a dowel pin or shaft to retain bearings

spacers; slip solvent-cleaned bearings and
washers into countergear. Dip in lube so
they’ll stay in place.
4. The 40 rollers inside countergear are in 4

rows of 10 each, separately by two
narrow spaces, one long spacer. Pin is
removed as rollers go in.

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5. Liberal application cluster gear thrust
hold them in countergear is transmission.
of lube on washer helps place when
inserted into
6. Rest transmission on its side, with side

cover opening toward assembler. Put
countergear thrust washer in place; hold
with a coat of heavy grease.
7. Set countergear in place at bottom of

case; be sure the tanged thrust washers
have not been moved or dowel pin has
not slipped away from rollers.
8. Shaft must be removed or it wiIl interfere

with assembly of mainshaft and clutch
gear. Leave thrust washer in place,
countergear at case bottom.
9. Reinstall the 14 roller bearings inside

main drive gear; use heavy-duty grease
to hold bearings in position while
assembly is inserted.

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10. When assembling the front reverse idler
gear, make sure the teeth are pointed
forward with hub facing to rear of the
transmission case.
11. The 1st 2nd and 3rd gears, with synchro

rings, are assembled on mainshaft. Hub
of 3rd notches on synchro ring should
always face forward.
12. Install 3rd, 4th gear clutch assembly with

taper to front. Be sure keys in hub match
notches in 3rd gear synchro ring. Insert
main drive gear.
13. Before assembly is put in case, put new

selective snap rings (that’ll fit in groove)
on mainshaft in front of 3rd~, 4th speed
gear clutch unit.
14. Rear bearing retainer can be slid over

end of mainshaft. Spread snap ring in
pliers so it will drop around rear bearing
when aligned with groove.

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15. First insert reverse idler shaft into
housing, then slide flat thrust washer in
place. Tang on thrust washer should face
thrust portion of case.
16. Next slip reverse idler gear onto shaft,

engaging spiines with portion of gear
within case. Place new gasket on rear
bearing retainer’s face.
17. Pull reverse shift shaft partially out of

extension; rotate shaft to get reverse shift
fork as far forward in rear extension
housing as possible.
18. Now, you can start the extension onto the

mainshaft while pushing in on shifter
shaft to engage shift fork with reverse
gear shift collar.
19. When fork engages shift fork, rotate

shifter shaft to move reverse gear
rearward, permitting extension to mate to
transmission case.

ALT723313b 8/ 25/ 2003 06/01/21 19
20. With pin in shifter lever boss, torque rear
extension housing bolts to 40 ft -lbs.
install rear extension-to-bearing retainer
bolts, 25 ft-lbs. maximum
21. With hammer and punch, tap clutch

bearing in place. Be sure bearing is
clean, lubricated, checked for roughness
(by turning race in hand.)
22. Use snap ring pliers to slide selective fit

snap rings, spacer washer, bearing snap
ring over maindrive gear and into proper
places.
23. Be sure to use a new gasket that’s

slightly moist with lube, before you bolt
bearing retainer to front of 1-10
transmission case.
24. New front bearing retainer gasket should

be firmly in place and the retainer snug
on case. Use good sealer, torque
capscrews to 18 ft.-lbs

ALT723313b 8/ 25/ 2003 06/01/21 20
25. Shift forks must fit snugly in grooves on
3rd 4th speed clutch sliding sleeve and 1st
and 2nd speed clutch sliding sleeve, as
shown.
26. Shift trans into 2nd position side cover,

attach new gasket, engage shift forks in
collars; install side cover, seal and torque
capscrews.
27. After trans is filled and shifter linkage is

attached your just- like-new Warner T-
10 transmission is all ready to tackle the
streets again.

ALT723313b 8/ 25/ 2003 06/01/21 21
JOB SHEET LO1-3
ASSEMBLING A MUNCHE 4-SPEED
1. Drain lube from trans; remove side cover,

clutch retainer housing, rear extension
housing, countergear, main drive gear
units; clean and inspect.
2. Begin assembly by checking bearings for

undue wear, then lubricate with light
engine oil Check gears for wear, clutch
sleeves for sliding.
3. After inspecting all moving parts, insert

rear bearing in rear bearing retainer;
release snap ring, position correctly in
retainer groove.
4. Once 1st and 2nd gears (with their

synchros, clutch sleeves, etc.) have been
installed on mainshaft, tap rear bearing
retainer onto shaft.

ALT723313b 8/ 25/ 2003 06/01/21 22
5. Spread snap ring with pliers, then ailow
ring to align with groove in end of
mainshaft to help retain rear bearing.
Install reverse, anti-rattle springs.
6. Install 3rd and 4th gears (hub to front of

trans), synchronizers and 3rd 4th gear
clutch assemblies with both sleeves to
front of trans case.
7. Cluster goes in bottom of case with all

bearings held in place by dowel. Then tap
main drive gear and bearing into hole in
case; work from inside.
8. Position reverse idler gear thrust washer

on machined face of ear cast in case of
reverse idler shaft. Hold assembly in
case with heavy lube coating.
9. Shove reverse idler gear next to thrust

washer, with the hub facing to rear of
case. Install flat thrust washer on reverse
idler gear.

ALT723313b 8/ 25/ 2003 06/01/21 23
10. Stick cage and its17 roller bearings into
maindrive gear; use heavy grease to hold
bearings in place.Put oil slinger
(concaveforward) on gear.
11. Now you can lower mainshaft assembly

into case. Be sure notches on 4th gear
synchro ring correspond to the keys on
the clutch assembly.
12. Align countergear with shaft in rear and

hole in front of case, press countershaft
in case, push assembly dowel out until
shaft is flush with case.
13. Cut on rear of countershaft must be

aligned so it will mate to similar cut in
rear extension housing to keep shaft from
spinning in trans case.
14. Install reverse idler shaft roll pin (pin

should be in vertical position), and thrust
washer into gear, front boss of case, pick
up front-tanged washer.

ALT723313b 8/ 25/ 2003 06/01/21 24
15. Rear extension housing is turned to
reveal shifter fork for reverse gear. Arrow
shows slot that reverse idler shaft roll pin
alions with.
16. Pull reverse shifter side of extension, to

bring reverse extension housing detent
position). shaft to left rotate shaft shift
into (reverse
17. Start rear extension housing onto trans

case, while slowly pushing it on the
shifter shaft to engage the shift fork with
the reverse shift collar.
18. Pilot reverse idler shaft into extension;

slide onto case attach bolts. Line up shaft
with holes in boss and insert lock pin.
Install shifter, side cover.

ALT723313b 8/ 25/ 2003 06/01/21 25
JOB SHEET LO1-4
ASSEMBLING A FORD 4-SPEED
1. Assembly is started by putting the cluster

and reverse goodies in position, but the
cluster is lying on the bottom of the case
and shaft.
2. The reverse shifter shaft is now in and

secured. A set screw holds the shifter
fork to the rail. Note the holes for two
more shifter shafts.
3. Support thrust washer and low gear to

prevent them from sliding off end of shaft;
then carefully lower output shaft
assembly into case.
4. Place front synchronizer into 3rd gear

position; install set screw in 3rd and 4th
gear shift fork. Move synchronizer to
neutral.

ALT723313b 8/ 25/ 2003 06/01/21 26
5. The mainshaft, with all the gears already
on it, goes in through the top of the case.
Then the shift forks and the shafts are put
into their positions.
6. Tightening the set screw in the shift fork

that helps secure it to the rail. All of the
steps are described in detail in detail in
genuine Ford manual.
7. The detent on the bottom shift rail screws

in from the side of the case. Note dummy
aluminum bearing temporarily holding
mainshaft in position.
8. Another shift rail is tapped from the front.

Bar across the front of the transhold the
front of mainshaft in position while doing
the good work.
9. Not many people have this press, but it’s

the right way to put the rear bearing into
the case — with no beating. Hammer
mechanic, please take note.

ALT723313b 8/ 25/ 2003 06/01/21 27
\10. After the bearing is in position, the snap
ring slips on easily - if you have snap ring
pliers. Another snap ring goes on the
shaft against bearing.
11. After the main drive gear and its bearings

are slipped into position, the front bearing
retainer, with a new seal inside, is bolted
on the case.
12. Standing the box on end makes it easier

to move the gear cluster into position so
the shaft can be inserted. Lower hand is
catching dummy shaft.
13. The cluster gear shaft and reverse idler

shaft are kept from turning by roll pins
that must enter these recesses in the
case to be held securely.
14. First a gasket, and then the tailshaft

housing is slid into position. A new seal
should be installed in the end of the
housing to stop drip.

ALT723313b 8/ 25/ 2003 06/01/21 28
16. Detent for the dropped into the place by
the breather on top relieve pressure. top
shift rail is hole, and held in cover. Note
of housing to
17. The bolts are well greased so that the

torque readings will be consistent but no
sealer is used on the cover gasket. Fluid
leaks are not a problem.
18. That’s right, even the cover is torqued. If

you’re going to be super accurate, why
not go all the way? Reminder: Don’t
forget to put in lube.

ALT723313b 8/ 25/ 2003 06/01/21 29
LEARNING OUTCOME #2 : Install and mount manual transmission and associated parts

3. Transmission assembly is mounted to the engine/vehicle in correct steps as per
specification.
5. Transmission associated component were installed or mounted properly according to
steps and procedures.
RESOURCES:

1. Hoist 11. Rags
2. Jack stands 12. Soap
3. Drop light 13. Mechanic’s wire
4. Wrenches 14. Oil catch pan
5. Transmission trolley
6. Car with manual transmission and
transaxle
7. Hand tools
8. Crocodile jack
9. Manual transmission
10. Working tables
REFERENCES:
1. Manual Transmission and Power Trains by John H. White

2. The Automotive Power Train and Running Gear, Power Flow and Chassis Unit, by
Felizardo Y. Francisco, Cayetano R. Rivera

ALT723313b 8/ 25/ 2003 06/01/21 30
Learning Outcome #2 : Install, mount manual transmission and associated parts
In the workshop with appropriate and Follow the procedures in examining and
equipment and other instructional materials, inspecting the most common causes of
the trainees will perform the correct procedure manual shift transaxle problem including its
in installing/ mounting manual transmission installation.
and associated parts.
1. Install transaxle  Follow the procedures in Job Sheet LO2-

1 “Transaxle Installation Procedure”
2. Inspect standard transmission  Follow the steps in Assignment Sheet

LO2-1 “Inspecting Standard
Transmission”
 Report results in oral or written format

3. Evaluate the inspection. using criteria in the Self-Check LO2-1
 Follow the procedures in Job Sheet LO2-

4. Install transmission 2 “Transmission Installation Procedure”
 Follow steps in Operation Sheet LO2-1

5. Replace standard transmission “Replacing Standard Transmission”
 Report results in oral or written format

6. Evaluate the installation using criteria in the Self-Check LO2-2

ALT723313b 8/ 25/ 2003 06/01/21 31
JOB SHEET LO2-1
TRANSAXLE INSTALLATION PROCEDURE
1. Have a colleague help place the transaxle assembly onto the transaxle jack. Chain and
install two locating pins in the engine block assembly.
2. Make up and install two locating pins in the engine block assembly.
Service Tip:
In transmission work, housing and bolt hole alignment are important and often necessary.
Get into the habit of having two or three aligning pins for each common bolt diameter. An
aligning pin can be a bolt with the hex head removed and a radius ground on the end to ease
piloting of parts through a hole. Often pin to ease installation and removal with a standard
screwdriver.
3. Position the transaxle assembly and jack in place under the vehicle and align with the
engine and clutch assembly.
4. At the rear of the transaxle, push the jack and transaxle toward the engine while aligning
the two locating pins with their respective holes in the transaxle housing.
5. With the transaxle assembly in place, install and tighten the transaxle to the engine block
bolts. Replace the two locating pins with the proper bolts.
6. Remove the safety chains and transaxle jack from under the vehicle.
7. Install the antirotational link, left engine mount, and splash shield.
8. When installing the left drive shaft, hold the inner universal joint assembly at the housing
while aligning and inserting the spline into the transaxle housing.
9. Place the outer splined shfat into the steering knuckle support.
10. Install the lower ball joint into the left steering knuckle support.
NOTE: The original or equivalent bolt must be used. No substitutes are allowed.
11. Torque the steering knuckle clamp bolt I
to manufacturer’s specifications.
12. Unwrap the speedometer pinion, adapter,
and cable and install into the transaxle
extension housing.
13. While supporting the right side inner
universal joint housing, push the drive
shaft into place.
14. Insert the outer end of the right drive
shaft into the right side steering knuckle.
Tighten the steering knuckle clamp bolt to

manufacturer’s specifications.
15. Install the lower ball joint stud into the steering knuckle and retain with the steering knuckle
clamp bolt.

ALT723313b 8/ 25/ 2003 06/01/21 32
16. Install the front wheel hub nut and wheel nuts according to the sequence outlined in the
service manual.
17. Add lubricant to the proper level as recommended by the manufacturer.
18. Connect the gearshift operating lever and selector shaft.
19. Lower the vehicle to the floor
20. Torque the hub nut and wheel lug nuts to manufacturer’s specifications.
21. Repeat the gearshift linkage adjustment.
22. Adjust the clutch pedal clearance.
23. Connect the battery negative cable to the battery.
24. Remove the engine support fixture and install the #4 cylinder exhaust manifold bolt.
25. Remove fender covers.
26. Road test the vehicle for quiet operation, smooth upshifting, and downshifting.
FACTS TO REMEMBER:
1. Some of the factors that contribute to a transmission slipping out of gear center around the
parts of a synchronizer assembly.
2. A clicking noise in one gear range during vehicle operation indicates a damaged gear
tooth.
3. When assembling a synchronizer assembly, align the indexing marks.
4. During assembly always lubricate the gear’s inside diameter to provide initial lubrication
and ensure easy rotation.
5. After pressing a bearing into a shaft, always check the gears turn freely on the shaft and
that the synchronizer blocker rings are free.

ALT723313b 8/ 25/ 2003 06/01/21 33
ASSIGNMENT SHEET LO2-1
INSPECTING STANDARD TRANSMISSION
OBJECTIVE What you need Tools to remove and replace a

standard transmission
What you will do Inspect parts of a standard
transmission
How well So that you can determine
which parts are damaged and
must be replaced.
If you feel able to meet this objective now, turn to the Self Check.
PURPOSE Standard transmission are powered by the engine through one or
more drive couplings. This LE will show you how to inspect
transmission parts for damage in order to determine if they must be
replaced.
Materials and  Vehicle
Equipment  Shop manuals
 Safety glasses
 Hand tools set
 Seal puller
 Seal driver
 Transmission gasket
 Transmission seals
 Can opener or oil spout
 Shop towels
 Jack stands
 Floor jack
 Drain pan
 Gasket sealer
 Creeper
 Transmission fluid
 Transmission jack
 Gasket scraper
 Fender covers
 Blowgun
 Air cornpressor

ALT723313b 8/ 25/ 2003 06/01/21 34
INSPECTING STANDARD TRANSMISSION
STEP 1. Wash all bearings in clean solvent.
STEP 2. Dry bearings by using air blow gun and compressed air.
CAUTION: Hold bearings while blowing with compressed air to prevent bearings from
spinning in their race.
STEP 3. Check bearings for roughness or pitting.
STEP 4. Clean and inspect the inside of the transmission case for cracks.
STEP 5. Clean and inspect all gears for broken teeth, wear or other damage.
STEP 6. Inspect synchronizer assemblies for grooving or excessive wear.
NOTE: Any parts showing damage or wear must be replaced.

ALT723313b 8/ 25/ 2003 06/01/21 35
Self-Check LO2-1
Inspect Standard Transmissions
Directions At this time, check your skills by reviewing the following criteria.
1. Bearings are cleaned and dried correctly.
2. Transmission parts are inspected for damage or excessive wear.
3. Parts to be replaced are determined.
4. All safety rules are observed.
If you do not feel you can do some of these skills, see your instructor for help.
After you have done all your checking

remember to clean and put away your
materials and equipment.

ALT723313b 8/ 25/ 2003 06/01/21 36
JOB SHEET LO2-2
TRANSMISSION INSTALLATION PROCEDURE
1. Have a colleague help you lift the transmission onto the transmission jack. Wrap the safety
chains around the transmission housing and transmission jack.
2. After aligning the transmission jack and transmission with the clutch assembly, shift the
transmission into gear. Rotate the transmission output shaft so the transmission input shaft
aligns and engages with the clutch driven disc splines.
3. Remove the safety chains from around the transmission housing and transmission jack.
Slide the transmission off the transmission jack and into place.
4. Install and tighten the transmission mounting bolts to manufacturer’s specifications with a
torque wrench.
5. Install the cross member and transmission mount.
6. Remove the masking tape from the rear universal joint and align the indexing marks on the
rear universal joint yokes. Install the rear universal joint and be careful not to tighten the
mounting U bolts.
7. Connect the speedometer cable.
8. Install the shift levers at the side of the transmission cover plate
9. Connect the backup light connector and the transmission control switch connector.
10. Remove the engine support stand.
11. Install transmission gear lubricant to the required level. Be sure to tighten the filler hole
plug.
12. Lower the vehicle, but leave the driving wheels free of the floor.
13. Connect an exhaust system pipe to the vehicle.
14. Start the engine and operate the transmission through the various gear ranges checking
for smooth shifting and quiet operation. If the transmission checks out satisfactorily, lower
the vehicle to the floor.
15. The vehicle should now be road tested for smooth, quiet transmission operation.

ALT723313b 8/ 25/ 2003 06/01/21 37
FACTS TO REMEMBER:
1. The parts on the four-speed transmission output shaft are the third and fourth synchronizer
assembly, third speed gear, second speed gear, first and second synchronizer assembly,
first speed gear, and the rear bearing assembly.
2. The synchronizer assembly hub will have a longer hub at the front than at the rear.
3. When assembling the synchronizer assembly, the synchronizer sleeve groove must be at
the opposite end of the synchronizer assembly to the long hub on the synchronizer hub.
4. Synchronizer blocker ring notches must be always align with the synchronizer inserts.
5. After the assembling the output shaft, a good service technician always checks his or her
work.
6. Cluster assembly thrust washer tangs must always face away from the cluster gear
assembly.
7. When installing the front bearing retainer. The lubrication drainage groove must align with
the transmission housing.
8. When installing the transmission, shift into gear so the transmission input shaft can be
aligned with the clutch driven disc.
9. Indexing marks must be aligned when installing the drive shaft to maintain alignment and
balance.
TRANSMISSION LUBRICANT LEVEL CHECK
Lubricant in a transmission reduces friction, wear, and heat. If the lubricant level is low, the
rotating gear teeth cannot throw enough oil onto the synchronizer assemblies and rotating
parts. Gear clashing problems and premature parts wear result from low lubricant levels.
When checking the lubricant be sure the transmission is at operating temperature. The
lubricant level should be at the lower edge of the filler plug hole. If the transmission is cold, the
lubricant level should be adjusted to approximately %“to ¾ (12 mm to 19 mm) below the filler
plug hole.
These recommendations are important because when the lubricant is cold it contracts and
when hot it expands. If the transmission is filled and when hot it expands. If the transmission is
filled to the bottom of the filler plug hole when cold, heat will cause the lubricant to expand and,
consequently, overfill the transmission. The surplus fluid could flood the front transmission seal
and flow onto the clutch driven disc. Lubricant on the clutch driven disc causes clutch chatter
and grab.

ALT723313b 8/ 25/ 2003 06/01/21 38
OPERATION SHEET 2-1
REPLACING STANDARD TRANSMISSION
STEP 1. Replace the transmission
Here’s how:
a. Place transmission on transmission jack with input facing the clutch housing
b. Raise transmission jack high enough to align input shaft clutch housing.
c. Slowly and carefully roll transmission jack forward until the shaft goes into
transmission housing.
NOTE: Make sure clutch release bearing is in place.
d. Move transmission slightly to the left or right, up or down, until alignment dowel pins
go through the bolt holes in the transmission housing.
e. Remove alignment dowel pins and start attaching the bolts with your fingers.
f. Start the bottom attaching bolts.
NOTE: Make sure bolts are started straight and not cross-threaded.
g. Use socket and wrench and snug down transmission mounting bolts.
NOTE: Alternate from one bolt to the other. Make sure the transmission case has equal
pressure applied to it.
h. Use torque wrench and torque to specifications.
Use the combination wrench to install the crossmember to the bolts.
j. Use combination wrench to install transmission mounts to transmission and

crossmember
NOTE: If any exhaust system parts were removed, replace them at this time.
k. Remove engine support jack and wooden blocks
I. Install shift linkages
NOTE: Make sure the shift linkages do not bind and that they are properly attached
m. Use pliers to connect speedometer cable.
n. Reconnect all wires that were attached to the transmission.
NOTE: The wires and linkages should have been numbered with masking tape for ease
in
installation.
ALT723313b 8/ 25/ 2003 06/01/21 39
o. Use crescent wrench or combination wrench to install drain plug.
p. Use crescent wrench or combination wrench to remove filler plug found on side
transmission case.
q. Fill the transmission with proper lubricant.
NOTE: Check manual for type of lubricant to use and amount required to fill.
r. Use crescent wrench or combination wrench to replace filler plug.
STEP 2. Install the drive shaft.
STEP 3. Use the jack to raise the vehicle and remove jack stands.
STEP 4. Lower the vehicle to the floor
STEP 5. Clean the work area of all oil spills.
STEP 6. Return tools and equipment to their proper storage area.

ALT723313b 8/ 25/ 2003 06/01/21 40
Self-Check LO2-2
Replace Standard Transmissions
Directions: At this time, check your skills by reviewing the following criteria.
1. Transmission is installed correctly.
2. Drive shaft is installed correctly.
3. All tools and equipment are returned to their proper storage area.
4. All safety rules are observed.
If you do not feel you can do some of these skills, see your instructor for help.
After you have done all your checking

remember to clean and put away your
materials and equipment.

ALT723313b 8/ 25/ 2003 06/01/21 41
QUALIFICATION : AUTOMOTIVE SERVICING NC III
LEARNING OUTCOME #3 : Test manual transmission performance
1. Transmission is tested while the engine is running and transmission in neutral position.
3. Visual/ocular evaluation of transmission performance was conducted with emphasis on
performance of every shifting pattern, noise and operation.
RESOURCES:

1. Car with manual transmission and 5. Rags
transaxle. 7. Soap
2. Testing instruments
8. Fuel
3. Hand tools
9. Warning devices
4. Wrenches
10. Troubleshooting chart
5. Socket wrench set
REFERENCES:
1. Manual Transmission and Power Trains by John H. White

2. The Automotive Power Train and Running Gear, Power Flow and Chassis Unit, by
Felizardo Y. Francisco, Cayetano R. Rivera

ALT723313b 8/ 25/ 2003 06/01/21 42
Learning Outcome #3: Test manual transmission performance
In the workshop using appropriate tools and

equipment and other instructional materials,
the trainees will test newly repaired manual
transmission.
1. Read: Steps in troubleshooting  Job Sheet #LO3-1 “Testing Manual

defective transmission and power train Transmission”
components.
2. Test : Newly repaired running manual  Install the transmission into the vehicle
transmission. and check for defects using the
procedures in Job Sheet #LO3-1
3. Observe shop practices and safety.
4. Report results in oral or written format

ALT723313b 8/ 25/ 2003 06/01/21 43
JOB SHEET LO3-1
TESTING MANUAL TRANSMISSION
OBJECTIVE What you need A troubleshooting chart and a vehicle with

defective transmission and power train
components
What will you do Troubleshoot transmission and power train
problems and determine their causes
How well So that you identify at least 75% of the causes
of noises and vibrations in the given
transmission and drive trains
If you feel able to meet this objective now, turn to the self check.
PURPOSE Noises and vibrations are common in transmissions and drive trains.
Many of these can cause serious damage to the vehicle if not found
and corrected. A mechanic must be able to troubleshoot and isolate
the causes of these in order to make the correct repairs. In this Job
Sheet you will learn how to find and identify these causes.
Materials and  Motor or shop manual
Equipment
 Troubleshooting checklist
 Vehicle with defective transmission and power train components

ALT723313b 8/ 25/ 2003 06/01/21 44
STEP 1. Check noises in the clutch.
Possible Cause Correction
1. Dry clutch linkage 1. Lubricate where necessary

2. Worn release bearing. 2. Replace release bearing
3. Worn disc assembly 3. Replace disc assembly
4. Worn release levers 4. Replace cover assembly
5. Worn or dry pilot bushing. 5. Lubricate or replace bushing
6. Dry contact-pressure plate lugs in cover. 6. Lubricate very lightly
STEP 2. Check chatter in the clutch
1. Worn or damaged disc assembly. 1. Replace disc assembly

2. Grease or oil on disc facings. 2. Replace disc assembly cause of
contamination.
3. Improperly adjusted cover assembly. 3. Replace cover assembly
4. Broken or loose engine mounts. 4. Replace or tighten mounts
5. Misaligned clutch housing. 5. Align clutch housing and correct
STEP 3. Check why a clutch jumps out of gear
1. Gearshift linkage incorrectly adjusted. 1. Adjust linkage

2. Gearshift linkage bent or binding. 2. Correct bind, replace bent parts.
3. Clutch housing misaligned. 3. Check runout at rear face of clutch
housing.
4. Worn pilot bushing 4. Replace bushing.
5. Worn or damaged clutch shaft roller 5. Replace bearings.
bearings.
6. Worn, tapered gear teeth; synchronizer 6. Inspect and replace as required.
parts worn.
7. Shifter forks, shift rails, or detent-interlock 7. Inspect and replace as required
parts worn, missing, etc.
8. Excessive end play of output shaft gear 8. Replace thrust washers, and snap rings
train, countershaft gear or reverse idler (output shaft gear train)
gear.
STEP 4. Check why clutch is slipping.
1. Insufficient pedal free play. 1. Adjust release fork rod.

2. Burned, worn or oil-soaked facings. 2. Replace disc assembly and correct
cause of contamination.
3. Weak or broken pressure springs. 3. Replace cover assembly.

ALT723313b 8/ 25/ 2003 06/01/21 45
STEP 5. Check why gears clash when shifting from one forward gear to another.
1. Incorrect clutch adjustment - 1. Adjust clutch

2. Clutch linkage binding 2. Lubricate or repair linkage as required
3. Gear shift linkage incorrectly adjusted, 3. Adjust linkage, correct binds, replace
bent or binding. bent parts.
4. Clutch housing misalignment. 4. Check runout at rear face of clutch
housing.
5. Damaged or worn transmission 5. Inspect components. Repair or replace
components: shift forks, synchronizers, as required.
shift rails and interlocks. Excessive end
play to worn thrust washers.
STEP 6. Check the causes of transmission noises.
1. Low fluid level 1. Check for leakage and refill

2. Wrong fluid 2. Replace with proper fluid
3. Dirt or chips in fluid 3. Drain and flush transmission
4. Plugged or restricted screen 4. Clean or replace screen
5. Damaged screen to valve body gasket 5. Replace valve body gasket.
6. Damaged or worn pump oil seals. 6. Replace pump oil seals.
7. Loose converter to flywheel bolts. 7. Tighten flywheel bolts
8. Gearshift linkage bent, binding, or 8. Adjust linkage, correct binds, replace
adjusted wrong bent parts.
9. Clutch housing aligned wrong. 9. Check runout at rear of housing clutch.
STEP 7. Check why a transmission is locked in one gear.
1. Gearshift linkage binding or bent. 1. Correct bind, replace bent components.

2. Transmission shifter lever attaching nuts 2. Tighten nuts, replace worn levers.
loose or levers are worn at shifter fork
shaft hole.
3. Shift rails worn or broken, shifter fork lock 3. Inspect and replace worn or damaged
plug missing or worn. parts
4. Broken gear teeth on countershaft gear, 4. Inspect and replace damaged part.
clutch shaft, or reverse idler gear.

ALT723313b 8/ 25/ 2003 06/01/21 46
STEP 8. Check why a transmission will not shift into a certain gears when all others are
working correctly.
1. Gearshift linkage not adjusted correctly 1. Adjust linkage

2. Bent shift rod at transmission 2. Replace rod
3. Transmission shifter levers reversed 3. Correctly position levers
4. Worn or damaged shift rails, shift forks, 4. Inspect and repair or replace parts as
detent-interlock plugs, loose setscrew in required.
shifter fork, worn synchronizer parts.
STEP 9. Check why a transmission shifts hard.
1. Incorrect clutch adjustment 1. Adjust clutch pedal free-play

2. Clutch linkage binding 2. Lubricate or repair linkage as required
3. Gearshift linkage incorrectly adjusted, 3. Adjust linkage — correct any bind.
bent, or binding. Replace bent pads
4. Bind in steering column, or column is 4. Disconnect shift rods at column. Check
misaligned. for bind/misalignment between tube and
jacket by shifting lever into all positions.
Correct as required.
5. Incorrect lubricant 5. Drain and refill transmission.
6. Internal bind in transmissions - e.g. shift 6. Remove transmission and inspect shift
rails, interlocks, shift forks, synchronizer mechanism. Repair as required.
teeth.
7. Clutch housing misalignment. 7. Check runout at rear face of clutch
housing.
STEP 10. Check why it is difficult to shift the gears.
1. Excessive pedal free play 1. Adjust release fork rod.

2. Excessive deflection in linkage or firewall 2. Repair or replace linkage
3. Worn or damaged disc assembly 3. Replace disc assembly
4. Improperly adjusted cover assembly 4. replace cover assembly
5. Clutch disc splines sticking. 5. Remove disc assembly splines or replace
disc.
6. Worn or dry pilot bushing. 6. lubricate or replace bushing
7. Clutch housing misaligned. 7. Align clutch housing and free up

ALT723313b 8/ 25/ 2003 06/01/21 47
STEP 11. Check why lubricant is leaking in differential and drive axles.
1. Lubricant level too high 1. Drain excess lubricant

2. Worn axle shaft oil seals 2. Replace worn oil seals with new ones.
Prepare new seals before replacement.
3. Cracked rear axle housing 3. Repair or replace housing as required.
4. Worn drive pinion oil seal 4. Replace worn drive pinion oil seal with a
new one.
5. Scored and worn companion flange 5. Replace worn or scored companion
flange and oil seal.
6. Clogged vent 6. Remove obstruction.
7. Loose carrier housing bolts or housing 7. Tighten bolts or cover screws to
cover screws specifications and fill to correct level with
proper lubricant.
STEP 12. Check for cause of noise in rear wheel.
1. Loose wheel 1. Tighten loose wheel nuts

2. Spalled wheel bearing cup or cone 2. Check rear wheel bearings. If spalled or
worn, replace.
3. Defective or brinelled wheel bearing 3. Defective or brinelled bearings must be
replaced.
4. Excessive axle shaft end-play 4. Readjust axle shaft end-play
5. Bent or sprung axle shaft flange. 5. Replace bent or sprung axle shaft.
STEP 13. Check for cause of noise in rear axle.
1. Insufficient lubricant 1. Refil rear axle with crrect amount of the

proper lubricant. Also check for leaks and
correct as necessary.
2. Improper ring gear and pinion adjustment 2. Check ring gear and pinion tooth contact
3. Unmatched ring gear and pinion 3. Remove unmatched ring gear and pinion.
Replace with a new matched gear and
pinion set.
4. Worn teeth on ring gear or pinion. 4. Check teeth on ring gear and pinion for
contact. If necessary, replace with new
matched set.
5. End-play in drive pinion bearings. 5. Adjust drive pinion bearing preload.
6. Side-play in differential bearings 6. Adjust differential bearing preload
7. Incorrect drive gear lash 7. Correct drive gear lash
8. Limited-slip differential — moan and 8. Drain and flush lubricant. Refill with
chatter proper lubricant

ALT723313b 8/ 25/ 2003 06/01/21 48
STEP 14. Check for cause of overheating.
1. Lubricant level too low. 1. Refill rear axle

2. Incorrect grade of lubricant 2. Drain, flush and refill rear axle with
correct amount of the proper lubricant
3. Bearings adjusted too tightly 3. Readjust bearings.
4. Excessive wear in gears 4. Cheek gears for excessive wear or

scoring. Replace as necessary.
5. Insufficient ring gear to-pinion clearance 5. Readjust ring gear and pinion backlash
and check gears for possible scoring.
STEP 15. Check for cause of vibrations.
1. Unbalanced or damaged drive shaft 1. Check drive for damage and balance.
2. Worn universal joints 2. Check u-joints and replace as needed
3. Misaligned drive shaft at companion 3. Adjust and align drive shaft
flange.
STEP 16. Check to see if differential gears and pinion are scored.
1. Insufficient lubrication 1. Replace scored gears. Scoring marks on

the pressure face of gear teeth or in the
bore are caused by instantaneous fusing
of the mating surface. Scored gears
should be replaced. Fill rear axle to
required capacity with proper lubricant.
2. Improper grade of lubricant 2. Replace scored gears. Inspect all gears
and bearings for possible damage. Clean
and refill axle to required capacity with
proper lubricant.
3. Excessive spinning of one wheel. 3. Replace scored gears. Inspect all gears,
pinion bores and shaft for scoring, or
bearings for possible damage.

ALT723313b 8/ 25/ 2003 06/01/21 49
STEP 17. Check tooth breakage on ring gear and pinion.
1. Overloading 1. Replace gears. Examine other gears and

bearings for possible damage. Avoid
future overloading.
2. Erratic clutch operation 2. Replace gears, and examine remaining
parts for possible damage. Avoid erratic
clutch operation.
3. Ice-spotted pavements 3. Replace gears. Examine remaining parts
for possible damage. Replace parts as
required.
4. Improper adjustment 4. Replace gears. Examine other parts for
possible damage. Be sure ring gear and
pinion backlash is correct.

ALT723313b 8/ 25/ 2003 06/01/21 50
PERFORMANCE TEST
Learner’s Name: Date:

Test Attempt
Competency: Overhaul Manual Transmission 1st 2nd 3rd
Directions: OVERALL EVALUATION

Level
CALL INSTRUCTOR. Ask instructor Achieved PERFORMANCE LEVELS
to assess your performance in the 4 – Can perform this skill without supervision and with initiative
following critical task and and adaptability to problem situations.
performance criteria below.
3 – Can perform this skill satisfactorily without assistance or
You will be rate based on the supervision.
overall evaluation on the right side. 2 – Can perform this skill satisfactorily but requires some
assistance and/or supervision.
1 – Can perform parts of this skill satisfactorily, but requires

considerable assistance and/or supervision.
Instructor will initial the level achieved.
PERFORMANCE STANDARDS
For acceptable achievement, all items should receive a “Yes” Yes No N/A
or “N/A” response.
1. Did you clean, lubricate and coat manual
transmission components with new gear oil as per manufacturers
manual?
2. Have you clean transmission bearings
following the proper procedure?
3. Did you follow the correct steps in installing
and mounting manual transmission?
4. Did you properly test the manual
transmission performance meet in the required conditions?

ALT723313b 8/ 25/ 2003 06/01/21 51
Learner’s diary
DIARY NOTES
Record important dates, jobs undertaken and other workplace events that will assist you in providing further
details to your Assessor.
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ALT723313b 8/ 25/ 2003 06/01/21 52
Record of Achievement
Module: Assembling and Testing Manual Transmission

Learning Outcome #1 - Assemble manual transmission component
Performance Criteria:
1. Manual transmission component parts cleaned, lubricated and coated with new gear oil as per
manufacturer’s manual.
COMMENTS:
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Learner has satisfied the above performance criteria.
Learner’s signature: ……………………………………….
Trainer’s signature: ………………………………………..
Date: ……………………………………………………….

ALT723313b 8/ 25/ 2003 06/01/21 53
Learning Outcome #2 - Install and mount manual transmission and associated parts

3. Transmission assembly is mounted to the engine/vehicle in correct steps as per specification.
5. Transmission associated component were installed or mounted properly according to steps
and procedures.
COMMENTS:
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Date: ……………………………………………………….

ALT723313b 8/ 25/ 2003 06/01/21 54
Learning Outcome #3 - Test manual transmission performance
1. Transmission is tested while the engine is running and transmission in neutral position.
3. Visual/ocular evaluation of transmission performance was conducted with emphasis on
performance of every shifting pattern, noise and operation.
COMMENTS:
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ALT723313b 8/ 25/ 2003 06/01/21 55
EVIDENCE PLAN
Sector: AUTOMOTIVE SERVICING NC III
Unit of Competency: OVERHAUL MANUAL TRANSMISSION
Module Title: ASSEMBLING AND TESTING MANUALS TRANSMISSION
QuestioningDemonstration
Ways in which evidences will be collected:
(tick the column)
Interview
Portfolio
The evidence must show that the candidate …
1. Assemble manual transmission components X

2. Install, mount manual transmission and associated
X
parts
3. Test manual transmission performance X
Note: *Critical aspects of competency
Prepared by: Date:

Instructor
Date:
Supervisor

ALT723313b 8/ 25/ 2003 06/01/21 56
Demonstration
Questions Satisfactory Response

The candidate should answer the following questions: Yes No
1. What are the steps in cleaning the transmission bearing and  
associated components?
2. Explain the steps/procedure in installing and mounting manual  
transmission and associated parts.
3. Did you meet the required condition in testing manual  
transmission performance?
 
 
 
 
 
 
 
 
 
 
 
 
 
The candidate’s underpinning knowledge was:
Rating: _________
Feedback to candidate
The candidate’s overall performance was:
Rating: _________
Candidate’s signature: Date:
Assessor’s signature: Date:

ALT723313b 8/ 25/ 2003 06/01/21 57
Demonstration
Candidate’s name:
Assessor’s Name:
Competency Assessment Title: OVERHAUL MANUAL TRANSMISSION
Qualification: AUTOMOTIVE SERVICING NC III
Date of Assessment:
Tome of Assessment:
Instructions for Demonstration:
Given the following material, tools and equipment, the candidate must be able to overhaul the
manual transmission.
a. Car equipment with manual transmission/transaxle
b. Hand tools
c. Working table, stand
d. Manual
Tick () to show if evidence is

OBSERVATION
demonstrated
Yes No
During the demonstration of skills, did the candidate: ACTUAL
1.0 – 3.0 5.0
1. Clean, lubricate manual transmission component
parts.   
2. Coat with nuts gear oil as per manufacturer’s
manual   
3. Perform assembling manual transmission as per
steps and procedures.   
4. Fill transmission gear oil properly and in
appropriate level.   
5. Position transmission jack in accordance with
safety procedure.   
6. Mount transmission assembly the engine/vehicle in
correct steps as per specification.   
7. Install transmission associated component
according to steps and procedure.   
8. Use appropriate tools and procedure for the job.   
9. Apply personal safety procedure.   
10. Torque bolts and nuts according to specifications
and in correct sequence.   
11. Test transmission while the engine is running and
transmission in neutral position   
12. Conduct visual/ocular evaluation of transmission
performance of every shifting pattern, noise and   
operation.
  
  
The candidate’s demonstration was:
Rating ______________

ALT723313b 8/ 25/ 2003 06/01/21 58
TECHNICAL TERMS
1. Transaxle Power transmission device, attached to one end of the

transmission and driveshaft final drive and differential into a
single assembly
2. Overdrive A device or transmission gear arrangement which cause the
output shaft to overdrive or rotate faster than the input shaft.
3. Steering Column shift An arrangement in which the transmission shift lever is mounted
on the steering column.
4. Synchomesh A transmission with a built-in device that automatically matches
transmission the rotating speed automatically matches the rotating speed of
the transmission gears as they are about to mess there
eliminating the need for double clutching.
5. Transmission Oil A small, sometimes finned, tube or tank, either mounted
cooler separately or included as part of the engine radiator, which
cools the transmission fluid.
6. Transfer case An auxiliary
7. Transmission A metal case containing an assembly of shafts gears and related
parts. used to transmit power from the engine to the drive shaft
or final drive of an automatic vehicle; provide different gear
ratios as well as neutral and reverse; may be manual, automatic
or continuously variable.
8. Gears Wheel with meshing teeth that transmit power or turning force
between shafts.
9. Bearing A part that transmit a load to a support and in so doing absorbs
most of the friction of moving parts.
10. Gear Ratio A number of revolution of a driving gear required to turn a driver
gear through one complete revolution.
11. Gear shift A linkage type mechanism by which the gears of an automotive
transmission are engage and disengaged.
12. Synchronizer A device in the transmission that synchronizes gear about to be
meshed so that no miss will occur.
13. Reverse Iidler gear in a transmission, an additional gear that must
meshed to obtained reverse gear a gear use only in reverse.
That does not transmit power when transmission is in any other
position.
14. Ratio The relationship in size or quantity of two or more objects. A gear
ratio is derived by dividing the number of teeth on the driver gear
by the number of teeth on the driving gear.
15. Shift lever The lever used to shift gears in a transmission.

ALT723313b 8/ 25/ 2003 06/01/21 59

Assembling and Testing Manual Transmission

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COMPETENCY BASED LEARNING MATERIAL

ASSEMBLING AND TESTING MANUAL TRANSMISSION

NATIONAL CERTIFICATE LEVEL II

COMPETENCY-BASED LEARNING MATERIALS

Recognition of Prior Learning (RPL)

 Talk to more experience workmates and ask for their guidance.

At the end of this module you will be able to:

1. Assemble manual transmission component;

Code No. Date: Developed Date: Revised Page #

Equipment Supplies and Materials

1. Manual Transmission and Power Trains by John H. White, pp 453-460

Code No. Date: Developed Date: Revised Page #

LEARNING ACTIVITIES SPECIAL INSTRUCTIONS

1. In the workshop with appropriate

1.2 Follow the procedures in Operation  Follow safety precautions.

Code No. Date: Developed Date: Revised Page #

Cars need transmissions

Photo courtesy DaimlerChrysler

The transmission usually consists of four major components:

 Final drive assembly

- provides a suitable top gear ratio;

Location of engine and transmission

- Front engine with front and rear wheel

ENGINE IN THE FRONT – FRONT AND REAR

- Front engine and front wheel drive

ENGINE IN THE FRONT – FRONT WHEEL

- Rear engine and rear wheel drive

ENGINE IN THE REAR – REAR WHEEL DRIVE

Code No. Date: Developed Date: Revised Page #

 Conventional differential mechanisms are used on the majority of motor vehicles.

When serving a vehicle fitted with a limited-slip

Portable ‘on car’ type wheels balances are not

Code No. Date: Developed Date: Revised Page #

 Avoid scalds from the hot oil when:

 Ensure that the wheels are chocked before

Removing the gearbox

When removing and replacing gearboxes

 Plug the opening in the gearbox extension

 Support the engine assembly before

 Do not manually lift or support the weight of

General safety precautions are to be observed.

Code No. Date: Developed Date: Revised Page #

 Use proper work stands or fixtures to

USE A TRANSMISSION PULLEY

When dismantling certain types of clutch

 Mark the clutch cover and pressure plate to

Parts to be examined are:

Code No. Date: Developed Date: Revised Page #

TRANSAXLE SUBASSEMBLY ASSEMBLY PROCEDURE

1. Insert the third and fourth synchronizer

NOTE: This alignment should also index

NOTE: If the synchronizer blocker rings

2. Assemble all three synchronizer

Code No. Date: Developed Date: Revised Page #

Code No. Date: Developed Date: Revised Page #

14. After installing the fifth gear strut retainer

The shift pin is located in the shift fork.

Code No. Date: Developed Date: Revised Page #

4. Place pilot end (front) of transmission output shaft upward.

Layout of the transmission output shaft

Code No. Date: Developed Date: Revised Page #

18. Install the speedometer drive gear and retaining clip.

a. Check that all gears on the output shaft rotate freely.