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Automotive
Servicing NC II
Quarter 2 – Module 6 to 8:
Test Manual Transmission
TLE/TVL Automotive Servicing NCII – Grade 12
Self-Directed Learning Material
Quarter 2 – Module 6 – 8: Test Manual Transmission
First Edition, 2020

Republic Act 8293, section 176 states that: No copyright shall subsist in any work of
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over them.

Published by the Department of Education

Secretary: Leonor Magtolis Briones
Undersecretary: Diosdado M. San Antonio

Development Team of the Module

Writers: Manolito S. Cabigas
Editor: Robin C. Baja
Reviewers: Marcelo O. Roco and Glenn T. Zabate
Illustrator: Name
Layout Artist: Name
Management Team: Reynaldo M. Guillena
Jinky B. Firman
Marilyn V. Deduyo
Alma C. Cifra,
Aris B. Juanillo
Marcelo O. Roco

Printed in the Philippines by ________________________

Department of Education – Region XI Davao City Division

Office Address : DepEd Davao City Division, E. Quirino Ave.,

Davao City, Davao del Sur, Philippines
Telefax : (082) 2240100
E-mail Address : info@deped-davaocity.ph
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Automotive
Servicing NC II
Quarter 2 – Module 6 to 8:
Test Manual Transmission
Introductory Message
For the facilitator:

Welcome to the TLE/TVL – Automotive Servicing NCII Self-Directed Learning

Materials (SDLM) on Test Manual Transmission.

This module was collaboratively designed, developed, and reviewed by educators

both from public and private institutions to assist you, the teacher, or facilitator in
helping the learners meet the standards set by the K to 12 Curriculum while
overcoming their personal, social, and economic constraints in schooling.

This learning resource hopes to engage the learners in guided and independent
learning activities at their own pace and time. Furthermore, this also aims to help
learners acquire the needed 21st-century skills while taking into consideration their
needs and circumstances.
In addition to the material in the main text, you will also see this box in the body of
the module:

Notes to the Teacher

This contains helpful tips or strategies that
will help you in guiding the learners.

As a facilitator, you are expected to orient the learners on how to use this module.
You also need to keep track of the learners' progress while allowing them to manage
their learning. Furthermore, you are expected to encourage and assist the learners
as they do the tasks included in the module.

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For the learner:

Welcome to the TLE/TVL – Automotive Servicing NCII Self-Directed Learning

Material (SDLM) on Test Manual Transmission.

The hand is one of the most symbolized parts of the human body. It is often used
to depict skill, action, and purpose. Through our hands, we may learn, create, and
accomplish. Hence, the hand in this learning resource signifies that you as a learner
is capable and empowered to successfully achieve the relevant competencies and
skills at your own pace and time. Your academic success lies in your own hands!

This module was designed to provide you with fun and meaningful opportunities for
guided and independent learning at your own pace and time. You will be enabled to
process the contents of the learning resource while being an active learner.

This module has the following parts and corresponding icons:

What I Need to Know This will give you an idea of the skills or
competencies you are expected to learn in the
module.

What I Know This part includes an activity that aims to

check what you already know about the
lesson to take. If you get all the answers
correct (100%), you may decide to skip this
module.

What’s In This is a brief drill or review to help you link

the current lesson with the previous one.

What’s New In this portion, the new lesson will be

introduced to you in various ways such as a
story, a song, a poem, a problem opener, an
activity, or a situation.

What is It This section provides a brief discussion of the

lesson. This aims to help you discover and
understand new concepts and skills.

What’s More This comprises activities for independent

practice to solidify your understanding and
skills of the topic. You may check the
answers to the exercises using the Answer
Key at the end of the module.

What I Have Learned This includes questions or blank

sentences/paragraphs to be filled in to
process what you learned from the lesson.

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 What I Can Do This section provides an activity that will help
you transfer your new knowledge or skill to
real-life situations or concerns.

Assessment This is a task that aims to evaluate your level

of mastery in achieving the learning
competency.

Additional Activities In this portion, another activity will be given

to you to enrich your knowledge or skill of the
lesson learned. This also tends to the
retention of learned concepts.

Answer Key This contains answers to all activities in the

module.

At the end of this module you will also find:

References This is a list of all sources used in developing

this module.

The following are some reminders in using this module:

1. Use the module with care. Do not put unnecessary mark/s on any part of
the module. Use a separate sheet of paper in answering the exercises.
2. Don’t forget to answer What I Know before moving on to the other activities
included in the module.
3. Read the instruction carefully before doing each task.
4. Observe honesty and integrity in doing the tasks and checking your answers.
5. Finish the task at hand before proceeding to the next.
6. Return this module to your teacher/facilitator once you are through with it.
If you encounter any difficulty in answering the tasks in this module, do not
hesitate to consult your teacher or facilitator. Always bear in mind that you are
not alone.

We hope that through this material, you will experience meaningful learning and
gain a deep understanding of the relevant competencies. You can do it!

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 What I Need to Know

This module was designed to help you master the skill of testing manual
transmission. This includes knowing how to check transmission oil after
installation, mounting manual transmission, installing transmission linkages and
attachments, and conducting transmission testing.

Further, this was anchored on the Curriculum Guide in TLE/TVL Automotive

Servicing NC II under Industrial Arts component.

LO 5. Test manual transmission. (TLE_IAAUS9- 12OMT-IIc-h-47)

After going through this module, you are expected to:

1. Check transmission oil after installation.

2. Mount manual transmission.

3. Install transmission linkages and attachments.

4. Conduct transmission testing.

What I Know

Choose the letter of the best answer. Write the chosen letter on a separate sheet of
paper.

1. Which part of a synchronizer is splined to a shaft?

a) Hub c. Synchronizer blocker ring
b) Speed gear d. Synchronizer sleeve

2. A rear-wheel-drive 5-speed manual transmission is being discussed. What

is the gear ratio when the transmission is in 4th gear?
a. 1:1 c. 8:1
b. 1.5:1 d. 3:1

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 3. A five-speed transmission is in third gear. Which is correct?
a. The 1-2 synchronizer is in neutral
b. The 3-4 synchronizer is moved to engage third gear
c. Both A and B
d. Neither A nor B

4. A five-speed manual transaxle is noisy in all gears. Which is the least likely
cause?
a. A pilot bearing c. An input shaft bearing
b. An output shaft bearing d. Final drive side (differential)
bearings

5. The idler gear is used for which gear?

a. First c. Third
b. Second d. Reverse

Lesson
Test Manual Transmission
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Manual gearboxes are limited mostly to sports and performance cars and
include 4, 5, and 6-speed transmissions. The top gear in 5- and 6-speed manual
transmissions are usually an overdrive ratio to improve highway fuel economy.
Manual gearboxes are relatively trouble-free and long-lived, but gears and
synchronizers (which allow you to shift gears smoothly) can be damaged by abusive
driving.

Transmission is an important component of your vehicle. That is why it is a

must to keep your transmission in good condition. To help you understand the
condition of your transmission, checking transmission oil levels, color and scent
will help you do it.

Mounting manual transmission, installing transmission linkages and

attachments, and conducting transmission testing is an equally important skill that
you need to keep your vehicle in good condition.

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 What’s In

In the previous lesson, you were taught how to inspect manual transmission
internal components for defects and were exposed to various possible manual
transmission troubles. In this module, you will be taught how to check transmission
oil after installation, learn how to mount manual transmission, install linkages and
attachments, and familiarize the procedures in testing newly repaired manual
transmission.

Notes to the Teacher

With the availability of some pictures or illustration that serves as
an actual procedure of how the tasks is done. As basis of learning
the learner should make a summary of how the tasks is done.

What’s New

What do you think will happen if transmission oil breaks down? Why is it important
to check and maintain manual transmission’s good condition?

Manual transmissions consist of internal gears, bearings, and synchronizers that

allow the driver to shift gears. Many manual transmissions are lubricated with
heavy petroleum-based oil. When this oil breaks down its lubricating properties
break down, which will make it harder for the driver to get the transmission into
gear.

Manual transmission’s good condition is as important as any other key component

of a vehicle, so, to prevent worse problems it is appropriate to protect your vehicle
through proper transmission tests.

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 What is It

Source: Google stock photos

Manual transmission problems can be developed due to high mileage, abuse,

or lack of proper maintenance. But they are rather rare. Most manual transmission
issues originate not with the transmission itself, but from related components like
the clutch assembly, linkage, or driveline: the components that transmit turning
power from the transmission to the wheels. Also, as we discuss below, symptoms
that seem to be coming from the transmission can come from unrelated parts of the
car.

The key to diagnosing your manual transmission problem is to gather

detailed information about the particular problem. For example, does the problem
appear in only one of the gears, only at a certain speed, only when turning, only
when downshifting, or after having serviced the clutch or another transmission
component? Can you feel a vibration? Can you hear a clunking or grinding noise?

Symptoms of a Bad Transmission

Here are some symptoms that can indicate a worn-out transmission, each one of
which we discuss below.

1. Odd sounds (whirring, squealing, bumping, or thumping)

2. Grinding noise

3. Transmission jumps out of gear (into neutral)

4. Difficulty shifting gears

5. Car stuck in one gear

6. Car that can't get into gear

7. Leaking transmission oil

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 This guide will get you started on identifying the source of these problems. You'll
need to investigate further and remember that manual transmission configurations
can change from one model to the next.

Remember that this guide only deals with symptoms coming from the manual
transmission (or transaxle) itself. Some symptoms that may appear to originate in
the transmission come from the clutch (or another system), and vice versa. To get a
more accurate diagnosis, take a look at the Bad Clutch Symptoms guide as well.

Source: Google stock photos

Your noise may not be coming from the transmission; a bad CV joint can produce noises when you
accelerate or make a turn.

1. Odd Noises That May Come From the Transmission

The most common cause of a noisy transmission is insufficient oil, causing

the gears or internal assembly to hum or whir. If a noisy transmission does have
enough oil, the lubricant may be contaminated with metal shavings or particles.

Insufficient or contaminated oil may cause the transmission to become noisy in

some or all of the gears. But if you hear noises in a specific gear, that gear's
teeth or synchronizer may be worn or damaged.

Sources inside the transmission that can cause noise:

1. A worn-out synchronizer

2. The gears on the speedometer drive

3. Misaligned transmission

4. A worn or damaged input shaft bearing, if your transmission makes noises

only in neutral (sometimes a bumping sound)

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 5. Worn-out gears

6. Output shaft pilot bearing problems

7. Metal shavings in the oil

Sources outside the transmission that can cause noise:

Some noises that seem to come from the transmission are coming from
outside though possibly related source. For example, if you hear a thumping
noise when you accelerate or decelerate, check first for these problems before
you blame the transmission:

• A loose or damaged engine or transmission mount

• A worn or damaged drive axle inner CV joint
• Problems with the differential case

Noises that manifest when turning could point to a problem with the CV
joint. Knocking noises when driving at low speeds could come from the
differential case or the CV joint.

A Three-Step Test for Transmission Bearing Noises

That noise you keep hearing may come from a bearing. This three-step test is
simple and can reveal problems with one or more transmission bearings.

1. Fire up the engine and set the transmission to neutral. If you can hear a
noise in neutral, suspect a worn-out input shaft bearing. Watch the video at
the bottom of this article to see how internal problems can affect input shaft
operation.
2. Now, with the engine running, depress the clutch pedal just enough to
remove the free play, to the point where you feel you need to apply force to
the pedal to push it down further. You may need to push the pedal a little
more. If you hear a squealing noise, you may have a worn-out release
bearing.

3. Fully depress the clutch pedal to release the clutch. If you hear a whirring
sound then, you probably are dealing with a bad pilot bearing.

2. The Transmission Makes a Grinding Noise

Problems with the transmission can also be revealed through a grinding noise.

A grinding noise may come from clashing gears. The clashing may happen
because of linkage problems like wear or need for adjustment.

Other potential sources could be worn or damaged synchronizer, shift fork, or

rail and bearing shafts.

If you can hear the gears clashing only when downshifting, the problem may
come from the synchronizer (too much play at the output shaft end).

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 However, a grinding noise may also come from a dragging clutch.

Source: Google stock photos

3. The Transmission Jumps into Neutral

This seems to be a common problem with worn-out transmissions. You shift

into gear, and the transmission jumps out of gear.
Once again, there could be other several causes for this problem, besides a
worn-out transmission:

• A common problem is a worn out, stretched, or maladjusted shift linkage. A

stretched linkage can be caused by a damaged engine or transmission
mount. An external linkage can wear out or become loose and maladjusted,
causing the transmission to jump out of gear. Look for rust and binding. You
can try to adjust the linkage. But in most cases, you'll have to rebuild or
replace that part of the assembly.

• You may be dealing with a weak or broken spring in the shift rail. In an
internal shift linkage, the spring is part of the spring-loaded ball that locks
the transmission into gear. If the ball slips out of the notch, the transmission
will jump out of gear.

• Also, you may be dealing with a worn-out pilot bearing (the gap causes the
input shaft to vibrate, which causes the shift forks or synchronizers to move).

• You may have problems with a worn synchronizer or shift fork assembly or
other internal components.

Other potential causes to keep in mind:

• Loose or misaligned transmission (possibly after service)

• Misaligned clutch housing
• Loose shifter cover
• Worn-out gear teeth

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 Note: When the transmission only jumps out of high gear, check the clutch
housing bolts for tightness, or the transmission for misalignment.

Source: Google stock photos

A worn-out shift fork can make it hard to shift gears

4. It’s Hard to Shift Gears

This problem happens when you find it hard to move the shift lever from one
gear to another. Usually, this points to a problem with a loose linkage, worn shift
cables, or worn bearings.

Check the linkage. You may need to raise the vehicle and safely support it on
jack stands or remove a component to make the inspection, depending on your
vehicle model. You may need to remove a shift lever boot.

Get the help of an assistant to operate the linkage while you inspect the linkage,
if necessary. Look for problems like binding, poor lubrication, misaligned
components.

To remove components for inspection, consult your vehicle repair

manual. Haynes is a good aftermarket manual: get the manual for your exact
model.

Other causes for a hard-to-shift manual transmission include:

• Worn or loose internal components (shift fork, levers, shafts)

• Low oil level (or the wrong type of oil)

• Misaligned transmission

• Synchronizer problems

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 Source: Google stock photos

5. The Transmission Is Stuck in Gear

You may find that you can't get the transmission out of gear. This symptom may
indicate:

• Low oil level or the wrong type of oil

• Problems with the linkage or shifter assembly. Look for maladjustment, or

wear or damage to rods, bushings, or shifter arms.

• Internal components: shift rail, detents, forks, or a stuck synchronizer sleeve

• Worn-out or broken drive gear teeth

• A stuck shift rail

• Misaligned transmission

6. The Transmission Won't Get Into Gear

When you have trouble getting the transmission into gear, inspect the shift
linkage for adjustment, looseness, or damage.

However, remember that failure to get into gear can also be caused by the clutch
if the clutch isn't fully releasing or has other problems. The clutch might need
adjustment. Also, consult your vehicle repair manual.

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 Source: Google stock photo

Inspect gaskets, seals, or loose bolts when looking for oil leaks

7. Leak from the Transmission

Manual transmission leaks can be caused by:

• bad or worn-out seals or gaskets,

• a damaged case or component,

• or even loose bolts.

To verify that a leak exists, first, check the transmission case and oil level. If it
leaks after you just replaced the oil, you may have put too much. Consult your
vehicle repair manual.

Locate the source of the leak. Inspect the transmission oil seal and the O-ring
in the vehicle speed sensor.

Consult your vehicle repair manual for the proper procedure to replace seals,
bearings, or gaskets. Some of these repairs don't require much work, and you
may be able to do the job in your garage with a few common tools.
Knowing about common manual transmission problems can help you diagnose
your problems sooner, and possibly save money. This guide helps you identify
and explore those common and not-so-common areas. Still, manual
transmissions vary between models, so once you have an idea of the possible
problem with your transmission, consult your model's vehicle repair manual to
troubleshoot that particular issue. You may be able, in some cases, to repair
yourself.

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 What’s More

A. Discussion: Read the questions carefully. Write your answer on a

separate sheet of paper.

1. Why is it necessary to conduct Manual Transmission testing?

2. How important is Manual Transmission’s good condition?

What I Have Learned

Direction: Read the question carefully and answer it comprehensively. Write your
answer in a separate answer sheet.
1. What is your most significant learning in this lesson and how will you
apply it in a real-life situation?

What I Can Do

Steps/Procedures:

1. Before beginning the transmission test, check enough gear oil on the
case.
2. Shift manually shifter of the transmission through the gears and identify
any problem you might feel.

a. Did it easily shift into first? ______ Yes ____ No

b. Did the gear change feel smooth? ______ Yes ____ No

c. Did it easily shift into second? ______ Yes ____ No

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 d. Did the gear change feel smooth? ______ Yes ____ No

e. Did it easily shift into third? ______ Yes ____ No

f. Did the gear change feel smooth? ______ Yes ____ No

g. Did it easily shift into fourth? ______ Yes ____ No

h. Did the gear change feel smooth? ______ Yes ____ No

i. Did it easily shift into fifth? ______ Yes ____ No

j. Did the gear change feel smooth? ______ Yes ____ No

k. Did it easily shift into reverse? ______ Yes ____ No

m. Did the gear change feel smooth? ______ Yes ____ No

Assessment

Multiple Choice. Choose the letter of the best answer. Write the chosen letter on a
a separate sheet of paper.

1. What causes Manual transmission problems?

a. Bad driving habit c. High mileage
b. Defective clutch system d. Overloading

2. Which is the most common cause of a noisy transmission?

a. Bad driving habit c. Insufficient oil
b. Defective clutch system d. Wrong shifting

3. Which is the cause of the grinding noise of manual transmission?

a. from clashing gears c. Linkage adjustment
b. Insufficient oil d. Wrong shifting

4. What is the common problem when transmission jumps into

neutral?
a. Bad driving habit c. worn out
b. Insufficient oil d. Wrong shifting

5. Which causes the shift lever hard to move from one gear to
another?
a. clashing gears c. loose linkage
b. Insufficient oil d. Wrong shifting

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 Additional Activities

Enumeration: Write your answer on a separate sheet of paper.

1. Give at least 10 testing procedure in manual Transmission

testing.

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 18
Additional Activities
1. Check if Manual Transmission can easily shift into first.
2. Check if Manual Transmission can change gear smoothly.
3. Check if Manual Transmission can easily shift into second.
4. Check if Manual Transmission can change gear smoothly.
5. Check if Manual Transmission can easily shift into third.
6. Check if Manual Transmission can change gear smoothly.
7. Check if Manual Transmission can easily shift into fourth.
8. Check if Manual Transmission can change gear smoothly.
9. Check if Manual Transmission can easily shift into fifth.
10. Check if Manual Transmission can change gear smoothly.
What’s More Assessment What I Know
1. The teacher will rate 1. C 1. A
the learner’s answers. 2. C 2. A
3. A 3. B
2. The teacher will rate 4. C 4. A
the learner’s answers. 5. C 5. D
Answer Key
References
aamco. n.d. https://www.aamco.com.

andymohr. n.d. https://www.andymohr.com.

axleaddict. n.d. https://axleaddcit.com .

firestonecompleteautocare. n.d. https://www.firestonecompleteautocare.com

(accessed 2020).

James D. Halderman. Automotive Technology: Principles, Diagnosis and Service 4th

Edition. Pearson Education, Inc., 2012.

mistertransmission. 1963. https://www.mistertransmission.com.

Tom Denton. Automobile Mechanical and Electrical Systems. London: Routledge,

2017.

William Crouse / Donald Anglin. Automotive Mechanics 10th Edition. Glencoe

Publishing Co., 1993.

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For inquiries or feedback, please write or call:

Department of Education – Region XI Davao City Division

Office Address: DepEd Davao City Division, E. Quirino Ave.,

Davao City, Davao del Sur, Philippines

Telefax: (082) 224 0100

E-mail Address: info@deped-davaocity.ph

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