KAMPALA POLTECHNIC

MENGO

PLOT NO 1102 KABAKA NJAGALA ROAD

TOWARDS KABAKA PALACE

P.O BOX 14349

TEL. 0414272673

INSITITUTION : KAMPALA POLYTECHNIC MENGO

DEPARTMENT :

PROJECT TITLE :

NAME : WANI DAVID

YEAR OF STUDY

: 1STYEAR

PLACE : KAMPALA POLYTECHNIC MENGO

REG. NUMBER :

SUPERVISOR’S NAME : MR. WEJULI GODFREY

A REALLIFE PROJECT TO BE SUBMITED TO UGANDA BUSINESS AND TECHNICAL EDUCATION BOARD IN PARTIAL
FULLFILLMENT OF THE REQUIREMENT FOR THE AWARD OF UGANDA NATIONAL CERTIFICATE IN AUTOMOTIVE.
 1. DECLARATION:
I WANI DAVID hereby declare that the above report is the original and has never been handed
in anywhere for the related purpose and all this information in this report was done and compiled
on my own to the best of my knowledge and findings during the reallife project.

SIGNATURE: …………………………………….

I
 2. DEDICATION:
I dedicate this report to my parents, sisters, brothers, friends, lecturers and fellow students at
large for all the supportive efforts towards my academic excellence. They have been supportive
at all aspects and have always encouraged, motivated and guided me in any aspects of life and to
stay focused. I pray that the Almighty God bless them infinity.

APPROVAL:
This is to approve that this real life project report was done under my supervision and is now
ready for submission.

Supervisor: ……………………………………………………..

Signature: …………………………………..

Date: ……………………………………..

I
ACKNOWLEDGEMENETS
First of all, I thank the Almighty God for the good days and taking me through the real life
project session.

I extended my heartfelt gratitude to the academic supervisor Mr. Wejuli Godfrey and Mr.Dumba
George for the guidance and support in the project.

I want to thank the Ave Maria Stationers that helped me print out my report.

II
EXECUTIVE SUMMARY OR ABSTRACT;
The report mainly shows the practical work done during the real life project and is written to
show the knowledge that is acquired during the project. This report is to emphasize the
practical skills that are achieved from the project.

The content in this report covers different tasks of the work performed which includes
highlights of the work done and the main frame work of the project, materials and tools used
during the working process.

The project started with a brief opening meeting and roll call. We cleaned up the workshop for
the project work. We organized the tools that we were going to use in our project.

1. During the project, we measured marked and cutting of materials

III
Table of Contents
DECLARATION:..............................................................................................................................................i
DEDICATION:................................................................................................................................................i
APPROVAL:..................................................................................................................................................ii
ACKNOWLEDGEMENETS.............................................................................................................................iii
EXECUTIVE SUMMARY OR ABSTRACT;........................................................................................................iii
List of figures:...............................................................................................................................................i
CHAPTER ONE: INTRODUCTION....................................................................................................................i
Problem statement:..................................................................................................................................i
Objective:.................................................................................................................................................i
Scope of work:..........................................................................................................................................i
CHAPTER TWO: LIST OF TOOLS AND MATERIALS USED:...............................................................................i
Tools used during the project:..................................................................................................................i
Materials used during the project:..........................................................................................................ii
CHAPTER THREE: DISCRIPTION OF WORK:...................................................................................................ii
Preparation of materials and tools to be used:........................................................................................ii
Removal of the gearbox:.........................................................................................................................iii
Removal of the clutch assembly:............................................................................................................iii
Gearbox overhauling:.............................................................................................................................iii
Installing back the gearbox:....................................................................................................................iv
CHAPTER FOUR:...........................................................................................................................................v
BILL OF QUANTITIES:................................................................................................................................v
Safety precautions:.................................................................................................................................vi
CHAPTER FIVE............................................................................................................................................vii
Challenges:.............................................................................................................................................vii
Recommendations:................................................................................................................................vii
Conclusion:............................................................................................................................................vii
Reference:..............................................................................................................................................vii
List of Acronyms/ Abbreviation:...............................................................................................................viii
CHAPTER SIX: Appendices:..........................................................................................................................ix

IV
 Introduction:...........................................................................................................................................xi
Problem statement:................................................................................................................................xi
Objectives:..............................................................................................................................................xi
CHAPTER :..................................................................................................................................................xii
LIST OF TOOLS AND MATERIALS USED:..................................................................................................xii
Tools used during the project............................................................................................................xii
Materials used during the project:.....................................................................................................xii
Scope of work:.......................................................................................................................................xii
Description of work:..............................................................................................................................xiii
Safety precautions taken:......................................................................................................................xiii
Challenges:............................................................................................................................................xiii
Recommendations:...............................................................................................................................xiv
Conclusion:............................................................................................................................................xiv
References:...........................................................................................................................................xiv
Appendices:.................................................................................................................................................1

V
VI
List of figures:

I
CHAPTER ONE: INTRODUCTION
The project which was fabricating incinerator was done by first cleaning the workshop place,
then followed by organizing the tools and the materials to use in the projects

Insipection of materials to be used In the process

I
Problem statement:
Overhauling a gearbox that was difficult in engaging gears, noisy during gear engagement and
gears jumping out after engagement so that the vehicle can have its gearbox back to its high peak
of performance.

Objective:
To overhaul the gearbox so as to service, repair and renew faulty components.

Scope of work:
 Preparation of materials.
 Measuring marking and cutting of tools
 Jerking the vehicle.
 Loosening the gearbox mounting.
 Removal of the gearbox
 Removal and servicing of the clutch assembly
 Overhauling the gearbox and renewing the faulty parts.

CHAPTER TWO: LIST OF TOOLS AND MATERIALS USED:

Tools used during the project:

 Spanners,(ring spanners, fixed spanners, box spanners)
 Screwdrivers,( flat and star screwdrivers)
 Pliers
 Car jerk
 Axle stands

I
  Clip remover
 Bearing remover

Materials used during the project:

 Water
 Detergent
 Cotton waste
 Sand paper
 Oil

II
CHAPTER THREE: DISCRIPTION OF WORK:
Preparation of materials and tools to be used:
We started by cleaning up the place where we were having our project from. We then prepared
the tools and the materials to be used in the project.

The materials included the water, detergent, cotton waste, sand paper, oil, basin, axle stands and
brooms.

Removal of the gearbox:

The vehicle was first parked a levelled ground, we jerked it and supported it on the axle stands.
The speedometer was disconnected from the gearbox and its mountings were loosened. We
had the gearbox put on ground with the help of the jerk to give in more support not to have it
hint on the ground for further damages.

The gearbox was then carried to the working surface and ready for servicing and repairing.

Removal of the clutch assembly:

After setting the gearbox on the work space, we had to remove the clutch assembly too for
inspections and servicing.

It was found the clutch plate was worn which was renewed and had the clutch assembly
reinstalled again.

III
Gearbox overhauling:
We started overhauling the gearbox. We removed the release bearing and the fork. We drained
out the cc oil from the gearbox. We dismantled the gearbox so as to access the interior
components for inspections. We removed the main shaft with its gears and the layshaft had it
removed too. We put all the components on ground such as the selector fork, release bearings
etc.

We washed all the components in the water with detergent and left them to dry under the
sunshine which after we carried a clear inspection on the components.

Installing back the gearbox:

After carrying the clear inspections on the gearbox components, we found out that some of the
driving gears were worn out which caused the gears jump of after engaging and we had to
renew before installing back the gearbox. We also we found the selector fork was faulty which
caused the gears difficult in engagement. We renewed the release bearing after reassembling
the gearbox and for the installation.

We carried the gearbox under a well jerked vehicle at certain height supported by the axle
stands which had enough space created for working.

We lifted the gearbox while gradually jerking in upwards with the jerk to have less effort used.
The gearbox was well fitted to the clutch assembly and then tightened its bolts.

We then had the gearbox mountings well worked on and tightened to the right torque. We
reconnected the speedometer cable to the gearbox and the gear lever was installed back too.
The vehicle was taken on the road test the gearbox was finally at its high peak of performance
without any faulty in it.

IV
CHAPTER FOUR:
BILL OF QUANTITIES:
NO. MATERIAL QUANTITY UNIT COST AMOUNT
1. Cotton waste 250grams 5000 5000
2. Detergent 1 bucket 9000 9000
3. Seals 2 35000 70000
4. Gaskets 1 set 50000 50000
5. CC Oil (transmission oil) 10litres 6500 650000
6.
7.
8.
9.
TOTAL

V
Safety precautions:
I used the safety boots, overall during the project and the projected ended well without any injury
registered.

The place was well cleaned before any work for clean work during the project period and
cleaning was undertaken after work so as to leave the work place clean.

CHAPTER FIVE:

Challenges:
 Some tools to use were few compared to the number of students.
 We had very less time to concentrate on the project so as to get it done without any rush.

Recommendations:
 I recommend the provision sufficient tools in the workshop to ease work during project
activities.
 I recommend the provision of adequate time for the project running to have it done
calmly.

VI
Conclusion:
In conclusion, the positives of the project were greater than the negatives, therefore the project
was a success no individual got harmed and injured during the real-life project and even all the
skills were effectively acquired.

Reference:
Automotive engineering powertrain, chassis system and vehicle body: edited by David A. Crolla.

List of Acronyms/ Abbreviation:

 NCAM- National Certificate in Automotive Mechanics.
 i.e. - that is to say.
 Etc. - and many others.
 REG. NUMBER- registration number.
 NO. – Number
 KPM- Kampala Polytechnic Mengo.

VII
CHAPTER SIX: Appendices:

VIII
AUTOMATIC
HYDRAULIC
STEERING
SYSTEM
PROJECT
IX
Introduction:
This project we serviced and repaired the automatic hydraulic steering system of a Toyota corsa vehicle.

We started with a brief meeting and roll call by our project supervisor who guided us throughout the
project.

The project took place at kampala polytechnic Mengo main campus located along Kabaka agyagala road.

We also serviced and renewed where necessary.

Problem statement:
Servicing the hydraulic steering system was due the difficulty experienced turning corners during the
driving. The project was to ensure proper functioning of the steering system.

Objectives:
To service and repair the steering system to have it work well during driving.

X
CHAPTER :
LIST OF TOOLS AND MATERIALS USED:
Tools used during the project.
 Screw driver
 Spanners
 Pliers
 Jerk
 Axle stands
Materials used during the project:
 Hydraulic oil
 Water
 Cotton waste
 detergents

Scope of work:
 Servicing the reservoir tank
 Renewing the steering pump
 Steering wheel alignment
 Cleaning of the place before the project
 Cleaning of the components

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B.O.Q

NO. ITEM QUANTITY COST AMOUNT

1. Hydraulic oil 2 litres 35000 70000
2. Seals 1 set 50000 50000
3. Detergent 1 bucket 9000 9000
4. Cotton waste 250grams 5000 5000
5.
6.
TOTAL

XII
Description of work:
We started with a brief meeting and roll calling by the project supervisor.

We parked the vehicle on a well leveled ground and jerked it to create enough working space. we
opened the car bonnet and checked the hydraulic reservoir. We found out the hydraulic in the
reservoir was not enough so we topped up to the maximum level with the International super HX
ATF type-A.

We checked the steering pump and tested. We first removed the drive belt and had the steering
pump off. We put the pump on the ground and connected the delivery pipe in the basin of water
and the pump, we turned the pump pulley and found the pump was not pumping the water.

We checked the ball joints, rod ties, steering column, steering rack ends etc.

We washed all the components disconnected and therefore reinstalled and renewed the steering
pump and finally had the vehicle taken for a road test and the steering system was well
functioning.

Safety precautions taken:

I used the safety boots, overall during the project and the projected ended well without any injury
registered.

The place was well cleaned before any work for clean work during the project period and
cleaning was undertaken after work so as to leave the work place clean.

Challenges:
 Some tools to use were few compared to the number of students.

XIII
  We had very less time to concentrate on the project so as to get it done without any rush.

Recommendations:
 I recommend the provision sufficient tools in the workshop to ease work during project
activities.
 I recommend the provision of adequate time for the project running to have it done
calmly.

Conclusion:
In conclusion, the positives of the project were greater than the negatives, therefore the project
was a success no individual got harmed and injured during the real life project and even all the
skills were effectively acquired.

References:
Automotive suspension and steering systems 5th Edition Classroom manual: Don Knowles.

XIV
Appendices: