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Manual Drivetrains and Axles Fourth Edition

Manual Drivetrains and Axles Fourth Edition. Tom Birch and Chuck Rockwood. Chapter 8 Transaxle / Transmission Service. Transmission service includes:. preventive maintenance. trouble shooting and problem diagnosis, and. repair and overhaul.

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Manual Drivetrains and Axles Fourth Edition

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  1. Manual Drivetrains and AxlesFourth Edition Tom BirchandChuck Rockwood Chapter 8 Transaxle / Transmission Service

  2. Transmission service includes: • preventive maintenance • trouble shooting and problem diagnosis, and • repair and overhaul.

  3. Gear oil/transmission fluid should be kept at the proper level.

  4. Gear oil/transmission fluid should be changed: • As recommended by the vehicle manufacturer • If it becomes contaminated • If it gets severely overheated.

  5. Transaxles and transmissions with external linkage might need a linkage adjustment if there is a problem with shifts.

  6. A gauge is used to hold the shift arms in position when the linkage is adjusted.

  7. Problem diagnosis includes checking shift lever travel and feel with the engine off and running.

  8. A road test confirms the customer compliant.

  9. Measuring shift effort determines if there is a problem with the shift mechanism or synchronizer.

  10. Most transmission/transaxle repairs require removal from the vehicle.

  11. Guide pins support the transmission and prevent damage to the clutch disc.

  12. The engine must be supported before you can remove a transaxle.

  13. Transmission/transaxle disassemble varies significantly. Always check the vehicle’s service information.

  14. A technician normally checks the following for wear or damage during disassembly: • Internal shift linkage • Shift fork - sleeve clearance • The bearings on all shafts • Floating gear bearing surfaces • Blocker ring wear • Gear damage

  15. Pullers are often required to remove gears and bearings during disassembly.

  16. Some transmission countershafts are normally pushed out of the case using a dummy countershaft. The dummy shaft keeps the needle bearings in place.

  17. The contact pattern can often be read on a used gear. It should show proper gear contact.

  18. Damage that extends into the contact pattern normally indicates a gear that should be replaced.

  19. Bearings can be checked by supporting the outer race and spinning the shaft; roughness indicates a bad bearing.

  20. Close inspection can reveal bearing damage.

  21. The bearing should be properly supported when pressing it on or off of a shaft. Do not put pressure on the bearing’s rolling member.

  22. Other tips to follow when removing or replacing bearing are: • Never hammer directly on a bearing • Heating the case will let a bearing enter easier • Heating a bearing makes it easier to place over a shaft

  23. Floating gears and synchronizers are pressed or slid off the shaft after removing the retaining rings.

  24. A disassembled mainshaft with the parts arranged in order.

  25. The synchronizer sleeve is left on the hub to protect it. After removal for inspection, it must be replaced in the same position.

  26. Synchronizer sleeves, hubs, and clutching teeth are inspected for wear and proper movement.

  27. A blocker ring should have the proper clearance and release cleanly from the cone.

  28. A mainshaft should be checked for wear and damage.

  29. A transmission rebuild kit includes the parts that normally wear.

  30. Pre-assembly of the synchronizer, shift sleeve, and speed gear will keep the blocker ring in proper alignment as they are pressed onto the mainshaft.

  31. Every speed gear must have the proper end float. It can be corrected using a selective snap ring.

  32. Transaxle differentials should be checked for excess wear.

  33. Some differentials have thrust washers that can be replaced to adjust clearance.

  34. Differential bearings must be removed using a puller and installed using a press and the proper adapters.

  35. Excess clearance indicates a worn shift fork or synchronizer sleeve.

  36. Threaded holes in all aluminum castings should be checked, and stripped or damaged threads should be repaired.

  37. All lip seals are usually replaced. Using the proper driver prevents seal damage.

  38. End play should be checked as the shafts are installed into the case.

  39. End play is corrected by installing a shim of the correct size.

  40. B – A + 0.003” equals the shim size that will apply the correct preload on this bearing.

  41. A loading tool/dummy shaft holds the needle bearings in place as the countershaft is installed into the cluster gear.

  42. Many covers are sealed to the case using an anaerobic or RTV, room temperature vulcanizing sealant.

  43. Gaskets seal some covers; cover bolts should be tightened in a sequence that insures even tightening.

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