9781401834005

TechOne: Manual Transmissions

by
  • ISBN13:

    9781401834005

  • ISBN10:

    1401834000

  • Edition: 1st
  • Format: Paperback
  • Copyright: 2003-08-04
  • Publisher: Cengage Learning

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Supplemental Materials

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  • The New copy of this book will include any supplemental materials advertised. Please check the title of the book to determine if it should include any access cards, study guides, lab manuals, CDs, etc.
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Summary

Delmar Learning's new TechOne: Manual Transmissions simplifies teaching and learning with its unique format. Concise chapters cover theory, diagnosis, service, and repair for manual transmission systems, sub-topics, and components. This easy-to-follow method helps students rapidly progress from one topic to the next. Strong illustrations and photos enhance the approach for visual learners, and all students can benefit from the coverage of ASE certification requirements. Once the course is completed, an ASE practice exam in the Appendix allows students to put their skills to the test.

Table of Contents

Preface x
About the Author xii
Acknowledgments xiii
Features of the Text xiv
Section 1: Safety and Communication
1(34)
Safe Work Practices
3(8)
Introduction
3(1)
Safe Work Areas
3(1)
Personal Safety
3(1)
Lifting and Carrying
4(1)
Fire Hazards and Prevention
5(1)
Using a Fire Extinguisher
5(1)
Safe Tools and Equipment
5(1)
Lift Safety
5(1)
Jack and Jack Stand Safety
6(1)
Batteries
6(1)
Accidents
7(1)
Electrical System Repairs
7(1)
Air Bag Safety and Service Warnings
7(1)
Hazardous Materials
7(1)
OSHA
8(1)
Handling Shop Wastes
8(1)
Summary
9(1)
Review Questions
10(1)
Measuring Systems, Fasteners, and Measuring Tools
11(8)
Introduction
11(1)
Measuring Systems
11(1)
Fasteners
11(1)
Bolt Identification
12(1)
Tightening Bolts
13(1)
Measuring Tools
13(2)
Micrometers
15(2)
Summary
17(1)
Review Questions
18(1)
Common Hand Tools
19(6)
Introduction
19(1)
Wrenches
19(1)
Ratchets and Sockets
20(1)
Torque Wrenches
20(1)
Screwdrivers
21(1)
Pliers
21(1)
Hammers and Mallets
21(1)
Punches and Chisels
21(1)
Files
21(1)
Taps and Dies
21(1)
Service Information and Manuals
22(1)
Summary
23(1)
Review Questions
23(2)
Power and Special Tools
25(6)
Introduction
25(1)
Air Wrenches
25(1)
Blowgun
26(1)
Bench Grinder
26(1)
Trouble Light
26(1)
Presses
26(1)
Jacks and Lifts
26(1)
Transmission Jack
26(1)
Engine Hoist
27(1)
Transaxle Removal and Installation Equipment
27(1)
Transmission/Transaxle Holding Fixtures
27(1)
Gear and Bearing Pullers
27(1)
Bushing and Seal Pullers and Drivers
28(1)
Special Pliers
28(1)
Clutch Alignment Tool
28(1)
Universal Joint Tools
29(1)
Special Tool Sets
29(1)
Summary
29(1)
Review Questions
29(2)
Working As a Drivetrain Tech
31(4)
Introduction
31(1)
Compensation
31(1)
Employer-Employee Relationships
32(1)
Customer Relations
32(1)
ASE Certification
32(1)
Duties of a Drivetrain Tech
33(1)
Diagnostics
33(1)
Summary
34(1)
Review Questions
34(1)
Section 2: Basic Theories and Services
35(46)
Drivetrain Theory
37(11)
Introduction
37(1)
Engine
37(1)
Basic Gear Theory
38(1)
Transmission
39(1)
Transmission Gears
40(1)
Drivetrain Configurations
41(1)
Types of Gears
42(1)
Gear Wear
43(1)
Bearings
44(1)
Basic Gear Adjustments
45(1)
Summary
46(1)
Review Questions
46(2)
Basic Electrical Theory
48(11)
Introduction
48(1)
Basic Electricity
48(1)
Electrical Terms
49(1)
Electrical Circuits
50(1)
Conductors and Insulators
50(1)
Ohm's Law
51(1)
Circuit Components
51(2)
Electromagnetism Basics
53(1)
Basics of Electronics
54(2)
Summary
56(1)
Review Questions
57(2)
Common Drivetrain Electrical Components
59(4)
Introduction
59(1)
Clutch Safety Switch
59(1)
Reverse Lamp Switch
60(1)
Upshift Lamp Circuit
60(1)
Shift Blocking
60(1)
Self-Shifting Manual Transmissions
60(1)
ABS Speed Sensor Circuits
61(1)
Other Electronic Systems
61(1)
Summary
62(1)
Review Questions
62(1)
Basic Electrical Service
63(10)
Introduction
63(1)
Quick Overview of Electricity
63(1)
Electrical Problems
64(1)
Basic Electrical Testing
65(1)
Ammeters
66(1)
Voltmeters
66(1)
Ohmmeters
67(1)
Multimeters
68(1)
Test Lights
68(1)
Jumper Wires
69(1)
Electrical Wiring
69(1)
Electrical Wiring Diagrams
69(1)
Basic Electrical Repairs
70(1)
Summary
71(1)
Review Questions
71(2)
Testing Drivetrain Electrical Circuits
73(8)
Introduction
73(1)
General Guidelines
73(1)
Testing Circuit Protection Devices
74(1)
Testing Switches
75(2)
Testing Speed Sensors
77(1)
Testing Solenoids
78(1)
Testing Electromagnetic Clutches
78(1)
Testing Electronic Circuits
78(2)
Summary
80(1)
Review Questions
80(1)
Section 3: Drivelines
81(76)
Front Drive Axles and Wheel Bearings
83(5)
Introduction
83(1)
Drive Axle Construction
83(1)
Drive Axles
84(2)
Drive Axle Supports
86(1)
FWD Wheel Bearings
86(1)
Summary
87(1)
Review Questions
87(1)
CV Joints
88(7)
Introduction
88(1)
CV Joint Boots
88(1)
Types of CV Joints
88(2)
Outboard CV Joint Designs
90(2)
Inboard CV Joint Designs
92(1)
CV Joint Wear
93(1)
Summary
94(1)
Review Questions
94(1)
Diagnosing FWD Axles and Joints
95(6)
Introduction
95(1)
Talk to the Customer
95(1)
Road Test
95(2)
Visual Inspection
97(2)
Summary
99(1)
Review Questions
100(1)
Servicing FWD Axles and Joints
101(8)
Introduction
101(1)
Drive Axle Removal
101(2)
Bench Inspection
103(1)
Service Kits
104(1)
General Service Procedures
104(3)
Summary
107(1)
Review Questions
107(2)
Servicing FWD Wheel Bearings
109(6)
Introduction
109(1)
Wheel Bearing Checks
109(1)
Replacing Front Wheel Bearings
110(3)
Summary
113(1)
Review Questions
114(1)
Drive Shafts
115(5)
Introduction
115(1)
Drive Shaft Construction
115(2)
Types of Drive Shafts
117(1)
Slip Joints
117(2)
Summary
119(1)
Review Questions
119(1)
Universal Joints
120(6)
Introduction
120(1)
Single Universal Joints
120(1)
Double Cardan Universal Joint
121(1)
Speed Variations
122(2)
Phasing of Universal Joints
124(1)
Canceling Angles
125(1)
Summary
125(1)
Review Questions
125(1)
RWD Drive Axles
126(5)
Introduction
126(1)
Drive Axle Shafts
126(1)
Types of Axle Shafts
126(1)
Axle Bearing Designs
127(1)
Ball-type Axle Bearings
127(1)
Straight Roller Axle Bearings
128(1)
Tapered Roller Axle Bearings
128(1)
Independent Rear Suspension (IRS) Axle Shafts
128(1)
Summary
129(1)
Review Questions
130(1)
Diagnosing Drive Shafts, U-Joints, and RWD Drive Axles
131(9)
Introduction
131(1)
Talking to the Customer
132(1)
Road Test
132(1)
Possible Sources of Leaks
133(2)
Vibrations
135(1)
Noises
136(2)
Limited-Slip Differential Diagnostics
138(1)
Driveline Inspection
138(1)
Summary
139(1)
Review Questions
139(1)
Servicing Drive Shafts and U-Joints
140(10)
Introduction
140(1)
Maintenance
140(1)
Removing and Installing a Drive Shaft
141(1)
Disassembling and Assembling Universal Joints
142(2)
Double Cardan U-Joints
144(1)
Drive Shaft Balance
145(1)
Drive Shaft Runout
146(1)
Universal Joint and Shaft Angles
147(1)
Summary
148(1)
Review Questions
149(1)
Servicing RWD Drive Axles
150(7)
Introduction
150(1)
RWD Axle Inspection
150(1)
Removing Axles
150(2)
Installing Axles
152(1)
Axle Bearings
152(3)
Axle Shaft Seals
155(1)
Summary
156(1)
Review Questions
156(1)
Section 4: Final Drives
157(64)
Final Drive and Differential Assemblies
159(13)
Introduction
159(1)
Components of a Differential
160(1)
Differential Operation
161(2)
Axle Housings
163(1)
Final Drive Gears
164(2)
Final Drive Gear Ratios
166(1)
Determining Final Drive Ratios
167(1)
Hunting and Non-hunting Gears
167(1)
Final Drive and Differential Bearings
168(1)
Differential Case Bearings
168(1)
Drive Pinion Bearings
168(2)
Summary
170(1)
Review Questions
171(1)
Diagnosing RWD Differential and Final Drive Units
172(9)
Introduction
172(1)
Talking to the Customer
172(1)
Road Test
172(3)
Types of Noises
175(1)
Types of Vibrations
176(1)
Checking Backlash of the Assembly
176(1)
Checking Bearing Preload
177(1)
Possible Sources of Leaks
177(2)
Summary
179(1)
Review Questions
180(1)
Servicing RWD Differential and Final Drive Units
181(10)
Introduction
181(1)
In-Vehicle Services
181(1)
Out-of-Vehicle Services
182(1)
Disassembling an Integral Carrier Differential
183(2)
Ring and Pinion Gear Installation
185(1)
Assembling an Integral Carrier Differential
186(1)
Removing and Disassembling a Removable Carrier Differential
187(1)
Assembling and Installing a Removable Carrier Differential
188(1)
Summary
189(1)
Review Questions
190(1)
Differential and Final Drive Adjustments
191(11)
Introduction
191(1)
Pinion Gear Depth
191(2)
Pinion Bearing Preload
193(1)
Backlash and Side Bearing Preload
194(2)
Gear Tooth Patterns
196(4)
Summary
200(1)
Review Questions
201(1)
FWD Final Drive Units
202(10)
Introduction
202(1)
Types of Final Drives
202(2)
Servicing FWD Final Drive Units
204(5)
FWD Final Drive Adjustments
209(1)
Part Replacement
210(1)
Summary
210(1)
Review Questions
211(1)
Limited-Slip Differential Units
212(9)
Introduction
212(1)
Limited-Slip Differentials
213(4)
Limited-Slip Differential Diagnostics
217(1)
Servicing Limited-Slip Differentials
217(2)
Summary
219(1)
Review Questions
219(2)
Section 5: Clutch Assemblies
221(42)
Clutch Operations
223(13)
Introduction
223(1)
Basic Clutch Operation
223(1)
Clutch Location
224(1)
Clutch Design
224(7)
Clutch Linkages
231(3)
Summary
234(1)
Review Questions
235(1)
Diagnosing Clutch Problems
236(7)
Introduction
236(1)
Diagnosis by Symptom
236(3)
Visual Inspection
239(2)
Summary
241(1)
Review Questions
242(1)
Servicing Clutch Linkages
243(10)
Introduction
243(1)
Mechanical Clutch Controls
243(4)
Hydraulic Clutch Controls
247(3)
Clutch Pedal and Release Assemblies
250(1)
Summary
251(1)
Review Questions
251(2)
Servicing Clutch Assemblies
253(10)
Introduction
253(1)
Removing the Clutch Assembly
253(1)
Pressure Plate
254(1)
Clutch Disc
255(1)
Flywheel
256(2)
Input Shaft Pilot Bearing and Bushings
258(1)
Clutch Release Bearing
259(1)
Assembling the Clutch
260(1)
Installing the Transmission
261(1)
Summary
261(1)
Review Questions
261(2)
Section 6: Manual Transmissions
263(62)
Manual Transmissions
265(13)
Introduction
265(1)
Transmission Gears
265(1)
Types of Manual Transmissions
266(1)
Synchronizers
267(2)
Transmission Designs
269(2)
Basic Operation of Manual Transmissions
271(2)
Power Flow of a Five-Speed Transmission
273(2)
Gear Shift Linkages
275(1)
Summary
276(1)
Review Questions
277(1)
Manual Transaxles
278(7)
Introduction
278(1)
Basic Transaxle Construction
278(3)
Power Flow through a Transaxle
281(2)
Differential Action
283(1)
Summary
284(1)
Review Questions
284(1)
Diagnosing Manual Transmissions/Transaxles
285(8)
Introduction
285(1)
Identification
285(1)
Diagnostics
286(1)
Troubleshooting Transmission/Transaxle Problems
287(2)
Diagnosis by Symptom
289(2)
Summary
291(1)
Review Questions
292(1)
In-Vehicle Transmission Service
293(6)
Introduction
293(1)
Fluid Changes
293(2)
Rear Oil Seal and Bushing Replacement
295(2)
Linkage Adjustment
297(1)
Speedometer Drive Gear Service
297(1)
Summary
298(1)
Review Questions
298(1)
Disassembling a Manual Transmission/Transaxle
299(8)
Introduction
299(1)
Transmission/Transaxle Removal
299(3)
Disassembling a Transaxle
302(2)
Disassembling a Transmission
304(2)
Summary
306(1)
Review Questions
306(1)
Inspection and Cleaning of Transmission Parts
307(9)
Introduction
307(1)
Inspection of Transmission/Transaxle Parts
307(7)
Cleaning Transmission/Transaxle Components
314(1)
Summary
314(1)
Review Questions
314(2)
Reassembling a Manual Transmission/Transaxle
316(9)
Introduction
316(1)
Reassembling a Transaxle
316(2)
Servicing a Transaxle's Differential Case
318(1)
Reassembling a Transmission
319(2)
Installation
321(1)
Summary
322(1)
Review Questions
323(2)
Section 7: Four-Wheel Drive Systems
325(50)
Four-Wheel Drive Systems
327(13)
Introduction
327(1)
Various Designs
328(1)
Limited-Slip Differentials
329(1)
4WD Systems
329(1)
Components
329(3)
All-Wheel Drive Systems
332(1)
Transfer Cases
332(1)
Locking Hubs
333(2)
Viscous Couplings
335(1)
4WD Suspensions
336(2)
Summary
338(1)
Review Questions
339(1)
Diagnosing 4WD Systems
340(15)
Introduction
340(1)
Diagnosis
340(2)
Inspection
342(4)
General Shift Controls
346(2)
Center Differentials
348(1)
Viscous Coupling
348(1)
``Shift on the Fly'' Systems
348(3)
On-Demand 4WD Systems
351(2)
AWD Systems
353(1)
Summary
353(1)
Review Questions
354(1)
Servicing 4WD Systems
355(8)
Introduction
355(1)
Maintenance
355(1)
Axle Housings and Differentials
355(1)
Front Axles and Hubs
356(4)
Viscous Coupling
360(1)
Wheel Bearings
360(1)
Typical 4WD Modifications
361(1)
Summary
361(1)
Review Questions
362(1)
Transfer Cases
363(12)
Introduction
363(1)
Transfer Cases
363(4)
Transfer Case Designs
367(2)
Removal of a Transfer Case
369(1)
Disassembly of a Transfer Case
369(1)
Assembly of a Transfer Case
370(2)
Summary
372(1)
Review Questions
373(2)
Appendices
375(7)
Appendix A ASE Practice Exam for Manual Drivetrain and Axles
375(4)
Appendix B USCS and Metric Conversions
379(1)
Appendix C Fractions of Inches to Decimal and Metric Equivalents
380(1)
Appendix D General Torque Specifications
381(1)
Bilingual Glossary 382(17)
Index 399

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