BOOK 2; VOLUME 1 (EXTRA)

What are three typical symptoms of manual transaxle problems?

- Abnormal bearing and gear noises. - Shifting problems. - Fluid leaks.

Describe three symptoms of front drive axle troubles.

- Abnormal noises. - Vibration. - Excessive play in the universal joints.

What are the two types of lubricant commonly used in manual transaxles?

- Automatic transmission fluid. - Manual transmission gear oil.

Explain how a continuously variable transaxle can increase fuel economy.

A CVT possesses an infinite number of driving ratios, rather than three, four, or five forward speeds. The CVT uses spring-loaded, two-piece pulleys that have variable diameters. The variable diameters and driving ratios maintain the vehicle's road speed without changing the engine or motor-generator speed, creating the ability to keep the engine at its most efficient operation. This may result in up to a 25% increase in fuel economy.

When is a center support bearing needed and why?

A center support bearing is needed to hold the middle of a two-piece drive shaft. Pickup trucks commonly use a center support bearing because of the long distance between the transmission and rear axle.

What is the difference between a fixed transmission solenoid and a variable transmission solenoid?

A fixed transmission solenoid can produce only fully "on" or "off" locations for the spool valve to open or close the fluid control valve. A variable transmission solenoid can adjust the distance of spool valve opening by conducting different ECM duty cycles or signal frequencies.

Explain the difference between a hunting gearset and a nonhunting gearset.

A hunting gearset does not mesh the same gear teeth during each revolution of the ring gear. A nonhunting gearset meshes the same gear teeth over and over during gearset operation

A manual transaxle's lubricant level needs to be checked. Technician A looks for the transaxle's dipstick or fill hole. Technician B says all manual transaxles use a dipstick for checking lubricant level. Who is right?

A only.

A particular transmission's drive gear has 10 teeth and the gear being driven has 30 teeth. Technician A says the gear ratio in this situation would be 3:1. Technician B says the gear ratio in this situation would be 4:1. Who is right?

A only.

An automobile is brought into the shop with an automatic transmission "slippage" problem. Technician A checks the transmission's fluid level. Technician B inspects the condition of the transmission's valve body first. Who is right?

A only.

Technician A says a drive shaft assembly's slip yoke is normally splined to the transmission output shaft. Technician B says the drive shaft assembly's slip yoke is usually bolted to the transmission output shaft. Who is right?

A only.

Technician A says a pilot bearing is a bushing that supports the forward end of the transmission input shaft. Technician B says a pilot bearing is a bushing that reduces friction between the clutch fork and pressure plate. Who is right?

A only.

The _____ must be capable of providing torque to both axles when turning corners.

Differential.

The term _____ generally refers to the parts that transfer power from the transmission to the drive wheels.

Driveline.

What major problem is a differential designed to prevent?

The differential is designed to prevent the tires from sliding, squealing, and wear whenever the vehicle is turned.

Define the term clutch pedal "free play."

The distance the clutch pedal or clutch fork moves before the throw-out bearing acts on the pressure plate.

What are the symptoms of clutch slippage?

The engine races without an increase in the vehicle's road speed.

What is gear backlash?

It is the small clearance between the meshing gear teeth. Backlash allows lubricating oil to enter the high-friction area between the gear teeth and allows the gears to expand during operation without binding or damage.

What should you do if the drive shaft is within recommended runout limits but still vibrates?

It may need to be balanced by a machine shop that has specialized drive-shaft balancing equipment.

What is the function of an automatic clutch adjuster?

It removes play from the clutch cable as components wear.

What is the main purpose of the pressure plate cover?

Its main purpose is to hold the parts of the pressure plate assembly together.

_____ _____ often require a special type of gear fluid with friction additives intended for the wet clutch packs in modern differentials.

Limited-slip differentials.

A drive chain is sometimes used to send crankshaft power to the transaxle with a(n) _____ mounted engine.

Longitudinally.

How do you measure axle end play?

Mount the indicator so that the indicator plunger is parallel with the axle centerline. Set the indicator needle on zero. Pull the axle in and out while watching the indicator. Compare the readings to factory specifications.

A stall test is being performed on an automatic transmission. Technician A places the transmission in high gear during this test. Technician B places the transmission in neutral during this test. Who is right?

Neither A nor B.

Technician A says the torque converter housing bolts to the rear of the transmission case. Technician B says the converter housing bolts to the front of the automatic transmission's extension housing. Who is right?

Neither A nor B.

_____ tests are used to determine whether fluid pressure in the various circuits is normal.

Pressure.

The _____ usually has an exploded view of the transmission, showing how each part is located in relation to the others.

Service manual.

How do you check for clutch slippage?

Set the emergency brake and start the engine. Place the transmission or transaxle in high gear. Then, try to drive the vehicle forward by slowly releasing the clutch pedal.

How do shift valves work?

Shift valves use control pressure (oil pressure from regulator, solenoid valves, throttle valve, and manual valve) to operate the bands, servos, and gearsets.

A(n) _____ is a listening device that can be used to isolate differential and axle noises.

Stethoscope.

Define the term "gear ratio."

The number of revolutions a drive gear must turn before the driven gear completes one revolution.

If a transmission is only noisy in second gear, what does that tell you about the problem?

The problem is due to components related to that gear.

What is the common cause of a pulsating clutch pedal?

The runout (wobble or vibration) of one of the rotating components of the clutch assembly.

Why should you use an alignment tool or pilot shaft when installing a clutch?

To center the disc.

How is a dummy shaft used during transmission disassembly?

To drive out the countershaft and reverse idler shaft.

What is the purpose of shifting the transmission into high gear before installation?

To help position the input shaft into the clutch disc during transmission installation.

Why is an overdrive ratio used?

To increase fuel economy.

A(n) _____ is a fluid clutch that provides a means of coupling and uncoupling the engine from the transmission.

Torque converter.

Clutch disc _____ springs help absorb some of the vibration and shock produced by clutch engagement.

Torsion or Damping.

How do you check for worn universal joints?

Wiggle and rotate each universal joint back and forth while watching for side movement. Try to detect any play between the cross and yoke.

How does a constant velocity universal joint (double-cardan joint) work?

With two universal joints operating together on one end of the drive shaft, the output shaft shaft speed fluctuations are counteracted. The action of the second joint cancels the shaft speed changes produced by the first joint.

Identify four functions of a manual transmission in proper operating condition.

- Be able to increase torque going to the drive wheels for quick acceleration. - Supply different gear ratios to match different engine load conditions. - Have a reverse gear for moving backwards. - Provide the driver with an easy means of shifting transmission gears. - Allow downshifting into any gear while the vehicle is moving, with all gears synchronized. - Operate quietly, with minimum power loss.

What are the four main components of automatic transmission construction?

- Bell housing. - Case. - Pan. - Extension housing.

List four points to consider when diagnosing bearing failures.

- Check the general condition of all parts during disassembly, not just the most badly worn or damaged parts. - Compare the failure to any information in the service manual and your knowledge of component operation. - Determine the cause of the part failure. This helps ensure the problem does not reoccur. - Make all repairs following manufacturer's recommendations and specifications.

Name five general rules to remember when servicing a transaxle.

- Do not dent or nick the gasket sealing surfaces during disassembly or cleaning. - Keep all parts organized so that used parts can be returned to their original positions. - Clean all parts and closely inspect them for damage. Replace any parts showing wear. - Replace all gaskets and seals. - Use special tools when needed. - During reassembly, measure all gears, shafts, bearings, and other critical components as described in a shop manual. - Measure bearing preload as described in the service manual. - Make sure all snap rings, shims, and other parts are installed correctly. - Torque all bolts to specifications.

What components are normally included in a CV joint kit?

- New joint components. - Grease. - A boot. - Boot straps.

Drive shaft problems can normally be classified into two categories: drive shaft _____ and drive shaft _____.

- Noise. - Vibration.

Describe the two major types of transmission shift linkages.

- On an external shift rod, rods fit into levers on the shift mechanism and fork assembly. Spring clips hold the rods in the levers. One end of each linkage rod is threaded so that the linkage can be adjusted. - With an internal shift rail, the bottom of the shift lever catches in one of the gates when the driver shift gears. Each gate is mounted on a shift rail. Since the fork is located on the rail, it is also moved when changing gears.

List six possible advantages of a front-wheel-drive vehicle with a transaxle over a rear-wheel-drive vehicle with a transaxle.

- Reduced drive train weight and improved efficiency. - Improved traction on slippery pavement. - Increased passenger compartment space. - Smoother ride because of less unsprung weight. - Quieter operation because engine and drive train noise is centrally located in the engine compartment. - Improved safety because of increased mass in front of passengers.

Rear axle ration is determined by comparing the number of teeth on the _____ gear to the number of teeth on the _____ gear.

- Ring. - Pinion.

What are the four functions of a drive shaft?

- Sends turning power from the transmission to the rear axle assembly. - Flexes and allows vertical (up and down) movement of the rear axle assembly. - Provides a sliding action to adjust for changes in driveline length. - Provides smooth power transfer.

The _____ _____ or _____ _____ is splined to the transmission output shaft.

- Slip yoke. - Slip joint.

What are three typical symptoms of automatic transaxle problems?

- Slipping in gear. - Abnormal noises. - Fluid leaks.

Where do automatic transmission fluid leaks Commonly occur?

- The rear seal. - Front seal. - Oil pan gasket. - Extension housing gasket. - Shift lever shaft seal.

Describe some causes of a dragging clutch.

- Too much pedal free travel. - A warped or bent friction disc. - Oil or grease or corrosion on the friction surfaces. - Rusted or damaged transmission input shaft splines. - Other problems inside the clutch housing.

Technician A says cars equipped with a transaxle can use either a manual transmission or automatic transmission. Technician B says cars equipped with a transaxle can only use manual transmission. Who is right?

A only.

Technician A says modern differential ring and pinion gears are hypoid type. Technician B says modern differential ring and pinion gears are classified as a spiral bevel gearset. Who is right?

A only.

Technician A says the input shaft on a manual transaxle turns the gears in the transaxle. Technician B says the input shaft on a manual transaxle powers the torque converter. Who is right?

A only.

The transaxle on a front-wheel-drive car must be removed for major repairs. Technician A says that on most front-wheel-drive cars, the transaxle can be disconnected from the engine and removed from the bottom of the engine compartment. Technician B says that on any front-wheel-drive car, the transaxle and engine must be removed together through the top of the engine compartment. Who is right?

A only.

Explain the two methods commonly used to hold a rear drive axle in its housing.

A retainer plate type axle is commonly used with a removable carrier placed on the outside of the housing. A C-clip type axle is frequently used with an integral carrier, and the C-clips are placed on the inner ends of the axle.

What is a servo?

A servo is an apply piston that operates the automatic transmission bands.

What is a stall test?

A test that uses a tachometer to detect transmission slippage or a malfunctioning torque converter.

Explain the basic operation of a transfer case.

A transfer case sends power to both the front and rear axle assemblies in a four-wheel-drive vehicle.

What is a transaxle?

A transmission and a differential combined in a single assembly.

What is the benefit of a wet clutch?

A wet clutch does not slip, as a fluid coupling or torque converter may, and is more energy efficient.

A(n) _____ is used in the apply circuit of a band or clutch to cushion initial application of oil pressure.

Accumulator.

What is the potential danger of spinning a bearing with compressed air?

Air pressure can make the bearing whirl at tremendously high speed. The bearing can explode and fly apart with lethal force.

What is used to check driveline angle?

An angle gauge that reads in degrees.

List three common causes of drive shaft vibration.

Any problem affecting drive shaft balance, runout, and angle of the shaft.

Clutch disc lining may contain _____, which is a known cancer-causing substance.

Asbestos.

A car is brought into the shop with a worn clutch. Technician A tells the owner of the car that highway driving will wear out a clutch faster than city driving. Technician B tells the owner that city driving wears out a clutch faster than highway driving. Who is right?

B only.

A car's drive shaft needs to be checked for runout. Technician A is going to use an inside micrometer to perform this task. Technician B is going to use a dial indicator to perform this task. Who is right?

B only.

A car's manual transaxle produces a noise in every gear. Technician A inspects the condition of the valve body. Technician B checks the condition of the transaxle's shaft bearings. Who is right?

B only.

A grinding sound is coming from an automobile's drive shaft assembly. Technician A inspects the condition of the slip yoke. Technician B checks for a bad universal joint. Who is right?

B only.

A manual transmission is not operating properly. Technician A says the first step is to remove the transmission from the vehicle and begin teardown. Technician B says the first step is to determine the cause of the problem. Who is right?

B only.

A whining noise is coming from an automobile's drive shaft assembly. Technician A says this problem is the result of a bad transmission input shaft bushing. Technician B looks for a worn center support bearing. Who is right?

B only.

An automatic transmission's fluid has a "milky" color. Technician A checks to see if engine oil is leaking into the transmission. Technician B checks to see if engine coolant is leaking into one of the transmission lines. Who is right?

B only.

An automobile's clutch has too much "free play." Technician A says this problem can cause clutch slippage. Technician B says this problem can cause clutch dragging. Who is right?

B only.

Technician A says a differential's ring and pinion drive gears are never manufactured as a matched set. Technician B says a differential's ring and pinion gears are commonly manufactured as a matched set. Who is right.

B only.

Technician A says a manual transaxle transmission is always driven by a drive shaft powered by the engine's crankshaft. Technician B says a manual transaxle transmission is sometimes driven by a chain link powered by the engine's crankshaft. Who is right?

B only.

Technician A says an automatic transmission's extension housing supports the transmission input shaft. Technician B says an automatic transmission's extension housing supports the transmission output shaft. Who is right?

B only.

Technician A says an automatic transmission's valve body connects and disconnects the engine and transmission. Technician B says an automatic transmission's torque converter connects and disconnects the engine and transmission. Who is right?

B only.

Technician A says an automobile's rear axles transfer torque to the differential pinion gear. Technician B says an automobile's rear axles transfer torque to the rear wheels. who is right?

B only.

Technician A says clutch disc torsion springs are used to fasten the clutch disc to the transmission input shaft. Technician B says clutch disc torsion springs help absorb some of the vibration produced by clutch engagement. Who is right?

B only.

Technician A says drive shaft balancing weights are usually bolted to the drive shaft. Technician B says drive shaft balancing weights are normally welded to the drive shaft. Who is right?

B only.

Technician A says front-wheel-drive cars use a driveline with a single, long drive shaft. Technician B says front-wheel-drive cars are usually equipped with two drive axle shafts. Who is right?

B only.

Technician A says that screws are normally used to secure front drive axle CV joint boots. Technician B says that straps are normally used to secure front drive axle CV joint boots. Who is right?

B only.

Technician A says the clutch disc is bolted to the transmission input shaft. Technician B says the clutch disc is splined to the transmission input shaft. Who is right?

B only.

Technician A says transaxles are used only on front-wheel-drive cars. Technician B says transaxles are used on front-wheel-drive cars and certain types of rear-engine cars. Who is right?

B only.

Technician A says when a manual transmission is in neutral, all of the synchronizer sleeves are located at the end of thecountershaft. Technician B says when a manual transmission is in neutral, all of the synchronizer sleeves are located in the center of their hubs. Who is right?

B only.

The check valves in an automatic transmission are possibly malfunctioning. Technician A uses an ohmmeter to check the operation of these valves. Technician B performs an air test to check the operation of these valves. Who is right?

B only.

The lubricant in a limited-slip differential needs changing. Technician A tells the owner of the vehicle that all differential lubricant is the same. Technician B tells the owner of the car that certain limited-slip differentials require a special type of lubricant. Who is right?

B only.

While discussing the functions of the basic parts of a manual transmission, Technician A says the input shaft transfers rotating power out of the transmission to the drive shaft. Technician B says the input shaft is used to turn the gears inside the transmission. Who is right?

B only.

A clutch is being tested for slippage. Technician A says when performing this test, the emergency brake should be engaged. Technician B says when testing a clutch for slippage, the car's transmission should be placed in high gear. Who is right?

Both A and B.

A customer wants his/her automobile's universal joints greased. Technician A tells the customer that certain modern universal joints are normally sealed units that are filled with grease at the factory. Technician B tells the customer that some universal joints have grease fittings that allow for lubrication. Who is right?

Both A and B.

A customer wants to know what caused his/her car's ring and pinion gears to malfunction. Technician A says prolonged service may have caused this problem. Technician B says low differential lubricant level may have caused this problem. Who is right?

Both A and B.

A manual transmission is hard to shift into gear. Technician A looks for a bent shift rod. Technician B checks the condition of the clutch. Who is right?

Both A and B.

A rear axle must be removed from its housing. Technician A says a retainer plate may be used to hold this axle in its housing. Technician B says a C-clip may be used to hold this particular axle in its housing. Who is right?

Both A and B.

An automatic transaxle slips when placed in gear. Technician A checks for worn bands. Technician B checks the transaxle's fluid level. Who is right?

Both A and B.

Brass-colored particles are discovered in the case of a manual transmission during disassembly. Technician A checks the condition of the thrust washers. Technician B believes one or more synchronizers could be damaged. Who is right?

Both A and B.

Noise is coming from a car's rear drive axle assembly. Technician A checks for broken pinion gear teeth. Technician B inspects the condition of the ring gear. Who is right?

Both A and B.

Technician A says a drive shaft assembly sends turning power from the transmission to the rear axle assembly. Technician B says a drive shaft assembly must flex and allow up and down movement of the rear axle assembly. Who is right?

Both A and B.

Technician A says a rear drive axle assembly splits the amount of torque going to each wheel. Technician B says a rear drive axle assemble transfers torque through a 90 degree angle. Who is right?

Both A and B.

A(n) _____ switch signals the main control module when the driver begins to slow or stop the vehicle.

Brake pedal.

During clutch engagement, oil pressure is routed into the _____.

Clutch drum.

An automotive _____ connects and disconnects the engine and manual transmission or transaxle.

Clutch.

The teeth on _____ gears are machined at an angle to the centerline of the gear shaft.

Helical.

A(n) _____ uses a simple hydraulic circuit to transfer clutch pedal action to the clutch fork.

Hydraulic clutch release mechanism.

The _____ shaft is the center shaft that fits between the two CV joint.

Interconnecting.

What is the purpose of using a compound planetary gearset?

It can provide more forward gear ratios than a simple planetary gearset.

What is normally the cause of burned transmission oil?

It is caused by band and clutch friction material failure. It means serious damage has occurred, and the transmission will need major repairs.