Course Outline for Automotive Technology 64A, Page 3

Chabot College

Fall 2010

Chabot College Fall 2010

Course Outline for Automotive Technology 64A

MANUAL DRIVE TRAIN AND AXLE ASSEMBLIES

Catalog Description:

64A - Manual Drive Train and Axle Assemblies 3 units

(May be repeated three times)

Diagnosis, inspection, repair, and adjustment of automotive manual drive train and axle assemblies. Includes manual transmissions/transaxles, final drives, rear axle assemblies, clutches, viscous couplings, two, four and all-wheel drive assemblies. Prerequisite: Automotive Technology 50 (May be taken concurrently) or equivalent. Strongly Recommend: Industrial Technology 74. 1.5 hours lecture, 5 hours laboratory.

[Typical contact hours: lecture 26.25, laboratory 87.5]

Prerequisite Skills:

Before entering the course the student should be able to:

1. recognize unsafe working conditions and practices;

2. use common automotive shop equipment safely;

3. identify and recognize common automotive tools and equipment;

4. identify fasteners;

5. demonstrate proper procedures to repair a broken fastener and/or repair threads;

6. discuss automotive engine fundamentals;

7. perform engine vacuum tests;

8. perform cylinder compression tests;

9. perform cylinder leakage tests;

10. perform oil pressure tests;

11. perform oil and filter change;

12. assess and use service information;

13. demonstrate proper use of metric and standard micrometers;

14. demonstrate proper use of an analog or digital volt/ohmmeter;

15. select the appropriate automotive fluid for the selected application;

16. use appropriate methods for hazardous waste handling and disposal;

17. discuss potential areas of employment in the automotive industry

Expected Outcomes for Students:

Upon completion of the course, the student should be able to:

1. diagnose fluid usage, level, leakage and condition concerns, drain and fill manual transmission/transaxle and final drive unit;

2. diagnose clutch noise, binding, slippage, pulsation, and chatter, and determine necessary action;

3. inspect, clutch pedal linkage, cables, automatic adjuster mechanisms, brackets, bushings, pivots, and springs and perform necessary action;

4. inspect and replace hydraulic clutch slave and master cylinders, lines, hoses, and release bearing, lever and pivot; and perform necessary action;

5. inspect and replace pilot bearing or bushing, release bearing, clutch pressure plate assembly and clutch disc;

6. inspect flywheel and ring gear for wear and cracks, measure runout; and determine necessary action;

7. remove and reinstall transmission/transaxle;

8. diagnose noise, hard shifting, jumping out of gear, and fluid leakage concerns and determine necessary action;

9. disassemble, clean, inspect and reassemble transmission/transaxle components;

10. measure endplay or preload (shim or spacer selection procedure) on transmission/transaxle shafts, and perform necessary action;

11. diagnose constantvelocity (CV), and universal joint noise and vibration concerns, and determine necessary action;

12. inspect, service, and replace shafts, yokes, boots, and cv joints;

13. diagnose final drive noise and vibration concerns, and determine necessary action;

14. inspect and replace companion flange, pinion seal, and measure companion flange runout;

15. inspect ring gear, measure runout, and determine necessary action;

16. remove, inspect, reinstall and adjust drive pinion, seals, ring gear, spacers, sleeves, and bearings;

17. measure and adjust drive pinion depth, and pinion bearing preload;

18. check ring and pinion tooth contact patterns, gear backlash, and perform necessary action;

19. inspect and flush differential housing, and refill with correct lubricant;

20. inspect and replace drive axle shaft seals, bearings, and retainers;

21. remove and replace drive axle shafts;

22. disassemble, inspect, and reassemble transfer case and components.

Course Content:

1. Course content, lecture

2. Automotive safety and shop practice

3. Proper care and manipulation of basic hand tools

4. Fundamentals, operating and servicing principles of manual transmissions/transaxles

a. Design features

b. Power Flows- four and five speed transmissions/transaxles

c. Synchronizers

d. Shift Mechanisms

e. Lubrication

f. Problem diagnosis

g. Service procedures

5. Fundamentals, operating and servicing principles of drivelines and couplings

a. Universal and constant velocity joints

b. FWD/RWD driveshafts

c. Service procedures

6. Fundamentals, operating and servicing principles of clutches

a. Components – clutch discs, pressure plate assemblies, pilot and release bearings

b. Clutch linkage

c. Problem diagnosis

d. Service procedures

7. Fundamentals, operating and servicing principles of final drives, and drive axle assemblies

a. Components – ring and pinion gears, differential, axle shafts

b. Lubrication

c. Problem diagnosis

d. Service procedures

8. Fundamentals, operating and servicing principles of four wheel drive and all wheel drive assemblies

a. Transfer cases

b. Front drive axles

c. Lubrication

d. Problem diagnosis

e. Service procedures

9. h. Hazardous waste handling

10. Course content, laboratory

11. Each of the lecture content items is accompanied by a required NATEF (National Automotive Technical Education Foundation) lab “task sheet” with required levels of exposure (general knowledge, demonstration, basic skill level, advanced skill level. Examples include:

a. Repair/service clutch system

b. Disassemble, inspect, repair, and reassemble manual transmission

c. Diagnose and service a transaxle

Methods of Presentation:

1. Lecture/discussion

2. Laboratory

3. Guest speakers

4. Field trips

Assignments and Methods of Evaluating Student Progress:

1. Typical Assignments

a. Read chapter on Drive Axle Service

b. Perform differential drive pinion service, including removing, inspecting and replacing

c. bearings, checking pinion depth setting, and adjusting pinion bearing preload, and complete worksheet as assigned

2. Methods of Evaluating Student Progress

a. Class participation

b. Performance of laboratory task lists and projects

c. Homework assignments

d. Quizzes

e. Midterm examination

f. Final examination

Textbook(s) (Typical):

Manual Drivetrains and Axles 5th edition, by Tom Birch and Chuck Rockwood, Published by Prenticehall Automotive, 2008. Bundled with NATEF Correlated Task Sheets.

Special Student Materials:

1. Safety glasses

2. Shop/safety clothing

JGB

Atec 64A course outline

Revised: September 21, 2009