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(A3) Manual Drive Train Axles Task Sheets by ASE area

General

Research vehicle service information such as fluid type, vehicle service history, service precautions, technical service bulletins, and recalls including vehicles equipped with advanced driver assistance systems (ADAS).

Identify manual drive train and axles components and configurations.

Manual Transmission Identification

Microsoft Word version

Fillable PDF version

Manual Transaxle Identification

Microsoft Word version

Fillable PDF version

Retrieve and record DTCs, OBD monitor status, and freeze frame data; clear codes and data when directed.

Electronically Controlled Manual Transmission

Microsoft Word version

Fillable PDF version

Check fluid condition; check for leaks; determine needed action.

Retrieving OBD II Diagnostic Trouble Codes

Microsoft Word version

Fillable PDF version

Retrieve DTCs, Monitor Status & Freeze Frames

Microsoft Word version

Fillable PDF version

Drain and refill manual transmission/transaxle and final drive unit; use proper fluid type per manufacturer specification.

Drain and Fill Manual Transmission/Transaxle

Microsoft Word version

Fillable PDF version

Diagnose drive train concerns; determine needed action.

Diagnosing Hard Shifting Concerns

Microsoft Word version

Fillable PDF version

Clutch

Check and adjust clutch master cylinder fluid level; check for leaks; use proper fluid type per manufacturer specification.

Clutch Master Cylinder Fluid Level

Microsoft Word version

Fillable PDF version

Diagnose clutch noise, binding, slippage, pulsation, and chatter; determine needed action.

Inspect clutch pedal linkage, cables, automatic adjuster mechanisms, brackets, bushings, pivots, and springs; perform needed action.

Inspect and/or replace clutch pressure plate assembly, clutch disc, release (throw-out) bearing/ linkage, and pilot bearing/bushing (as applicable).

Inspect/Replace Clutch Components

Microsoft Word version

Fillable PDF version

Bleed clutch hydraulic system.

Bleed Clutch Hydraulic System

Microsoft Word version

Fillable PDF version

Inspect flywheel and ring gear for wear, cracks, and discoloration; determine needed action.

Flywheel and Ring Gear Inspection

Microsoft Word version

Fillable PDF version

Measure flywheel runout and crankshaft end play; determine needed action.

Describe the operation and service of a system that uses a dual mass flywheel.

Transmission/Transaxle

Describe the operational characteristics of an electronically controlled manual transmission/transaxle.

Electronically Controlled Manual Transmission

Microsoft Word version

Fillable PDF version

Inspect, adjust, lubricate and/or replace shift linkages, brackets, bushings, cables, pivots, and levers.

Manual Transmission/Transaxle Linkage

Microsoft Word version

Fillable PDF version

Diagnose noise concerns through the application of transmission/transaxle powerflow principles.

Diagnose hard shifting and jumping out of gear concerns; determine needed action.

Diagnosing Hard Shifting Concerns

Microsoft Word version

Fillable PDF version

Diagnose transaxle final drive assembly noise and vibration concerns; determine needed action.

Disassemble, inspect clean, and reassemble internal transmission/transaxle components.

Disassemble and Reassemble Transmission/Transaxle

Microsoft Word version

Fillable PDF version

Drive Shaft/Half Shaft and Universal Joint/CV Joint

Inspect, remove, and/or replace bearings, hubs, and seals.

Sealed Wheel Bearing Replacement

Microsoft Word version

Fillable PDF version

Inspect, service, and/or replace shafts, yokes, boots, and universal/CV joints.

Check for leaks at drive assembly and transfer case seals; check vents; check fluid level; use proper fluid type per manufacturer specification.

Diagnose constant-velocity (CV) joint noise and vibration concerns; determine needed action.

CV Joint Noise and Vibration Diagnosis

Microsoft Word version

Fillable PDF version

Diagnose universal joint noise and vibration concerns; determine needed action.

CV Joint Noise and Vibration Diagnosis

Microsoft Word version

Fillable PDF version

Check shaft balance and phasing; measure shaft runout; measure and adjust driveline angles; determine needed action.

CV Joint Noise and Vibration Diagnosis

Microsoft Word version

Fillable PDF version

Noise and Vibration Diagnosis

Microsoft Word version

Fillable PDF version

Drive Axle Diagnosis and Repair

Inspect differential housing; check for leaks; inspect housing vent.

Check and adjust differential case fluid level; use proper fluid type per manufacturer specification.

Drain and refill differential case; use proper fluid type per manufacturer specification.

Inspect and replace companion flange and/or pinion seal; measure companion flange runout.

Demonstrate knowledge of drive pinion and ring gear service and set up including depth, preload, backlash and gear tooth contact. (AST only)

Inspect ring gear and measure runout; determine needed action. (MAST only)

Diagnose noise and vibration concerns; determine needed action.

Differential Noise Diagnosis

Microsoft Word version

Fillable PDF version

Remove, inspect, reinstall and/or replace drive pinion and ring gear, spacers, sleeves, and bearings.

Differential Assembly Inspection

Microsoft Word version

Fillable PDF version

Measure and adjust drive pinion depth.

Measure and adjust drive pinion bearing preload.

Drive Pinion Bearing Preload

Microsoft Word version

Fillable PDF version

Measure and adjust side bearing preload and ring and pinion gear total backlash and backlash variation on a differential carrier assembly (threaded cup or shim types).

Differential Side Bearing Preload

Microsoft Word version

Fillable PDF version

Check ring and pinion tooth contact patterns; perform needed action.

Ring and Pinion Tooth Pattern

Microsoft Word version

Fillable PDF version

Disassemble, inspect, measure, adjust and/or replace differential pinion gears (spiders), shaft, side gears, side bearings, thrust washers, and case.

Differential Pinion Gears and Case

Microsoft Word version

Fillable PDF version

Reassemble and reinstall differential case assembly; measure runout; determine needed action.

Differential Case Assembly

Microsoft Word version

Fillable PDF version

Inspect and replace drive axle wheel studs.

Drive Axle Shaft Wheel Studs

Microsoft Word version

Fillable PDF version

Remove and replace drive axle shafts.

U-Joint and CV Joint Service

Microsoft Word version

Fillable PDF version

Inspect and replace drive axle shaft seals, bearings, and retainers.

U-Joint and CV Joint Service

Microsoft Word version

Fillable PDF version

Measure drive axle flange runout and shaft end play; determine needed action.

U-Joint and CV Joint Service

Microsoft Word version

Fillable PDF version

Diagnose drive axle shafts, bearings, and seals for noise, vibration, and fluid leakage concerns; determine needed action.

Inspect and Adjust Shifting Controls

Microsoft Word version

Fillable PDF version

Diagnose noise, slippage, and chatter concerns; determine needed action.

Limited Slip Differential Diagnosis

Microsoft Word version

Fillable PDF version

Measure rotating torque; determine needed action.

Limited Slip Differential Rotating Torque

Microsoft Word version

Fillable PDF version

Four-Wheel Drive/All-Wheel Drive Component Diagnosis and Repair

Identify concerns related to variations in tire circumference and/or final drive ratios.

Four-Wheel Drive Diagnosis

Microsoft Word version

Fillable PDF version

Inspect, adjust, and repair shifting controls (mechanical, electrical, and vacuum), bushings, mounts, levers, and brackets.

Inspect and Adjust Shifting Controls

Microsoft Word version

Fillable PDF version

Inspect, adjust, and repair shifting controls (mechanical, electrical, and vacuum), bushings, mounts, levers, and brackets.

Inspect Front Locking Hubs

Microsoft Word version

Fillable PDF version

Check for leaks at drive assembly and transfer case seals; check vents; check fluid level; use proper fluid type per manufacturer specification.

Transfer Case Lube Level Check

Microsoft Word version

Fillable PDF version

Diagnose noise, vibration, and unusual steering concerns; determine needed action.

Four-Wheel Drive Diagnosis

Microsoft Word version

Fillable PDF version

Diagnose, test, adjust, and replace electrical/electronic components of four-wheel drive systems.

Transfer Case Electrical Components

Microsoft Word version

Fillable PDF version

Disassemble, service, and reassemble transfer case and components.

Transfer Case Disassembly and Reassembly

Microsoft Word version

Fillable PDF version