Chabot College
Fall 2005
Replaced Fall 2010
Course Outline for Automotive Technology 64A
MANUAL DRIVE TRAIN AND AXLE ASSEMBLIES
Catalog Description:
64A-Manual Drive Train and Axle Assemblies
(May be repeated three times)
3 units
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:
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recognize unsafe working conditions and practices;
use common automotive shop equipment safely;
identify and recognize common automotive tools and equipment;
identify fasteners;
demonstrate proper procedures to repair a broken fastener and/or repair threads;
discuss automotive engine fundamentals;
perform engine vacuum tests;
perform cylinder compression tests;
perform cylinder leakage tests;
perform oil pressure tests;
perform oil and filter change;
assess and use service information;
demonstrate proper use of metric and standard micrometers;
demonstrate proper use of an analog or digital volt/ohmmeter;
select the appropriate automotive fluid for the selected application;
use appropriate methods for hazardous waste handling and disposal;
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;
Chabot College
Course Outline for Automotive Technology 64A, Page 2
Fall 2005
Expected Outcomes for Students (continued):
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 constant-velocity (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. Automotive safety and shop practice
2. Proper care and manipulation of basic hand tools
3. 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
4. Fundamentals, operating and servicing principles of drivelines and couplings
a. Universal and constant velocity joints
b. FWD/RWD driveshafts
c. Service procedures
5. 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
6. 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
Chabot College
Course Outline for Automotive Technology 64A, Page 3
Fall 2005
Course Content (continued):
7. 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
8. Hazardous waste handling
Methods of Presentation:
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Lecture/discussion
Laboratory
Guest speakers
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
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 exam
f. Final exam
Textbook(s) Typical:
Manual Drive Trains and Axles, Tom Birch, Prentice Hall Publishers, 2002.
Special Student Materials:
1. Safety glasses
2. Shop/safety clothing
RJ 09/2004
AT 64A course outline