Manual Drivetrains and Axles Book

CLASSROOM MANUAL

1. HAZ-MAT and Safety Objectives.

Key Terms

Introduction

Occupational Safety and Health Act

Hazardous Waste Disposal

Asbestos

Fire Safety

Fire Extinguishers

Electrical Equipment Safety

Hand Tool Safety

Power Tool Safety

Compressed Air Equipment Safety

Vehicle Operation

Lift Safety

Hydraulic Jack and Safety Stand Safety

Eye Injuries

First'Aid Kits

Logout/Tagout

Summary

Review Questions

2. Drive Train Fundamentals

Objectives

Key Terms

Introduction

Drive Train Purpose

Drive Train Configurations

Drivetrain Components

Transmissions and Transaxles

Driveline

Summary

Review Questions

3. Gears & Bearings.

Objectives

Key Terms

Introduction

Gear types

Gear Ratios

Torque, Speed & Power

Drivetrain Gear Ratios

Bearings

Bearing Types

Summary

Review Questions

4. Lubricants.

Objectives

Key Terms

Introduction

Friction

Lubricants

Engine Oil

Gear Oil

Automatic Transmission Fluid

Greases

Summary

Review Questions

5. Seals, Sealants, Gaskets, & Fasteners.

Objectives

Key Terms

Introduction

Gaskets

Seals

Sealants

Fasteners

Summary

Review Questions

6. Flywheel Clutch Assemblies And Release Mechanisms.

Objectives

Key Terms

Introduction

Flywheel Clutch Assembly

Flywheel

Pressure Plate

Friction Disc

Release Bearing Design

Clutch Operation System

Hydraulic Clutch System

Summary

Review Questions

7. Transmission/Transaxle Fundamentals.

Objectives

Key Terms

Introduction

Manual TransmissionConstruction

Manual Transmission Power Flow

Manual Transaxle Construction

Manual Transaxle Power Flow

Final Drives and Differentials for Transaxles

Shift Linkage

Transmission/Transaxle Lubrication

Transmission/Transaxle Sealing

Transmission/Transaxle Switches

Summary

Review Questions

8. Manual Transmission Operation.

Objectives

Key Terms

Introduction

Borg-Warner T5 Transmission Operation

NVG 4500 Transmission Operation

ZF 6-Speed Transmission Operation

Summary

Style Review Questions

9. Manual Transaxle Operation.

Objectives

Key Terms

Introduction

Getrag 5-Speed Transaxle Operation

Daimler-Chrysler A-578 Transaxle Operation

Summary

Review Questions

10. Driveshafts and Universal Joints.

Objectives

Key Terms

Introduction

REAR-WHEEL DRIVE DRIVELINES

UNIVERSAL JOINTS

DRIVELINE TYPES 

Summary

Review Questions

11. Front-Drive Axle, CV Joint, & Wheel Bearing Operation.

Objectives

Key Terms

Introduction

HALF SHAFT DRIVELINES

CONSTANT VELOCITY JOINTS

CONSTANT VELOCITY AXLE BEARING ASSEMBLIES

Summary

Review Questions

12. Drive Axle and Differential Operation.

Objectives

Key Terms

Introduction

The Final Drive

Differentials

Automatic Locking Differentials

Differential Eliminators

Rear Axle Designs

Lubrication

Axle Identification

Summary

Review Questions

13. 4-Wheel Drive/AWD System Operation.

Objectives

Key Terms

Introduction

4-Wheel Drive Systems

4-Wheel Drive Components

All Wheel Drive Systems

Summary

Review Questions

14. Electricity/ Electronics.

Objectives

Key Terms

Introduction

Basic Electrical Concepts

Electrical Components

Summary

Review Questions

15. Drive Train Electronic Control Systems.

Objectives

Key Terms

Introduction

Computer Control

Electronic Manual Transmission/Transaxle Control

Summary

Review Questions

Glossary

Index.

SHOP MANUAL

1. Safety in the Shop.

2. Tools and Measurement.

3. Bearing and Case Service.

4. Basic Lubrication & Preliminary Inspection.

5. Gasket, Seals and Sealant Service.

6. Clutch Diagnosis and Repair.

7. Diagnosing Transmissions & Transaxles.

8. Transmission Diagnosis and Repair.

9. Transaxle Diagnosis and Repair.

10. Driveshaft and U-Joint Diagnosis and Repair.

11. Front Drive Axle & Wheel Bearing Diagnosis and Repair.

12. Drive Axle Diagnosis and Repair.

13. 4-Wheel Drive/AWD Diagnosis and Repair.

14. Electrical/Electronic Systems Diagnosis and Repair.

15. Drive Train Electronic Control Systems Diagnosis and Repair.