AMT 46 Tasks

Manual Drive Train and Axles

For every task in Manual Drive Train and Axles, the following safety requirement must be strictly enforced:

Comply with personal and environmental safety practices associated with clothing; eye protection; hand tools; power equipment; proper ventilation; and the handling, storage, and disposal of chemicals/materials in accordance with local, state, and federal safety and environmental regulations.

III. Manual Drive Train and Axles

A. General Drive Train Diagnosis

1. Complete work order to include customer information, vehicle identifying information, customer concern, related service history, cause, and correction. P-1
2. Identify and interpret drive train concern; determine necessary action. P-1
3. Research applicable vehicle and service information, such as drive train system operation, fluid type, vehicle service history, service precautions, and technical service bulletins. P-1
4. Locate and interpret vehicle and major component identification numbers (VIN, vehicle certification labels, calibration decals). P-1
5. Diagnose fluid loss, level, and condition concerns; determine necessary action. P-1
6. Drain and fill manual transmission/transaxle and final drive unit. P-1

B. Clutch Diagnosis and Repair

1. Diagnose clutch noise, binding, slippage, pulsation, and chatter; determine necessary action. P-1
2. Inspect clutch pedal linkage, cables, automatic adjuster mechanisms, brackets, bushings, pivots, and springs; perform necessary action. P-1
3. Inspect hydraulic clutch slave and master cylinders, lines, and hoses; determine necessary action. P-1
4. Inspect release (throw-out) bearing, lever, and pivot; determine necessary action. P-1
5. Inspect and replace clutch pressure plate assembly and clutch disc. P-1
6. Bleed clutch hydraulic system. P-1
7. Inspect, remove or replace pilot bearing or bushing (as applicable). P-1
8. Inspect flywheel and ring gear for wear and cracks, determine necessary action. P-1
9. Inspect engine block, clutch (bell) housing, transmission/transaxle case mating surfaces, and alignment dowels; determine necessary action. P-3
10. Measure flywheel runout and crankshaft endplay; determine necessary action. P-2

III. Manual Drive Train and Axles

C. Transmission/Transaxle Diagnosis and Repair

1. Remove and reinstall transmission/transaxle. P-1
2. Disassemble, clean, and reassemble transmission/transaxle components. P-1
3. Inspect transmission/transaxle case, extension housing, case mating surfaces, bores, bushings, and vents; perform necessary action. P-3
4. Diagnose noise, hard shifting, jumping out of gear, and fluid leakage concerns; determine necessary action. P-2
5. Inspect, adjust, and reinstall shift linkages, brackets, bushings, cables, pivots, and levers. P-2
6. Inspect and reinstall powertrain mounts. P-2
7. Inspect and replace gaskets, seals, and sealants; inspect sealing surfaces. P-2
8. Remove and replace transaxle final drive. P-3
9. Inspect, adjust, and reinstall shift cover, forks, levers, grommets, shafts, sleeves, detent mechanism, interlocks, and springs. P-2
10. Measure endplay or preload (shim or spacer selection procedure) on transmission/transaxle shafts; perform necessary action. P-1
11. Inspect and reinstall synchronizer hub, sleeve, keys (inserts), springs, and blocking rings. P-1
12. Inspect and reinstall speedometer drive gear, driven gear, vehicle speed sensor (VSS), and retainers. P-2
13. Diagnose transaxle final drive assembly noise and vibration concerns; determine necessary action. P-3
14. Remove, inspect, measure, adjust, and reinstall transaxle final drive pinion gears (spiders), shaft, side gears, side bearings, thrust washers, and case assembly. P-2
15. Inspect lubrication devices (oil pump or slingers); perform necessary action. P-3
16. Inspect, test, and replace transmission/transaxle sensors and switches. P-1

III. Manual Drive Train and Axles

D. Drive Shaft and Half Shaft, Universal and Constant-Velocity (CV) Joint Diagnosis and Repair

1. Diagnose constant-velocity (CV) joint noise and vibration concerns; determine necessary action. P-1
2. Diagnose universal joint noise and vibration concerns; perform necessary action. P-1
3. Remove and replace front wheel drive (FWD) front wheel bearing. P-1
4. Inspect, service, and replace shafts, yokes, boots, and CV joints. P-1
5. Inspect, service, and replace shaft center support bearings. P-3
6. Check shaft balance and phasing; measure shaft runout; measure and adjust driveline angles. P-2

III. Manual Drive Train and Axles

E. Drive Axle Diagnosis and Repair

1. Ring and Pinion Gears and Differential Case Assembly

1. Diagnose noise and vibration concerns; determine necessary action. P-2
2. Diagnose fluid leakage concerns; determine necessary action. P-1
3. Inspect and replace companion flange and pinion seal; measure companion flange runout. P-2
4. Inspect ring gear and measure runout; determine necessary action. P-2
5. Remove, inspect, and reinstall drive pinion and ring gear, spacers, sleeves, and bearings. P-2
6. Measure and adjust drive pinion depth. P-2
7. Measure and adjust drive pinion bearing preload. P-2
8. 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). P-2
9. Check ring and pinion tooth contact patterns; perform necessary action. P-2
10. Disassemble, inspect, measure, and adjust or replace differential pinion gears (spiders), shaft, side gears, side bearings, thrust washers, and case. P-2
11. Reassemble and reinstall differential case assembly; measure runout; determine necessary action. P-2

2. Limited Slip Differential

1. Diagnose noise, slippage, and chatter concerns; determine necessary action. P-3
2. Clean and inspect differential housing; refill with correct lubricant. P-2
3. Inspect and reinstall clutch (cone or plate) components. P-3
4. Measure rotating torque; determine necessary action. P-3

3. Drive Axle Shaft

1. Diagnose drive axle shafts, bearings, and seals for noise, vibration, and fluid leakage concerns; determine necessary action. P-2
2. Inspect and replace drive axle shaft wheel studs. P-1
3. Remove and replace drive axle shafts. P-1
4. Inspect and replace drive axle shaft seals, bearings, and retainers. P-2
5. Measure drive axle flange runout and shaft endplay; determine necessary action. P-2

III. Manual Drive Train and Axles

F. Four-wheel Drive/All-wheel Drive Component Diagnosis and Repair

1. Diagnose noise, vibration, and unusual steering concerns; determine necessary action. P-3
2. Inspect, adjust, and repair shifting controls (mechanical, electrical, and vacuum), bushings, mounts, levers, and brackets. P-3
3. Remove and reinstall transfer case. P-3
4. Disassemble, service, and reassemble transfer case and components. P-3
5. Inspect front-wheel bearings and locking hubs; perform necessary action. P-3
6. Check drive assembly seals and vents; check lube level. P-3
7. Diagnose test, adjust, and replace electrical/electronic components of four-wheel drive systems. P-3