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. Identify and interpret drive train concern; determine necessary action. P-1
2. Research applicable vehicle and service information, such as drive train
system operation, vehicle service history, service precautions, and technical
service bulletins. P-1
3. Locate and interpret vehicle and major component identification numbers (VIN,
vehicle certification labels, calibration decals). P-1
4. Diagnose fluid usage, level, and condition concerns; determine necessary
action. P-1
5. Drain and fill manual transmission/transaxle and final drive unit. P-2
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-3
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-2
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-3
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-2
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. Replace front wheel drive (FWD) front wheel bearing. P-2
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; 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-2
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-1
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-1
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. Inspect and flush 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-3
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
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