DRIVE TRAIN

For every task in Drive Train, the following safety task 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 federal, state, and local regulations.

The first task in Drive Train is to listen to and verify the operator's concern, review past maintenance and repair documents, and determine necessary action.

III. DRIVE TRAIN

A. Clutch Diagnosis and Repair

1. Diagnose clutch noise, binding, slippage, pulsation, vibration, grabbing, and chatter problems; determine needed action. P-1

2. Inspect and adjust clutch linkage, cables, levers, brackets, bushings, pivots, springs, and clutch safety switch (includes push and pull-type assemblies); check pedal height and travel; perform needed action. P-1

3. Inspect, adjust, repair, or replace hydraulic clutch slave and master cylinders, lines, and hoses; bleed system. P-2

4. Inspect, adjust, or replace release (throw-out) bearing, sleeve, bushings, springs, housing, levers, release fork, fork pads, rollers, shafts, and seals. P-2

5. Inspect, adjust, and replace single-disc clutch pressure plate and clutch disc. P-1

6. Inspect, adjust, and replace two-plate clutch pressure plate, clutch discs, intermediate plate, and drive pins/lugs. P-1

7. Inspect and/or replace clutch brake assembly; inspect input shaft and bearing retainer; perform needed action. P-3

8. Inspect, adjust, and replace self-adjusting/continuous-adjusting clutch mechanisms. P-3

9. Inspect and replace pilot bearing. P-2

10. Inspect flywheel mounting area on crankshaft, rear main oil seal, and measure crankshaft end play; determine needed action. P-2

11. Inspect flywheel, starter ring gear and measure flywheel face and pilot bore runout; determine needed action. P-2

12. Inspect flywheel housing(s) to transmission housing/engine mating surface(s) and measure flywheel housing face and bore runout; determine needed action. P-2

III. DRIVE TRAIN

B. Transmission Diagnosis and Repair

1. Diagnose transmission noise, shifting, lockup, jumping-out-of-gear, overheating, and vibration problems; determine needed action. P-1

2. Diagnose transmission component failure cause, both before and during disassembly procedures; determine needed action. P-2

3. Inspect, adjust, service, repair, or replace transmission remote shift linkages, brackets, bushings, pivots, and levers. P-2

4. Inspect, test, repair, or replace air shift controls, lines, hoses, valves, regulators, filters, and cylinder assemblies. P-1

5. Inspect and replace transmission mounts, insulators, and mounting bolts; determine needed action. P-3

6. Inspect for leakage and replace transmission cover plates, gaskets, seals, and cap bolts; inspect seal surfaces and vents; repair as needed. P-1

7. Check transmission fluid level and condition; determine needed service; add proper type of lubricant. P-1

8. Inspect, adjust, and replace transmission shift lever, cover, rails, forks, levers, bushings, sleeves, detents, interlocks, springs, and lock bolts/safety wires. P-3

9. Remove and reinstall transmission. P-2

10. Inspect and replace input shaft, gear, spacers, bearings, retainers, and slingers. P-3

11. Inspect and adjust main shaft, gears, sliding clutches, washers, spacers, bushings, bearings, auxiliary drive assemblies, retainers, and keys; replace as needed. P-3

12. Inspect countershafts, gears, bearings, retainers, and keys; adjust bearing preload and time multiple countershaft gears; replace as needed. P-3

13. Inspect output shafts, gears, washers, spacers, bearings, retainers, and keys; replace as needed. P-3

14. Inspect and/or replace reverse idler shafts, gears, bushings, bearings, thrust washers, and retainers; check reverse idler gear end play (where applicable). P-3

15. Inspect and/or replace synchronizer hub, sleeve, keys (inserts), springs, blocking rings, synchronizer plates, blocker pins, and sliding clutches. P-3

16. Inspect transmission cases including surfaces, bores, bushings, pins, studs, and magnets; replace as needed. P-3

17. Inspect transmission lubrication system pumps, troughs, collectors, and slingers; service or replace as needed. P-3

18. Inspect transmission oil filters and coolers; replace as needed. P-2

19. Inspect mechanical and electronic speedometer components; determine needed action. P-2

20. Inspect and adjust power take-off (P.T.O.) assemblies, controls, and shafts; perform needed action. P-3

21. Inspect and test function of backup light, neutral start, and warning device circuits; repair as needed. P-1

22. Inspect and test transmission temperature gauge sending unit/sensor; determine needed action. P-3

23. Inspect, test operation, adjust, repair, or replace electronic shift controls, shift, range and splitter solenoids, shift motors, indicators, speed and range sensors, electronic/transmission control units (ECU/TCU), neutral/in gear and reverse switches, and wiring harnesses. P-2

24. Inspect, test operation, repair, or replace electronic shift selectors, air and electrical switches, displays and indicators, wiring harnesses, and air lines. P-2

25. Use appropriate diagnostic tools and procedures to diagnose automated mechanical transmission problems; check and record diagnostic codes, clear codes, and interpret digital multimeter (DMM) readings; determine needed repairs. P-2

III. DRIVE TRAIN

C. Driveshaft and Universal Joint Diagnosis and Repair

1. Diagnose driveshaft and universal joint noise and vibration problems; determine needed action. P-1

2. Inspect, service, or replace driveshaft, slip joints, yokes, drive flanges, and universal joints; check phasing of all yokes. P-1

3. Inspect and replace driveshaft center support bearings and mounts; determine needed action. P-1

4. Measure and adjust drive line angles. P-2

III. DRIVE TRAIN

D. Drive Axle Diagnosis and Repair

1. Diagnose drive axle(s) drive unit noise and overheating problems; determine needed action. P-2

2. Check and repair fluid leaks; inspect and replace drive axle housing cover plates, gaskets, sealants, vents, magnetic plugs, and seals. P-1

3. Check drive axle fluid level and condition; determine needed service; add proper type of lubricant. P-1

4. Remove and replace differential carrier assembly. P-2

5. Inspect and replace differential case assembly including spider gears, cross shaft, side gears, thrust washers, case halves, and bearings. P-3

6. Inspect and replace components of locking differential case assembly. P-3

7. Inspect differential carrier case and caps, side bearing bores, and pilot (spigot, pocket) bearing bore; determine needed action. P-3

8. Measure ring gear runout; determine needed repairs. P-3

9. Inspect and replace ring and drive pinion gears, spacers, sleeves, bearing cages, and bearings. P-3

10. Measure and adjust drive pinion bearing preload. P-3

11. Measure and adjust drive pinion depth. P-3

12. Measure and adjust side bearing preload and ring gear backlash. P-3

13. Check and interpret ring gear and pinion tooth contact pattern; determine needed action. P-3

14. Inspect, adjust, or replace ring gear thrust block/bolt. P-3

15. Inspect, adjust, repair, or replace planetary gear-type 2-speed axle assembly including: case, idler pinion, pins, thrust washers, sliding clutch gear, shift fork, pivot, seals, cover, and springs. P-3

16. Inspect, repair, or replace 2-speed axle shift control system, speedometer adapters, motors, axle shift units, wires, air lines, and connectors. P-3

17. Inspect power divider (inter-axle differential) assembly; determine needed action. P-3

18. Inspect, adjust, repair, or replace air operated power divider (inter-axle differential) lockout assembly including diaphragms, seals, springs, yokes, pins, lines, hoses, fittings, and controls. P-2

19. Inspect, repair, or replace drive axle lubrication system: pump, troughs, collectors, slingers, tubes, and filters. P-3

20. Inspect and replace drive axle shafts. P-1

21. Remove and replace wheel assembly; check rear wheel seal and axle flange gasket for leaks; perform needed action. P-1

22. Diagnose drive axle for wheel bearing noise and damage; perform needed action. P-2

23. Inspect and test drive axle temperature gauge sending unit/sensor; determine needed action. P-3

24. Clean, inspect, lubricate and replace wheel bearings; replace seals and wear rings; adjust drive axle wheel bearings. P-1

25. Inspect and test drive axle temperature sending unit/sensor; determine needed action. P-1