Powertrain Technology and Service: Manual Transmission Technology Introduction For enjoyable open-road driving, many people prefer a stick shift. In much the same way, there s nothing quite like the satisfaction of providing first-rate service and maintenance on a manual transmission. This video illustrates the engineering and operating principles of helical gear manual transmissions with help from high-energy graphics, animation, and live-action footage. Students will learn about the purpose and construction of housings, gaskets, seals, thrust washers, bearings, synchronizers, drive gears, shift mechanisms, and other components. With an overview of gear ratios and an illustration of power flow through the transmission gears, the program also compares the construction of different manual transmission and transaxle designs. In particular, the video explores automated manual transmission technology, which uses computer control and electric solenoids or servo motors to actuate large helical gearsets. Learning Objectives After viewing this video, the student will be able to: Explain the function of manual transmissions. Describe the construction and operation of a manual transmission. Identify the types of shift mechanisms used on manual transmissions, including automated manual transmissions. Explain the purpose of manual transmission cluster gears. Describe the purpose of an input shaft and output shaft. Explain the term transmission gear ratio. 1
Describe the function of gear synchronizers. Define the term fully synchronized transmission. Explain the term power flow. Explain the operation of paddle-shift, automated manual transmissions and explain ECM control of shift solenoids. To the Instructor This video is designed to be a valuable supplement to your curriculum. Since young people are highly acclimated to television or video, it is a natural way to help present important aspects of your subject matter. Feel free to print the contents of this user guide for classroom distribution. You can then hand out the printed quizzes and other information to your students as desired. Most educators agree that it is best to use as many instructional methods as possible. Utilize quality textbooks, workbooks, videos, lectures, demonstrations, overheads, and other methods to present the technical information. This will hold your students interest and help them to understand the large amount of information required to succeed in today s complex world of auto repair. This video is organized into major sections or topics. Each section covers one major segment of the subject. Graphic breaks are given between each section so that you can stop the video for class discussions, demonstrations, or Q & As. This allows you to either watch just a portion of the program each day or to present the complete video, depending on your curriculum requirements. The video is designed to simplify the complex. Concise wording and carefully selected graphics are used to provide maximum learning in minimum time. Computer animation is used to explain difficult-to-comprehend principles or techniques. These images show how parts work, how they fit together, or how they vary in design. Use your own judgment to evaluate the definitions, short answer questions, and discussion topics. Most instructors use these as open-book activities. Educational Standards This program content correlates with the present ASE (NATEF) auto repair standards but goes beyond them to help the student repair conventional and high-voltage hybrid vehicles. New information on hybrid and full electric, high-voltage drivelines has been included in this series of videos. For more information on educational standards for this series, please visit http://ffh.films.com/id/25198. 2
ASE ASE, or Automotive Service Excellence, is a nonprofit national institute that works to improve the quality of vehicle repair and service by testing and certifying automotive professionals. Today, more than 350,000 professionals hold ASE certifications, and work in every part of the automotive service industry. Our video producers work closely with ASE to communicate the types of subjects that must be included in our content. The information in this video and the entire Powertrain Technology and Service series will help you pass the following ASE Certification Tests: A2 Auto: Automatic Transmissions/Transaxles 25 A3 Auto: Manual Drive Train and Axles 20 For more information on ASE Certification, please visit www.ase.com NATEF The information in this video correlates with NATEF standards for auto repair. NATEF was founded as an independent, nonprofit organization with a single mission: to evaluate technician training programs against standards developed by the automotive industry and recommend qualifying programs for NATEF accreditation. Video Discussion Topics Here are a few topics that might be used for a class discussion: 1. What is the basic function of a manual transmission? 2. Describe the basic operation of a manual transmission. 3. Can you think of any ways to improve the performance of a conventional manual transmission? 4. Do all manual transmissions use the same type of shifting mechanism? 5. What is the basic purpose of a gear synchronizer? 6. Do all manual transmissions have the same gear ratio? 7. Where are the cluster gears usually located in a manual transmission? 8. What types of changes do you think will take place in manual transmission design 20 years from now? 3
Technical Terms Write definitions for the following terms. Use your textbook or review the video as needed. floor shift lever column shift lever transmission gear ratio drive wheel speed shift gates external shift rod internal shift rail gear synchronizers shift forks computer-controlled solenoid transmission case manual transaxle housing thrust washer rear-wheel-drive transmission housing plastic speedometer gear speed sensor oil seals gaskets integral bell housing manual transmission front hub rear extension housing input shaft 4
clutch throw-out bearing clutch disc cluster shaft reverse idler shaft reverse idler gear output shaft gears manual transmission output shaft clutch pilot bearing splines engine crankshaft snap rings input shaft gear cluster gears drive shaft slip yoke shaft endplay gear endplay power flow fully synchronized transmission forward output gears helical gear one-to-one gear ratio gear reduction overdrive 5
torque output rear-wheel drive transmission front-drive-transaxle dynamotor shift solenoid/transmission ECM shift servo paddle shifters 6
Short Answer Have students briefly answer the following questions in their own words: 1. Name the basic parts of a manual transmission. 2. What is happening when a manual transmission gear freewheels? 3. Where is a manual transmission s input shaft located? 4. Are all manual transmission cluster gears usually the same size? 5. Where is a manual transmission s rear extension housing located? 6. Define the term fully synchronized transmission. 7. What prevents oil leakage around the input shaft and housing of a manual transmission? 8. Name the parts of a gear synchronizer. 9. Describe how a gear synchronizer operates. 10. Explain the term front-drive transaxle. 7
Video Quiz Choose the most correct answer after reading the statement: 1. A column or floor shift lever allows the driver to select the set of gears to be engaged. a. differential b. transmission c. engine d. axle 2. Many shift mechanisms are mounted directly on top of the case. a. transmission b. differential c. engine d. pinion 3. A manual housing is usually more complex than that of a rear-wheel-drive transmission housing. a. pinion b. differential c. transaxle d. axle 4. A manual transmission s shaft mounts below and to one side of the input shaft. a. pinion b. cluster c. torque d. axle 5. A manual transmission s gears transfer power up to the main shaft. a. pinion b. axle c. cluster d. flange 8
6. Which of the following is another name for a manual transmission s main shaft? a. Torque shaft b. Friction shaft c. Spider shaft d. None of the above 7. Any time the clutch is engaged and sends power to the input shaft, the input shaft gear spins the gears on the shaft. a. pinion b. cluster c. drive d. engine 8. A allows the input shaft and main shaft to rotate independently when needed. a. bolt b. nut c. washer d. bearing 9. A large groove is provided in the sleeve for the shift fork. a. transmission b. synchronizer c. axle d. clutch 10. Most modem manual transmissions and transaxles are fully. a. equipped b. synchronized c. mounted d. torqued 11. flow refers to the transmission parts that transfer torque out to the drive shaft or drive axles. a. Power b. Gear c. Shaft d. Clutch 9
12. With a one-to-one gear ratio, the gear and driven gears are the same size. a. drive b. axle c. yoke d. disc 13. Manual transmission gear are usually machined at an angle to help quiet gear meshing and reduce transmission gear noise. a. bolts b. splines c. pins d. teeth 14. In neutral, no transmission gears are locked to the main shaft. a. piston b. spider c. output d. axle 15. Gear occurs when a small gear is used to drive a larger gear to increase turning force. a. ratio b. strength c. backlash d. reduction 10
Quiz Answer Key l. b 2. a 3. c 4. b 5. c 6. d 7. b 8. d 9. b 10. b 11. a 12. a 13. d 14. c 15. d Other Titles in This Series: Hybrid Powertrain Technology With all major car manufacturers now producing hybrid gas-electric vehicles, it is critically important that automotive students understand the design and function of hybrid technology and the differences between various hybrid systems. This video helps develop that understanding through the use of dynamic 3-D animation and detailed live-action visuals. A helpful summary opens the program, explaining the basics of hybrid vehicle technology and its dual use of piston engine and electric traction motor. In-depth topics include the battery stack and its contents of high-efficiency lithium-ion modules; the dynamotor with its brushless armature and multi-coil stator assembly; the PCM, or power control module, which regulates current flow to the battery and dynamotor; and the cable system which connects those components. Additional video sections focus on all-electric drive mode, regenerative braking, and other unique aspects of HV operation, as well as the various configurations of hybrid drive trains. A viewable/printable instructor s guide is available online. A Shopware Production. A part of the series Powertrain Technology and Service. (23 minutes) Item: 43859 Copyright date: 2012 DVD (Chaptered) ISBN 978-1-62290-507-2 Automatic Transmission Technology Driving a car with an automatic transmission may be relatively simple, but the machinery isn t! Technicians-in-training need a clear and thorough visual guide. This video provides an in-depth technological grounding that will enable students to troubleshoot and repair systems which make up today s automatic transmissions. Topics include transmission case construction; transmission hydraulics; electronic components, in particular the onboard computer or electronic control module (ECM) and how it sends signals to solenoids in the transmission valve body; the torque converter and its constituent parts; the holding devices that engage the different gearsets, including friction discs, bands, and one-way clutches; and the planetary gearsets, including sun, planet, carrier, and ring gears, as well as the parking pawl used to lock the transmission output shaft. A detailed section on various kinds of hybrid automatic transmission is also presented. A viewable/printable instructor s guide is available online. A Shopware Production. A part of the series Powertrain Technology and Service. (25 minutes) Item: 43860 Copyright date: 2012 DVD (Chaptered) ISBN 978-1-62290-508-9 11
Clutch Operation and Service Demonstrating a wide range of standard shop techniques as well as a few handy tricks of the trade, this video introduces viewers to the operation and service of typical automotive and light truck type clutches. Beginning with an overview of the theory and construction of clutches, the program then shows how to inspect, diagnose, remove, and replace clutch components efficiently. The inspection chapter focuses on observing pedal free play, checking free height, and listening for abnormal bearing-related noises during a test-drive. Instruction on clutch removal highlights removal of the U-bolts securing the shaft to the rear differential yoke, sliding the slip joint out of the rear of the transmission, using an extension or transmission jack, removing the rear crossmember bolts, unbolting the shifter, removing the clutch housing, and more. Inspecting the flywheel and the clutch pilot bearing and replacing the pilot are covered. A complete section on clutch installation is also included. A viewable/printable instructor s guide is available online. A Shopware Production. A part of the series Powertrain Technology and Service. (21 minutes) Item: 43862 Copyright date: 2012 DVD (Chaptered) ISBN 978-1-62290-510-2 CV Axle Technology Almost all new cars come equipped with constant-velocity, or CV, drive axles, and CV joints are needed in front-wheeldrive vehicles to avoid driveline vibration. Likewise, cars with front-wheel drive or independent rear suspension use CV axle shafts for maximum flexibility. Since millions of today s cars now utilize this technology, understanding the makeup and function of CV axles is crucial to mastering this high-demand area of auto repair work. Viewers of this program will learn about basic CV components, including inner-stub, outer-stub, and interconnecting shafts as well as the various types of CV joints and joint boots. An in-depth section on joint inspection depicts both road testing and shop analysis. Another chapter demonstrates axle removal, from loosening the axle nut to taking off the steering tie-rod (and possibly the inner-stub-shaft snap rings or circlips), while step-by-step sections on CV joint service and axle installation are also featured. A viewable/printable instructor s guide is available online. A Shopware Production. A part of the series Powertrain Technology and Service. (23 minutes) Item: 43863 Copyright date: 2012 DVD (Chaptered) ISBN 978-1-62290-511-9 Differential Technology As any automotive trainee soon learns, a car s differential must provide torque to propel the vehicle, even when the wheels and axles are turning at different speeds. Various differential designs are used to accomplish this and other functions in rear-wheel-drive, front-wheel-drive, and all-wheel-drive vehicles. This video guides students through various differential and drive designs and summarizes how each one operates. Viewers are shown the basic workings of an enclosed drive shaft and of a solid rear-axle assembly, and how either solid or flexible drive axles link the differential to the drive wheels. Subsequent chapters shed light on ring and pinion gears, open differentials (including the set of spider gears mounted inside the carrier), limited-slip or positraction differentials, Torsen-Gleason differentials using worm gears to produce a no-slip drive setup, and computer-controlled electric clutch differentials. Various all-wheeldrive designs are also discussed. A viewable/printable instructor s guide is available online. A Shopware Production. A part of the series Powertrain Technology and Service. (18 minutes) Item: 43864 Copyright date: 2012 DVD (Chaptered) ISBN 978-1-62290-512-6 12
Differential Service Since the differential must transfer engine power to both drive axles, it is exposed to high-stress loads. After prolonged driver use (or abuse), gears, bearings, shafts, and other parts can fail. Therefore, well-trained technicians are needed to service the front and rear differentials found in today s vehicles. This video shows how to diagnose common differential and drive axle problems and perform essential services and repair operations. An overview of differential disassembly shows how to remove the drive shaft and axle and unbolt the pinion gear assembly. Next, positraction service is illustrated, including removal of the roll pins or bolts that secure the spider gear shaft as well as any clutch pack guide inserts. The video concludes with differential reassembly, from installing new friction discs to checking the ring and pinion gear teeth contact. Helpful 3-D animation and live-action visuals are featured throughout to reinforce vital concepts and techniques. A viewable/printable instructor s guide is available online. A Shopware Production. A part of the series Powertrain Technology and Service. (21 minutes) Item: 43865 Copyright date: 2012 DVD (Chaptered) ISBN 978-1-62290-513-3 Additional Video Programs from Shopware: Braking Systems ASE Certification Series When it comes to automotive professionalism and a concern for customer safety, nothing is more important than highquality brake repair work. Use this three-part series to give auto-shop students and service trainees their best shot at acing the ASE A5 test, along with real-world capabilities in diagnosing and solving a variety of braking system problems. Episodes are divided into self-contained chapters, each of which pinpoints certain areas of ASE-related competence, and led by two authoritative, ASE-certified instructors who make it easy to identify parts and internalize maintenance lessons. Demonstrations are carried out in a fully equipped shop on a range of vehicles, while concise quizzes, helpful graphics, and friendly coaxing on the need for professional integrity add extra shine to this vital teaching toolkit. Correlates to ASE and NATEF standards. A viewable/printable instructor s guide including ASE/NATEF task correlation checklists is available online. A Shopware Production. 3-part series, 22 33 minutes each. Item: 44879 Copyright date: 2012 DVD (Chaptered) ISBN 978-1-62102-261-9 Engine Performance ASE Certification Series Fixing a car s engine is like being a cardiologist you re working with the most vital part of the vehicle and every decision requires fine-tuned know-how. With this three-part series on engine performance and repair, technicians-intraining develop the aptitude they ll need to succeed on the ASE A8 test while building hands-on skills that will enable them to diagnose and solve a range of engine problems. Videos are broken down into self-contained segments, each of which focuses on specific areas of ASE-related proficiency, and presented by two high-energy, ASE-certified instructors who make parts identification and maintenance lessons easy to follow. Demonstrations are performed in a full-service shop on a range of automobiles, while no-fluff graphics, on-screen quizzes, and plenty of upbeat reminders about professional integrity round out this must-have instructional resource. Correlates to ASE and NATEF standards. A viewable/printable instructor s guide including ASE/NATEF task correlation checklists is available online. A Shopware Production. 3-part series, 25 35 minutes each. Item: 44875 Copyright date: 2012 DVD (Chaptered) ISBN 978-1-62102-257-2 13
Hybrid Auto Repair Series A new generation of automotive technicians is emerging, made up of men and women with solid training in hybrid technology. Give your students a chance to be part of this technological revolution. This three-part series provides a thorough grounding in hybrid technologies, focusing on building both system knowledge and safety awareness. In addition to outlining the history and growth of electric, hydrogen, diesel, and other alternative propulsion systems, the series explores major hybrid components and details the safety challenges that these complex mechanisms present to technicians. Job seekers who are looking to set themselves apart from the average automotive trainee will find the ideal learning resource in this series. Viewable/printable instructor s guides are available online. A Shopware Production. 3-part series, 15 18 minutes each. Item: 35525 Copyright date: 2007 DVD (Chaptered) ISBN 978-1-4213-5010-3 Hybrid Auto Repair Series II Whether you re training students, new hires, or long-time employees, hybrid auto technology is a crucial part of today s automotive instruction. A natural follow-up to the Hybrid Auto Repair Series (item #35525), this three-part series guides viewers through the systems that hybrid auto professionals must become familiar with and shows what it takes to maintain shop safety and efficiency. Veteran automotive technicians share their hybrid knowledge and experience, explaining best practices and specific procedures relating to Ford, Honda, and Toyota models. Each program emphasizes the need for patience and caution while lowering the fear factor often associated with a hybrid s high-voltage components. A viewable/printable instructor s guide is available online. Correlates to all National CTE Organizational Standards (including the provisions of the Perkins Act). A Shopware Production. 3-part series, 21 23 minutes each. Item: 38765 Copyright date: 2008 DVD (Chaptered) ISBN 978-1-4213-9001-7 Chassis and Front End Make sure your students have the best possible training in chassis and front-end parts and service. This nine-part series will support any intensive course covering the following systems and how they are serviced: brakes, steering, suspension, and both conventional and front-wheel-drive wheel bearings. Wheel alignment theory and adjustment is also a program topic. Detailed yet easy-to-understand animation and graphics are found in each episode, accompanied by live-action video that takes students directly inside each inspection and service procedure. Correlates to all National CTE Organizational Standards (including the provisions of the Perkins Act). Viewable/printable instructor s guides are available online. A Shopware Production. 9-part series, 17 27 minutes each. Item: 24992 Copyright date: 2008 DVD (Chaptered) ISBN 978-1-4213-9884-6 14
Automotive Computer Systems As any automotive technician understands, the world of car technology is now fully computerized. This series provides a basic working knowledge of automotive computer systems and the ins and outs of OBD-II diagnostics. Students will absorb lessons in computer system operation, trouble codes, scan tools, and repair procedures. Ford, GM, Chrysler, and other makes are discussed, while hybrid engine technology is also addressed. Videos can stand alone or as a series for both beginning automotive students and more advanced classes. Correlates to all National CTE Organizational Standards (including the provisions of the Perkins Act). Viewable/printable instructor s guides are available online. A Shopware Production. 4-part series, 14 30 minutes each. Item: 24743 Copyright date: 2008 DVD (Chaptered) ISBN 978-1-4213-8059-9 Auto Shop Safety Reinforcing concepts with helpful animation, this video provides crucial knowledge about accidents that can occur in automotive repair shops. The best ways to prevent them, and the smartest and safest steps to take when they happen, are explained. The video covers all major shop areas, including the stall, grease rack, front-end rack, tool room, and classroom. Running engines, open fuel lines, welding tools, moving cars, cars on lifts or jacks, and other shop hazards are illustrated, with detailed information on avoiding fires, explosions, asphyxiation, chemical burns, electric shock, and impact injuries. Hybrid vehicle technology is also explored. Correlates to all National CTE Organizational Standards (including the provisions of the Perkins Act). A viewable/printable instructor s guide is available online. A Shopware Production. Part 6 of the Safety and Technology Series. (21 minutes) Item: 24746 Copyright date: 2008 DVD (Chaptered) ISBN 978-1-4213-9950-8 15