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.

NATEF Tasks	Description	Priority designation
A	General Drive Train Diagnosis
III.A.1	Identify and interpret drive train concern; determine necessary action.	P-1
III.A.2	Research applicable vehicle and service information, such as drive train system operation, vehicle service history, service precautions, and technical service bulletins.	P-1
III.A.3	Locate and interpret vehicle and major component identification numbers (VIN, vehicle certification labels, calibration decals).	P-1
III.A.4	Diagnose fluid usage, level, and condition concerns; determine necessary action.	P-1
III.A.5	Drain and fill manual transmission/transaxle and final drive unit.	P-2
B	Clutch Diagnosis and Repair
III.B.1	Diagnose clutch noise, binding, slippage, pulsation and chatter; determine necessary action.	P-1
III.B.2	Inspect clutch pedal linkage, cables, automatic adjuster mechanisms, brackets, bushings, pivots, and springs; perform necessary action.	P-1
III.B.3	Inspect hydraulic clutch slave and master cylinders, lines, and hoses; determine necessary action.	P-1
III.B.4	Inspect release (throw-out) bearing, lever and pivot; determine necessary action.	P-1
III.B.5	Inspect and replace clutch pressure plate assembly and clutch disc.	P-1
III.B.6	Bleed clutch hydraulic system.	P-1
III.B.7	Inspect, remove, or replace pilot bearing or bushing (as applicable).	P-1
III.B.8	Inspect flywheel and ring gear for wear and cracks; determine necessary action.	P-1
III.B.9	Inspect engine block, clutch (bell) housing, and transmission/transaxle case mating surfaces; determine necessary action.	P-3
III.B.10	Measure flywheel runout and crankshaft endplay; determine necessary action.	P-3
C	Transmission/Transaxle Diagnosis and Repair
III.C.1	Remove and reinstall transmission/transaxle.	P-1
III.C.2	Disassemble, clean, and reassemble transmission/transaxle components.	P-2
III.C.3	Inspect transmission/transaxle case, extension housing, case-mating surfaces, bores, bushings and vents; perform necessary action.	P-3
III.C.4	Diagnose noise, hard shifting, jumping out of gear, and fluid leakage concerns; determine necessary action.	P-2
III.C.5	Inspect, adjust, and reinstall shift linkages, brackets, bushings, cables, pivots, and levers.	P-2
III.C.6	Inspect and reinstall power-train mounts.	P-3
III.C.7	Inspect and replace gaskets, seals, and sealants, inspect sealing surfaces.	P-2
III.C.8	Remove and replace transaxle final drive.	P-3
III.C.9	Inspect, adjust, and reinstall shift cover, forks, levers, grommets, shafts, sleeves, detent mechanism, interlocks, and springs.	P-2
III.C.10	Measure endplay or pre-load (shim or spacer selection procedure) on transmission/transaxle shafts; perform necessary action.	P-1
III.C.11	Inspect and reinstall synchronizer hub, sleeve, keys (inserts), springs, and blocking rings.	P-2
III.C.12	Inspect and reinstall speedometer drive gear, driven gear, vehicle speed sensor (VSS), and retainers.	P-2
III.C.13	Diagnose transaxle final drive assembly noise and vibration concerns; determine necessary action.	P-3
III.C.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
III.C.15	Inspect lubrication devices (oil pump or slingers); perform necessary action.	P-3
III.C.16	Inspect, test, and replace transmission/transaxle sensors and switches.	P-1
D	Drive Shaft and Half Shaft, Universal and Constant-Velocity (CV) Joint Diagnosis and Repair
III.D.1	Diagnose constant-velocity (CV) joint noise and vibration concerns; determine necessary action.	P-1
III.D.2	Diagnose universal joint noise and vibration concerns; perform necessary action.	P-1
III.D.3	Replace front wheel drive (FWD) front wheel bearing.	P-2
III.D.4	Inspect, service and replace shafts, yokes, boots, and CV joints.	P-1
III.D.5	Inspect, service, and replace shaft center support bearings.	P-3
III.D.6	Check shaft balance; measure shaft runout; measure and adjust driveline angles.	P-2
E	Drive Axle Diagnosis and Repair
	1. Ring and Pinion Gears and Differential Case Assembly
III.E.1.1	Diagnosis noise and vibration concerns; determine necessary action.	P-2
III.E.1.2	Diagnose fluid leakage concerns; determine necessary action.	P-2
III.E.1.3	Inspect and replace companion flange and pinion seal; measure companion flange runout.	P-2
III.E.1.4	Inspect ring gear and measure runout; determine necessary action.	P-2
III.E.1.5	Remove, inspect and reinstall drive pinion and ring gear, spacers, sleeves, and bearings.	P-2
III.E.1.6	Measure and adjust drive pinion depth.	P-2
III.E.1.7	Measure and adjust drive pinion bearing preload.	P-1
III.E.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
III.E.1.9	Check ring and pinion tooth contact patterns; perform necessary action.	P-1
III.E.1.10	Disassemble, inspect, measure, and adjust or replace differential pinion gears (spiders), shaft, side gears, side bearings, thrust washers, and case.	P-2
III.E.1.11	Reassemble and reinstall differential case assembly; measure runout; determine necessary action.	P-2
	2. Limited Slip Differential
III.E.2.1	Diagnose noise, slippage, and chatter concerns; determine necessary action.	P-3
III.E.2.2	Inspect and flush differential housing; refill with correct lubricant.	P-2
III.E.2.3	Inspect and reinstall clutch (cone or plate) components.	P-3
III.E.2.4	Measure rotating torque; determine necessary action.	P-3
	3. Drive Axle Shaft
III.E.3.1	Diagnose drive axle shafts, bearings, and seals for noise, vibration, and fluid leakage concerns; determine necessary action.	P-2
III.E.3.2	Inspect and replace drive axle shaft wheel studs.	P-3
III.E.3.3	Remove and replace drive axle shafts.	P-1
III.E.3.4	Inspect and replace drive axle shaft seals, bearings, and retainers.	P-2
III.E.3.5	Measure drive axle flange runout and shaft endplay; determine necessary action.	P-2
F	Four-wheel Drive/All-wheel Drive Component Diagnosis and Repair
III.F.1	Diagnose noise, vibration, and unusual steering concerns; determine necessary action.	P-3
III.F.2	Inspect, adjust, and repair shifting controls (mechanical, electrical, and vacuum), bushings, mounts, levers, and brackets.	P-3
III.F.3	Remove and reinstall transfer case.	P-3
III.F.4	Disassemble, service, and reassemble transfer case and components.	P-3
III.F.5	Inspect front-wheel bearings and locking hubs; perform necessary action.	P-3
III.F.6	Check drive assembly seals and vents; check lube level.	P-3
III.F.7	Diagnose test, adjust, and replace electrical/electronic components of four-wheel drive systems.	P-3

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