AURLTX001 Diagnose and Repair Light Vehicle Manual Transmissions

This is a written assessment task that assesses the student's knowledge of diagnosing and repairing light vehicle manual transmissions. The assessment covers topics such as preparing to diagnose and repair, diagnosing and repairing manual transmissions, and completing work processes. The assessment includes 88 questions comprising of multiple choice, true and false, fill-in-the-gap, and short answer questions. The assessment is open book and should take 4-6 hours to complete.

AURLTX001 Diagnose and repair light vehicle manual transmissions
Student Assessment Agreement
Make sure you read through the assessments in this booklet before you fill out and sign the agreement below.
If there is anything that you are unsure of, consult your assessor prior to signing this agreement.
Have you read the assessment requirements for this unit?  Yes  No
Do you understand the requirements of the assessments for this unit?  Yes  No
Do you agree to the way in which you are being assessed?  Yes  No
Do you have any specific needs that should be considered?  Yes  No
If so, explain these in the space below.
Do you understand your rights to re-assessment?  Yes  No
Do you understand your right to appeal the decisions made in an assessment?  Yes  No
Unit Code and Title AURLTX001 Diagnose and repair light vehicle manual
transmissions
Assessor name
Assessor signature
Date
Assessment Task Cover Sheet
Student Declaration
To be filled out and submitted with assessment responses
 I declare that this task is all my own work and I have not cheated or plagiarised the work or colluded with any other
student(s).
 I understand that if I If I am found to have plagiarised, cheated or colluded, action will be taken against me
according to the process explained to me.
 I have correctly referenced all resources and reference texts throughout these assessment tasks.

AURLTX001 Diagnose and repair light vehicle manual transmissions
Student name
Student ID number
Student signature
Date
Assessor declaration
 I hereby certify that this student has been assessed by me and that the assessment has been carried out
according to the required assessment procedures.
Assessor name
Assessor signature
Date
Assessment outcome S NS DNS Resubmission Y N
Feedback
Student result response
 My performance in this assessment task has been discussed and explained to me.
 I would like to appeal this assessment decision.
Student signature
Date
A copy of this page must be supplied to the office and kept in the student’s file with the evidence
Assessment 1 –
Questioning –
Written Assessment
2

AURLTX001 Diagnose and repair light vehicle manual transmissions
This cover sheet is to be
completed by the student
and assessor and used as
a record to determine
student competency in this
assessment task
The assessment process and tasks were fully explained.
I am aware of which evidence will be collected and how.
I am aware of my right to appeal an assessment decision.
I am aware that I can locate The RTO Complaints and Appeals Policy and Procedure on their
website at (insert website address)
I have discussed any additional educational support or reasonable adjustments I require in order to
undertake this assessment with the Student Support Services Officer and Trainer / Assessor, (if
applicable). e.g. Student Handbook and Access and Equity Policy (insert website address)
I have access to all required resources?
Cheating & Plagiarism
Declaration
Student Declaration: In
accordance with The RTO
Plagiarism Policy, I hereby
acknowledge by signing
this declaration that I have
not cheated or plagiarised
any work regarding the
assessment tasks
undertaken in this unit of
competency except where
the work has been
correctly acknowledged.
NOTE: Student must
sign this prior to
submitting their
assessments to the
assessor
Signature Date: ______ / ______ / 20______
Assessment Results
Satisfactory or Not Yet Satisfactory
(Please circle the assessment
result for this task)
Feedback to Student -
Please provide general

AURLTX001 Diagnose and repair light vehicle manual transmissions
feedback on the Student’s
performance
Student Declaration: - I verify that the work completed
is my own and that I was adequately informed of the
assessment process prior to commencing this
assessment task.Assessor Declaration: - I verify that I
have adequately explained and negotiated the
assessment tasks with the student prior to commencing
assessment.
Student Name:Assessor’s Name:
Student Signature Date Assessor Signature Date
Student Guide
for Written
Knowledge
Assessment
Overview of Assessment This is a written
assessment task you will
be assess on your
knowledge of diagnosing
and repairing light vehicle
manual transmissions.
The topics that will be
covered in the assessment
are:
1. Prepare to
diagnose and
repair light vehicle
manual
transmissions
2. Diagnose manual
transmissions
3. Repair manual
transmissions
4. Complete work
processes
This assessment will
ensure that the elements,
performance criteria,
performance evidence and
knowledge evidence
required, and conditions
are adhered to
demonstrate competency
in this unit assessment
4

AURLTX001 Diagnose and repair light vehicle manual transmissions
task.
5. Read the
assessment
carefully before
commencing.
6. Your Assessor will
use the
assessment
criteria in this
document and will
provide feedback /
comment.
7. You MUST answer
all the questions in
the assessment
tasks in your own
words and own
handwriting.
8. This is an “Open
Book”
assessment, and
students can use
the resources
listed in the
“Resources
Required” section
below.
Task/s to be assessed To complete this written
assessment, you will need
to answer the 88 questions
comprising of Multiple
Choice, True and False,
Fill-in the Gap and Short
Answer questions.
Time allowed On average, the
Assessment should take 4
– 6 hours to complete.
Location This theory assessment
will be completed in a
classroom under the
supervision of a
trainer/assessor.
Decision making rules To receive a ‘satisfactory’
outcome for this
assessment students
MUST successfully answer
all questions. If a student
achieves less than 100%,
they can reattempt the
assessment after further
study has taken place.
Students who cannot
achieve a minimum of
100% you will not have
satisfactorily completed

AURLTX001 Diagnose and repair light vehicle manual transmissions
this assessment
Your assessor will be
looking for the following in
this assessment task: -
 Work health and
safety (WHS) and
occupational
health and safety
(OHS)
requirements
relating to
diagnosing and
repairing light
vehicle manual
transmissions,
including
procedures for
lifting, supporting
and manual
handling light
vehicle manual
transmissions
 Environmental
requirements,
including
procedures for
trapping, storing
and disposing of
fluids released
from
transmissions
 Operating
principles light
vehicle manual
transmissions,
including:
o Gear
types
o Gear
ratios and
torque
reduction
and
multiplicati
on
o Simple
gear
trains
o Compoun
d gear
trains
o Lubricant
types
 Application,
purpose and
operation of light
vehicle manual
transmissions and
components,
6

AURLTX001 Diagnose and repair light vehicle manual transmissions
including:
o Power
flows,
including:
 Lo
ng
itu
di
na
l
m
an
ua
l
tra
ns
mi
ssi
on
s
 Tr
an
sa
xl
es
 Tr
an
sf
er
ca
se
s
o Synchrom
esh
operation
o Gearshift
mechanis
ms
o Transfer
cases,
including:
 Pa
rt-
ti
m
e
fo
ur-
w
he
el
dri
ve
s
 Fu
ll-
ti
m
e
fo
ur-

AURLTX001 Diagnose and repair light vehicle manual transmissions
w
he
el
dri
ve
s
 All
-
w
he
el
dri
ve
s
 Diagnostic testing
procedures for
light vehicle
manual
transmissions,
including:
o Abnormal
noise
diagnosis
o Shift
diagnosis
 Repair procedures
for light vehicle
manual
transmissions,
including
procedures for
removing,
replacing and
adjusting them
 Post-repair testing
procedures for
light vehicle
manual
transmissions.
Assessment conditions Assessors MUST satisfy
NVR/AQTF assessor
requirements.
Competency is to be
assessed in the workplace
or a simulated
environment that
accurately reflects
performance in a real
workplace setting.
Assessment MUST include
direct observation of tasks.
Where assessment of
competency includes third-
party evidence, individuals
MUST provide evidence
that links them to the light
vehicle manual
transmissions that they
8

AURLTX001 Diagnose and repair light vehicle manual transmissions
have worked on, e.g.
repair orders.
Assessors MUST verify
performance evidence
through questioning on
skills and knowledge to
ensure correct
interpretation and
application.
The following resources
MUST be made available:
 Automotive repair
workplace or
simulated
workplace
 Workplace
instructions
 Manufacturer light
vehicle manual
transmission
specifications
 Two different light
vehicles with faults
in the manual
transmission
components
specified in the
performance
evidence
 Diagnostic
equipment for light
vehicle manual
transmissions
 Tools, equipment
and materials
appropriate for
repairing light
vehicle manual
transmissions.
Resources required Learning Resources
available to students
include:
 Automotive
Technology (A
System Approach)
6th Edition –
Chapters 5, 6, 7,
8, 41, 42 and 43
 Websites
 Trainer Handouts
Results/Re-assessment  The Assessor will
grade the
assessment and

AURLTX001 Diagnose and repair light vehicle manual transmissions
record the result
on the front page
of this document
(S) – Satisfactory
if all observable
behaviours are
correct and (NS)
not satisfactory if
any areas are left
incorrect
 Feedback will be
provided on either
result
 Where a student
receives a ‘NS –
Not Satisfactory’
result, the
assessor will
discuss the area of
the non-compliant
observable
behaviour and an
opportunity given
for re-assessment.
This may be
through direct
observation or a
different method of
assessment e.g.
verbal/oral
questioning,
problem solving
exercise.
 If the outcome is
again not
satisfactory the
student result will
be deemed (NYC)
not yet competent.
Additional
feedback will be
given, and a time
agreed upon for
further
assessment after
additional training
and skills practice
has taken place,
this information
will be recorded,
dated and signed
in the re-
assessment area
on the last page of
this document
 Where all the
assessment tasks
have been graded
10

AURLTX001 Diagnose and repair light vehicle manual transmissions
(S) Satisfactory,
the student will be
deemed C –
Competent for the
practical
component and
the result recorded
and signed in the
area indicated on
the last page of
this document
Reasonable Adjustment If the participant is unable
to undertake the written
assessment as designed,
an interview (verbal
questioning) may be used
as an alternate approach.

AURLTX001 Diagnose and repair light vehicle manual transmissions
Assessment 1 – Questioning
Written Assessment
1. Identify five (5) important items of personal safety when working on manual transmissions in an automotive
workplace?
1 Helmet offers protection from head injuries which are very lethal.
2 Safety Glasses are important for manual transmission of workplace.
3 Mask wearing a mask will protect the workers from hazardous air participants.
4 Protective Gloves are important for protection of injuries in hands.
5 Safety shoes provide solid protection to the feet.
2. List three (3) precautions when jacking a vehicle on the floor.
1 Never jack up the vehicles without blocking the wheels to prevent them from rolling.
2 Do not do this in free way or main road.
3 After completing the process replace the jack and remove the stands and lower the vehicle to the ground.
3. Why should safety stands be placed under a raised vehicle?
The safety stand provides the stability to the vehicle when it is raised at a certain height. This is because the Jack
does not provide enough stability when a person in under the car. No other substitute of the safety stand should be
used as it can be dangerous.
4. What precautions should be observed if a vehicle is to be raised on a hoist?
1 Inspect the lifting points of the vehicle and the hoist before it is raised this will ensure safety of the car.
2 Make sure that the vehicle lift is not exceeding the maximum capacity.
3 Do not rely on a single lift arm of the hoist as it is not able to bear all the vehicle weight.
4 Try to use the auto lifting features as it will prevent sudden lowering of the cars.
5 Make sure that the lift maintenance has been done of the hoist.
Multiple choice. Circle all the correct answer
5. When using lifting equipment, what does SWL stand for?
A. Safe weight lift.
B. Safe working load.
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AURLTX001 Diagnose and repair light vehicle manual transmissions
C. Safe working limit.
D. Secure working load.
Fill in the Gaps
6. Complete the following statement about safely manually lifting something like a transmission using the
following words.
Words: Back, Body, Close, Condition, Forward, Grasp, Heavy, Knees, Legs, Move, Object, Part, Pinch,
Straight, Travel, Wood
1 Place your feet close to the ___ Pinch ____________. Position your feet so you will be able to
maintain a good balance.
2 Keep your back and elbows as _____ Straight __________ as possible. Bend your ____ Back
_______ until your hands reach the best place to get a strong grip on the object.
3 If the part is in a cardboard box, make sure the box is in good _____ Condition __________. Old,
damp, or poorly sealed boxes will tear and the ____ Object ___________ will fall out.
4 Firmly _____ Move __________ the object or container. Never try to change your grip as you
_______ Grasp ________ the load.
5 Keep the object ______ Close _________ to your body and lift it up by straightening your ______
Knees _________. Use your leg muscles, not your back muscles.
6 If you must change your direction of ____Move___________, never twist your body. Turn your whole
_______ Body ________, including your feet.
7 When placing the object on a shelf or counter, do not bend ________ Legs _______. Place the edge
of the load on the shelf and slide it forward. Be careful not to _______ Pinch ________ your fingers.
8 When setting down a load, bend your knees and keep your _____ Back __________ straight. Never
bend forward. This strains the back muscles.
9 When lowering something _____ Close __________ to the floor, set the object on blocks of _____
Wood __________ to protect your fingers.
7. What precautions are needed when draining the fluid from a manual transmission?
The transmission jack must be used when removing or installing an automatic transmission. The floor jack also
works but it should be very carefully used as the transmission can easily fall off.
The transmission and trans axles are both heavy and cumbersome so should not be removed without help.
8. How should waste transmission oils be stored and disposed?
Collect all the waste oils in secure, and should be clearly labelled drums or tanks so that they can be stored in a
bunded uncover area.
If it is stored in a single skinned tank then its is essential for the tank to be bunded.
Multiple choice. Circle all the correct answer

AURLTX001 Diagnose and repair light vehicle manual transmissions
9. When changing the manual transmission oil, what should you use to catch the oil waste oil?
A. Drain pan.
B. Mop bucket.
C. Storm water drain.
D. Funnel.
10. When handling, trapping, storing and disposing of manual transmission/transaxle new or waste oils, which
document should you use to find this information?
When handling, trapping, storing and disposing of the manual transmission/transaxle new or waste oils the some
documents such as the licence of the state's environmental regulator is essential.
Clean away is a certified trackable waste transporter which is also important. Other documents such as the NLPS
review Document is also considerable for usefulness in this information.
11. What are the three (3) different types of gears in a manual transmission/transaxle?
1 Spur Gear transmit power through shafts which are parallel, the teeth of the spur gears are parallel to the
shaft axis. This causes the gear to create a radial reaction on the shaft.
2 Helical Gear teeth are oriented at an angle to the shaft. This creates more than one tooth to be in contact
during operation and helical gears for carrying more load than spur gears.
3 Double Helical Gear these are variations of two different helical faces which are placed next to each other
with a gap separating them.
Multiple choice. Circle all the correct answer
12. Gears can _____.
A. Transfer speed and torque.
B. Decrease speed and increase torque.
C. Increase speed and decrease torque.
D. All answers are correct.
Multiple choice. Circle all the correct answer
13. Which of the following is NOT a function of gears?
A. Multiply torque while increasing speed.
B. Multiply speed while decreasing torque.
C. Multiply torque while decreasing speed.
D. Transfer torque leave speed unchanged.
Multiple choice. Circle all the correct answer
14. To reduce gear whine, manufacturers use _____ gears.
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AURLTX001 Diagnose and repair light vehicle manual transmissions
A. Spur.
B. Helical.
C. Ellipsoidal.
D. Parabolic.
Multiple choice. Circle all the correct answer
15. A(n) _____ gear is used to transfer motion without changing rotational direction.
A. Differential.
B. Spur.
C. Counter.
D. Idler.
Multiple choice. Circle all the correct answer
16. In a five-speed manual transmission/transaxle, an idler gear is used for _____ gear.
A. First and second and third.
B. Direct drive [fourth gear].
C. Overdrive [fifth gear].
D. Reverse.
Multiple choice. Circle all the correct answer
17. When a large gear drives a smaller gear, the output speed _____.
A. Decreases and torque decreases.
B. Decreases and torque increases.
C. Increases and torque increases.
D. Increases and torque decreases.
Multiple choice. Circle all the correct answer
18. When a small gear drives a larger gear, the output speed _____.
A. Decreases and torque decreases.
B. Decreases and torque increases.
C. Increases and torque increases.
D. Increases and torque decreases.
Multiple choice. Circle all the correct answer
19. When an idler gear is placed between the driving and driven gear, the driven gear _____.
A. Rotates in the same direction as the driving gear.
B. Rotates in the direction opposite to the driving gear.
C. Remains stationary.
D. Rotates faster.

AURLTX001 Diagnose and repair light vehicle manual transmissions
Multiple choice. Circle all the correct answer
20. Which of the following gear ratios generates the highest torque or power output?
A. 0.85:1.
B. 2.67:1.
C. 5.23:1.
D. 11.12:1.
Multiple choice. Circle all the correct answer
21. A gear ratio of 0.80:1 is a(n) _____ ratio
A. Reduction.
B. Overdrive.
C. Direct drive.
D. Geometric.
True or False question
22. The higher gear ratios allow for higher vehicle speeds and more torque.
☐ True or ☐ False
True or False question
23. The lower gear ratios provide less torque and reduce vehicle speed.
☐ True or ☐ False
True or False question
24. A 1:1 ratio is called direct drive.
☐ True or ☐ False
True or False question
25. A 2.85:1 ratio represents a gear reduction.
☐ True or ☐ False
True or False question
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AURLTX001 Diagnose and repair light vehicle manual transmissions
26. If the engine is running at 3,000 rpm and the wheels are spinning at 500 rpm the overall gear ratio is six (6) to
one.
☐ True or ☐ False
27. Why are overdrive gear ratios used in most modern transmissions?
In general, it has been found that over-driven ratios are used as the highest gear in the transmission.
It allows the vehicle for improving with the better fuel efficiency and also be quieter in operation on the highway.
This allows the engine to operate at a lower RPM for the given road speed.
Fill in the Gaps
28. Complete the following statement about transmission gearsets using the following words.
Words: Axle, Calculated, Final, First, Fourth, Gears, Increased, Large, Meshes, Multiplying, Ratio, Second,
Shaft, Torque, Transmission,
Power is moved through the ____ Shaft ________ via four gears (two sets of two gears). Speed and torque
are altered in steps. To explain how this works, let us assign numbers to each of the _ Gear ________. The
small gear on the input shaft has twenty teeth. The gear it ______ Meshes _________ with has forty. This
provides a gear ratio of 2:1. The output of this gearset moves along the __ Torque ________ of the forty-
tooth gear and rotates other gears. The gear involved with ____ First ___________ gear has fifteen teeth.
This gear rotates with the same speed and with the same _____ Transmission __________ as the forty-tooth
gear. However, the fifteen-tooth gear is meshed with a _____ Fourth __________ gear with thirty-five teeth.
The gear _____ ratio __________ of the fifteen-tooth and the thirty-five-tooth gearset is 2.33:1. However, the
ratio of the entire gearset (both sets of two gears) is 4.67:1.
The driveline’s gear ratios are further _____ Increased __________ by the gear ratio of the ring and pinion
gears in the drive axle assembly. Typical _____ Final _______ ratios are between 2.5 and 4.5:1. The final
(overall) drive gear ratio is calculated by ______ Multiplying _______ the transmission gear ratio by the final
drive ratio. If a transmission is in first gear with a ratio of 3.63:1 and has a ____ Calculated ___________
drive ratio of 3.52:1, the overall gear ratio is 12.78:1. If ______ Final _________ gear has a ratio of 1:1, using
the same final drive ratio, the overall gear ratio is 3.52:1. The overall gear ratio is ____ Increased
___________ by multiplying the ratio of the first set of gears by the ratio of the _____ Axle __________ (3.63
times 3.52 equals 12.78).

AURLTX001 Diagnose and repair light vehicle manual transmissions
29. Calculate this gear ratio, divide the driven (output) gear of the first set by the drive (input) gear of the first set.
Do the same for the second set of gears, and then multiply the answer from the first by the second. The result
is equal to the gear ratio of the entire gearset.
Driven (24) X Driven (30) = 2:1 x 30:1 = 60
Drive (12) Drive (1)
30. What does the term “constant mesh” mean?
Constant mesh is the gearbox which is a type of transmission which allows the gear pairs to remain engaged while
moving forward.
In a constant mesh the drive ratio is changed by moving a mechanical coupling to select which gear wheels are
connected.
In a constant mesh gearbox all the gears are in mesh al the time.
The constant mesh gearbox the manual transmission happens through which the gears are meshed or fixed in their
given positions.
Multiple choice. Circle all the correct answer
31. Manual transmission/transaxle lubricants in use today include ______.
A. Automatic transmission fluids.
B. Engine oils.
C. Multiple viscosity gear oils.
D. All answers are correct.
32. What is the purpose of the transmission/transaxle in a light vehicle?
The purpose of transmission/transaxle in a light vehicle is to transfer power to the driveshaft and rear wheels or
axle half shafts and front wheels in a front wheel drive vehicle.
The gears present inside of the transmission changes the vehicle drive speed and torque in the relation to the
engine speed and torque.
In the light vehicle the transmission is helpful in reduction of the engine speed for slowing the wheel speed and
increasing the torque during the process.
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AURLTX001 Diagnose and repair light vehicle manual transmissions
33. Identify the nineteen [19] internal components of a manual transmission below.
1 Input Shaft 11 Fifth gear driving
2 Input Drive Gear 12 First gear driving
3 Third Drive Gear 13 Reverse Gear Driving
4 Synchronizer Reverse Driven Gear 14 Reverse Idle Gear
5 Reverse Driven Gear 15 Second Gear
6 First Gear 16 Third Driven Gear
7 Fifth gear synchronizer 17 Input Driven Gear
8 Fifth Gear 18 Clutch gear
9 Output shaft 19 Clutch shaft
10 Speedometer gear

AURLTX001 Diagnose and repair light vehicle manual transmissions
34. Draw the power-flow for 1st, 2nd, 3rd, 4th, 5th gears and reverse gear on the manual transmission images below
and describe the path of the power through for each gear selection.
1st Gear
For getting the vehicle to move from a standing position, the operator moves the gear shift lever into the first.
Then the main shaft of the first gear is slid into position, meshing the gear with its countershaft first speed gear.
Then the countershaft will affect the firs-speed gear and the main shaft transmitting the power to the main shaft.
In the following diagram the 1st gear ratio is approximately 7.55 to1.
2nd Gear
For shifting into the next gear that is second the operator will depress the clutch and move the shift of the lever
into the second gear.
In this the second and third speed synchronizer is then moved to the right of the internal teeth engagement and
the external teeth of the main shaft second speed gear.
Next to that the power is transmitted to the counter shaft of the second speed gear for the maintenance of the
main shaft second gear speed which is coupled with the main shaft by the second and third gear synchronizer.
The gear ratio in this scenario is 4.18: 1.
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AURLTX001 Diagnose and repair light vehicle manual transmissions
3rd Gear
In the third gear the operator depresses the clutch again and moves the shift lever for disengaging the second
and third speed synchronizer from the main shaft second gear to the third gear.
After the second third speed synchronizer has been moved to the left such that the internal teeth can be engaged
with their external teeth of the main shaft third speed gear.
Power being transmitted by the countershaft such that the third-speed gear through to the main shaft third speed
gear is also coupled with the main shaft by the second third synchronizer with the help of main shaft.
In this scenario the gear ratio is approximately 2.45 to 1.
4th Gear
For the fourth gear the operator depresses the clutch and moves the shift level towards the disengaging second
third synchronizer from the main shaft third-speed gear.
As the fourth fifth speed synchronizer is moved to the right its internal teeth start to engage the external teeth of
the main shaft speed gear.
Then the power is transmitted by the countershaft for the fourth speed gear through the main shaft of the fourth
speed gear which is coupled to the main shaft by the fourth-fifth speed synchronizer and into the main shaft.
Gear ratio is approximately around 1.45 to 1.

AURLTX001 Diagnose and repair light vehicle manual transmissions
22

AURLTX001 Diagnose and repair light vehicle manual transmissions
5th Gear
In this the operator depresses the clutch before moving the shift lever and disengaging the fourth-fifth-speed
synchronizer towards the main shaft fourth-speed gear.
Next to that the fourth-fifth-speed synchronizer is moved to their left towards the internal teeth for engaging with
the external teeth of the input gear. Then the power is transmitted through the input gear, which is again coupled
to the main shaft by the fourth-fifth-speed synchronizer. In this the interlocking action of the synchronizer starts to
take effect as the on continuous shaft is the input shaft and the main shaft so the drive is direct.For this gear the
ratio is at 1.00 to 1.
Reverse Gear
The construction of the synchromesh transmission is considered to be similar to the constant mesh transmission
with an exception to the synchronizer which has been added.
The addition of a synchronizer allows the gear to be with the constant meh such that the cluster gears can pass
from the neutral to the reverse.
In this the first reverse main shaft gear is shifted towards the mesh with the reverse idle gear.
Its main function is to make the main shaft rotate in the opposite direction to the input shaft.

AURLTX001 Diagnose and repair light vehicle manual transmissions
35. What movement occurs inside a transmission when the vehicle is stopped, the engine is running, and the
transmission is in neutral?
When the engine is running the spinning torque converter and the pump. Thus, the clutch packs are engaged so
the internals in the front of the clutch pack will be free spinning.
The Input shaft/first motion turns, together with the gear/s it is in constant mesh with.
36. Draw the power-flow for 1st, 2nd, 3rd, 4th, 5th gears and reverse gear on the manual transaxle images below.
1st Gear
Main shaft>Counter Shaft gear > First Gear> Output Shaft
2nd Gear
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AURLTX001 Diagnose and repair light vehicle manual transmissions
Input shaft>Counter Shaft gear > Second Gear> Output Shaft
3rd Gear
Input shaft>Counter Shaft gear > Third Gear> Output Shaft
4th Gear

AURLTX001 Diagnose and repair light vehicle manual transmissions
Input shaft>Counter Shaft gear > Fourth Gear output Shaft
26

AURLTX001 Diagnose and repair light vehicle manual transmissions
5th Gear
Input shaft>Counter Shaft gear > Fifth gear Output Shaft
Reverse
Input shaft>Counter Shaft gear > reverse gear output shaft >Rear counter shaft

AURLTX001 Diagnose and repair light vehicle manual transmissions
Fill in the Gaps
37. Complete the following statement about transaxle power flow using the following words.
Words: Differential, Gear, Output, Rotate, Selected, Shaft, Shift, Synchronizer
When first gear is _____ Selected __________, the first/second gear synchronizer engages with first gear.
Because the synchronizer hub is splined to the ______ Gear _________ shaft, first gear on the input shaft
drives its mating gear (first gear) on the output shaft. This causes the output shaft to ____ Shift ________ at
the ratio of first gear and to drive the differential ring _______ Output ________ at that same ratio.
As the other forward gears are selected, the appropriate _____ Output __________ fork moves to engage
the selected _______ Rotate ________ with the gear. Because the synchronizer’s hub is splined to the
output shaft, the desired gear on the input shaft drives its mating gear on the output ______ Synchronizer
_________. This causes the output shaft to rotate at the ratio of the selected gear and drive the _______
Differential ________ ring gear at that same ratio.
38. Draw the power-flow for two-wheel drive (high range), four-wheel drive (high range) and four-wheel drive (low
range) on the transfer case images below.
Two-wheel drive (high)
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AURLTX001 Diagnose and repair light vehicle manual transmissions
Four-wheel drive (high)

AURLTX001 Diagnose and repair light vehicle manual transmissions
Four-wheel drive (low)
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AURLTX001 Diagnose and repair light vehicle manual transmissions
39. Describe the path of the power through for each gear selection of the transfer case below.
Two-wheel drive, high range
In the two wheel drive, high range the two wheel in the rear of the vehicle are the one which are driving the
vehicle.
In this the H is the high range which shows the normal gear ratios which are used for everyday driving in an
exceptional case.
In this the TCCU is then transferred case to either the rear propeller shaft or the front propeller shaft.
Rear propeller shaft goes to rear axle and eventually to the rear wheel where as the front propeller shaft goes to
front axle and then to front wheel.
TCCU when is locked hub in solenoid then it goes through a locking hub operation which is transferred to the
front wheel.
Four-wheel drive, high range
In the four wheel drive range the default setting is in the high range.
In this the transmission starts Input shaft which provides transmission to rear output shaft and front output shaft
This is then transferred to rear propeller shaft and to the front propeller shaft.
The rear propeller shaft goes to the rear axle which operates both rear wheels.
The front propeller shaft goes through to the front axle which operates the fronts wheels.
Four-wheel drive, low range

AURLTX001 Diagnose and repair light vehicle manual transmissions
In the four wheel drive range the default setting is in the high range but as per the need of the drive the modes
are switched.
In this the transmission starts Input shaft which provides transmission to rear output shaft and front output shaft
This is then transferred to rear propeller shaft and to the front propeller shaft.
he rear propeller shaft goes to the rear axle which operates both rear wheels.
The front propeller shaft goes through to the front axle which operates the fronts wheels.
40. Name the five [5] part of a synchronizer assembly below.
1 Constant mesh gear
2 Strut
3 Blocker Ring
4 Shift Sleeve
5 Synchronizer Cone
True or False question
41. In a conventional transmission, the speed gears freewheel around the mainshaft until they are locked to it by
the synchronizer.
☐ True or ☐ False
True or False question
42. During a gear shift, the blocking ring is pushed into the speed gear cone by the shifter plates or keys.
☐ True or ☐ False
True or False question
43. The blocking ring eliminates friction between the cone-shaped surface on the speed gear and the
synchronizer assembly.
☐ True or ☐ False
Multiple choice. Circle all the correct answer
44. When fourth gear is selected on a five-speed manual transmission, the synchronizer couples the ______.
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AURLTX001 Diagnose and repair light vehicle manual transmissions
A. Fourth speed gear to the mainshaft.
B. Clutch [input] gear to the mainshaft.
C. Both “fourth speed gear to the mainshaft” and “clutch [input] gear to the mainshaft”.
D. Neither “fourth speed gear to the mainshaft” nor “clutch [input] gear to the mainshaft”.
Multiple choice. Circle all the correct answer
45. Which of the following is not part of a synchronizer assembly?
A. Blocking ring.
B. Synchronizer hub.
C. Shifting plates or keys.
D. Interlock pin.
46. What is the function of a synchronizer?
The synchronizer enables the meshing of the gear to be changed during a moving vehicle without suffering any
negative consequences.
It does not cause any mechanical integrity and interior noises.
During the synchronization the friction clutch must be disengaged.
Its main function is to allows the vehicle to have smooth engagement of the gears.
47. Name the seven [7] parts of a gearshift mechanism assembly for a manual transmission below.
1 Notch
2 Spring
3 Detent ball
4 Shift lever
5 Ball socket
6 Shift Fork shaft
7 Shift Fork
48. Explain the role of shift rails and shift forks in the operation of transmissions and transaxles.
Shift rails have detent and interlock notches to their sides.
A spring-loaded ball is fitted into the dented notch for locking the transmissions into gear.
The desired gear, the interlock pin prevents the transmission from the shifting into another gear.

AURLTX001 Diagnose and repair light vehicle manual transmissions
Multiple choice. Circle all the correct answer
49. When the 1-2 shift rail is moved into first gear, the 3-4 and 5-R shift rails are prevented from moving by the
______.
A. Detent ball and spring.
B. Shifter plate.
C. Shift fork.
D. Interlock pin.
True or False question
50. Cables are used to connect the shift lever to the transmission.
☐ True or ☐ False
True or False question
51. Rods are used to connect the shift lever to the transmission.
☐ True or ☐ False
52. Nearly all part-time 4WD systems have a transfer case that not only allows for 2WD or 4WD, but also offers?
The four wheel drive provides more control and more torque towards the offering of superior off road
performance with a 4:1 low gear ratio which lets the operator crawl at a lower speed with a greater increase in
torque at the wheels.
These 4WD are designed for off-road driving because they have twice the traction of the 2WD and the
combination of them provides best off-road performance.
True or False question
53. In a part-time four-wheel drive systems, 4WD [4 HI or 4 LO] should not be selected when the vehicle is
traveling on dry surfaces.
☐ True or ☐ False
Multiple choice. Circle all the correct answer
54. Which of the following components is (are) NOT found in a transfer case?
A. Drive chain.
B. Shifter forks.
C. Blocking rings.
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AURLTX001 Diagnose and repair light vehicle manual transmissions
D. Planetary gearset.
Multiple choice. Circle all the correct answer
55. Full-time four-wheel drive _____.
A. Is never disconnected.
B. Must be disconnected by a technician.
C. Is disconnected during off-road use only.
D. Is used with manual transmissions only.
Multiple choice. Circle all the correct answer
56. A 4WD vehicle may be shifted into four-wheel drive _____.
A. Only while stopped.
B. Only while moving.
C. At any time.
D. Only according to the owner's manual instructions.
Multiple choice. Circle all the correct answer
57. _____ are often used to link the input and output shafts in a transfer case and serve as a link that does not
influence gear ratios.
A. Drive chains.
B. Sprockets.
C. Locking hubs.
D. Pin and rocker joints.
Multiple choice. Circle all the correct answer
58. Which of the following components is NOT part of a viscous clutch assembly?
A. Sealed drum.
B. Hydraulic piston.
C. Externally splined steel plates.
D. Internally splined steel plates.
Multiple choice. Circle all the correct answer
59. In a viscous clutch, when the silicone fluid is heated, it ______.
A. Becomes a very thin fluid.
B. Boils to a vapour.
C. Thickens to a solid mass.
D. Stiffens.
Multiple choice. Circle all the correct answer

AURLTX001 Diagnose and repair light vehicle manual transmissions
60. In an automatic AWD vehicle, normally one axle receives all the torque; when slippage occurs, 50 percent of
the torque can be sent to the other axle by _____ means.
A. Hydraulic.
B. Mechanical.
C. Electrical.
D. All answers are correct.
True or False question
61. If a noise stops with the engine at idle and the clutch disengaged, the noise is probably coming from the
inside of the transmission.
☐ True or ☐ False
Multiple choice. Circle all the correct answer
62. A clicking noise during transmission/transaxle operation may be an indication of ______.
A. Worn main shaft (input shaft) bearings.
B. Faulty synchronizer operation.
C. Failed oil seals.
D. Worn, broken, or chipped gear teeth.
True or False question
63. A rough growling noise occurs when the engine is running, the transmission is in neutral, the clutch is
engaged, and the vehicle is not moving. The input shaft bearing may be faulty.
☐ True or ☐ False
Multiple choice. Circle all the correct answer
64. Gold-coloured particles in the transmission fluid are an indication of worn ______.
A. Blocking rings.
B. Gear teeth.
C. Roller bearings.
D. Shifter forks.
Multiple choice. Circle all the correct answer
65. A growling noise that occurs when the transaxle is in neutral, the vehicle is not moving, the engine is running,
and the clutch is engaged is most likely caused by ______.
A. Clutch pilot bearing.
B. Differential carrier bearing.
C. Output shaft bearing.
D. Input shaft bearing.
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AURLTX001 Diagnose and repair light vehicle manual transmissions
True or False question
66. A rough growling noise occurs when the vehicle is moving and the transmission is in forward or reverse
gears. The noise is not heard when the transmission is in neutral. The output or mainshaft bearings may be
faulty.
☐ True or ☐ False
67. What do shiny metallic particles in the oil indicate?
The conditions of the draining oil provides a lot of indication on the parts and components of the
transmission/tansaxle.
While driving the gear oil has some shiny metallic particles which is the indication of the extensive internal wear
or damage in the parts of the transaxle.
68. Identify three (3) causes of unusual noises from within a manual transmission.
1 Low fluid level in the manual transmission can be a cause of unusual noise.
2 Worn bearing also result in unusual noise of manual transmission.
3 Worn or failed synchronizer is also a reason for unusual noise from the manual transmission.
True or False question
69. A plugged transmission vent may cause a seal to leak.
☐ True or ☐ False
70. List eight (8) the areas of potential transmission fluid leakage.
1 Drain Plug which is a plug on the transmission pan which when loosens starts to drain old
transmission fluid.
2 Pan Gasket which is part of the transmission which is thin lining of rubber which is between the
transmission housing and the transmission pan for protection of two parts.
3 Pan/Seal has potential of fluid leakage as it at the bottom and any debris poking a hole in the
transmission can create leakage of fluid.
4 Torque convertor the pump that pushes transmission fluid through the transmission system and is a
area of fluid leakage.
5 Lines is the lines which are made from aluminium or steel and are also vulnerable like the
transmission pan.
6 Transmission pan Is the source of the transmission lead thus it leakage can be noticed on it.

AURLTX001 Diagnose and repair light vehicle manual transmissions
7 Valves and solenoids the ones which keep the flow of the fluid intact thus have the risk of leakage.
8 Misalignments is two component in the transmission are not aligned properly the alignment area can
also witness leakage.
Multiple choice. Circle all the correct answer
71. An excessively low lubricant level will most likely cause ______.
A. Gear clash.
B. Hard shifting.
C. Gear lockup or seizure.
D. Gear jump-out.
True or False question
72. Manual transmission/transaxle internal shift linkage should be adjusted if a shift linkage problem is identified.
☐ True or ☐ False
True or False question
73. Jumping out of gear is often caused by loose, worn, or out-of-adjustment shift linkage.
☐ True or ☐ False
Multiple choice. Circle all the correct answer
74. Using a lubricant that is thicker than service manual specifications can lead to ______.
A. Gear jump-out.
B. Hard shifting.
C. Gear lockup.
D. Gear slippage.
Multiple choice. Circle all the correct answer
75. A poorly adjusted shift linkage can cause which of the following problems?
A. Gear clash.
B. Hard shifting.
C. Jumping out of gear.
D. All answers are correct.
True or False question
76. Broken or worn engine and transaxle mounts can cause a transaxle to have shifting problems.
☐ True or ☐ False
38

AURLTX001 Diagnose and repair light vehicle manual transmissions
Multiple choice. Circle all the correct answer
77. Which of the following will NOT cause gear clash?
A. Incorrect lubricant.
B. Incorrect clutch adjustment.
C. Worn countergear bearings.
D. Worn synchronizer blocking rings.
Multiple choice. Circle all the correct answer
78. The owner of an FWD car complains that the vehicle jumps out of second and fourth gears when he
accelerates hard. What could the fault be?
A. There could be insufficient clearance between the shifter boot and the shifter.
B. One of the engine mounts could be broken.
C. Both “There could be insufficient clearance between the shifter boot and the shifter” and “One of the
engine mounts could be broken”.
D. Neither “There could be insufficient clearance between the shifter boot and the shifter” and “One of the
engine mounts could be broken”.
True or False question
79. Prior to disassembling a manual transmission, measure the input and output shaft end play with a dial
indicator.
☐ True or ☐ False
True or False question
80. End play and preload are usually set by placing shims under the bearing caps.
☐ True or ☐ False
Multiple choice. Circle all the correct answer
81. An engine support fixture is used to hold the engine in place while removing a ______.
A. FWD transaxle.
B. RWD transmission.
C. Both “FWD transaxle” and “RWD transmission”.
D. Neither “FWD transaxle” nor “RWD transmission”.
True or False question
82. On some vehicles, the engine and transmission must be removed as a unit.
☐ True or ☐ False

AURLTX001 Diagnose and repair light vehicle manual transmissions
83. List three (3) components that may need to be removed from the vehicle before the transmission/transaxle
can be removed.
1 Remove the battery cable for ensuring the safety.
2 Remove the black plastic air intake components for providing enough sufficient space.
3 Remove all the bracket, cables or hoses that connect the transmission.
84. Explain the four [4] procedure to replace the rear extension housing seal on an RWD manual transmission.
1 Disconnecting the negative battery cable and also raise and support the vehicle safety.
2 Also remove the suitable drain pan beneath the extension housing for cleaning the area around the
extension housing seal.
3 Match mark the driveshaft for creating a rear axle flange for disconnecting the driveshaft and pulling it
rearward from the unit.
4 Remove the extension housing seal using tool of T74P-77248-A or equivalent for removing the
extension housing seal.
Fill in the Gaps
85. Complete the following statement about linkage adjustment using the following words.
Words: Adjustments, Linkage, Provision, Service
Transmissions with internal linkage have no _______ Provision ________ for adjustments. However, external
linkages can be adjusted. ______ Linkage _________ are adjusted at the factory but worn parts may make
adjustments necessary. Also, after a transmission has been reassembled, ________ Adjustments _______
may be necessary. To begin the adjustment procedure, raise the car and support it on jack stands. Then
follow the procedure given in the ______ Service _________ information.
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AURLTX001 Diagnose and repair light vehicle manual transmissions
86. Consider the various post repair checks that you would make during a road test on the vehicle manual
transmissions?
While checking the post repair in the vehicle manual transmission the focus should be on the clutch.
If there are any errors with the clutch the lifespan of the transmission will start to slip during the acceleration or
may produce burning smell and the clutch may start to get depresses soon quickly after the pedal.
Alignments must be also checked. A car pulling constantly to one direction shows that there is a problem with
the alignment.
Multiple choice. Circle all the correct answer
87.Which source of information will give you the most detail about diagnosing and repairing light vehicle manual
transmissions on the vehicle you are working on?
A. Workshop manual.
B. Owner’s manual.
C. Google.
D. Textbooks.
88.Why is it very important that the Job Card is completed correctly?
The automotive job card is a card which is prepared for a specific job. It consists of the detailed list of the work
which is done in the that is taken, labour that is involved and the necessary materials which are required.
Job card's main role is in the repair workshop were the are used for sending the details to the workers in the field
and also gaining the feedback for the vehicle.
With the help of job card the mechanics can know how many vehicles are assigned to them, and they are able to
identify the task which allows them to fulfil the task which are required. It also services as the estimate for the
cost which is incurred on the repair work.