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35
CLUTCHES

CHAPTER OVERVIEW
This chapter describes in detail the design and operation of each part of a clutch. Considerable attention is given to clutch diagnosis and service.

CHAPTER OBJECTIVES
Describe the various clutch components and their functions.
Name and explain the advantages of the different types of pressure plate
assemblies.
Name the different types of clutch linkages.
List the safety precautions that should be followed during clutch servicing.
Explain how to perform basic clutch maintenance.
Name the six most common problems that occur with clutches.
Explain the basics of servicing a clutch assembly.

INSTRUCTIONAL OUTLINE WITH TEACHING HINTS

I. Operation
A. Flywheel
1. Dual-Mass Flywheel
B. Clutch Disc
C. Pilot Bushing/Bearing
D. Pressure Plate Assembly
1. Coils Spring Pressure Plate Assembly
2. Diaphragm Spring Pressure Plate Assembly
E. Clutch Release Bearing
1. Rotating Release Bearing
F. Clutch Fork
G. Clutch Linkage
1. Cable Linkage
2. Self-Adjusting Clutch
3. Hydraulic Clutch Linkage

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Clutches

II.

III.

IV.

V.

145

4. Internal Slave Cylinders

Hint: Compare different styles of clutch components. Explain the function
of the various features. Discuss the factors affecting clutch performance.
Clutch Service Safety Precautions
Hint: Emphasize the heath risks associated with clutch service. Make sure the
students understand the safety precautions.
Clutch Maintenance
A. Clutch Linkage Adjustment
B. External Clutch Linkage Lubrication
Clutch Problem Diagnosis
A. Slippage
B. Drag and Binding
C. Chatter
D. Pedal Pulsation
E. Vibration
F. Noises
G. Hydraulic Clutch Diagnosis
Hint: Describe the common clutch problems and their probable causes.
Explain how driving behavior affects clutch longevity.
Clutch Service
A. Removing the Clutch
B. Hydraulic Linkage Service
1. Bleeding the System

ANSWERS TO TEXTBOOK REVIEW QUESTIONS

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

11.
12.
13.
14.
15.
16.
17.
18.

Friction facings may be either (1) woven or (2) molded.

True. If the fluid reservoir is low, check the entire system for leaks.
A diaphragm spring is sometimes also referred to as a Belleville spring.
Clutch linkage may be (1) shaft and lever, (2) hydraulic, or (3) cable.
A tape measure or ruler can be used to measure clutch pedal play.
b. The friction disc is splined to the transmission input shaft and rotates with it.
c. Torsional springs in the clutch disc absorb and dampen torque forces.
The pressure plate moves away from the flywheel when the clutch pedal is depressed.
a. Excessive crankshaft endplay would be unlikely to cause clutch vibrations.
d. Neither technician is correct. Coil spring pressure plates are less commonly
used than diaphragm pressure plates, which are more compact, not larger, as stated
by Technician B.
a. When the clutch pedal is released, a spring returns the master cylinder piston to
its stop.
c. When the clutch is disengaged, power flow stops at the pressure plate and flywheel.
c. Both technicians are correct.
c. Insufficient clutch pedal clearance results in premature release bearing failure.
c. Both technicians are correct.
a. Measuring clutch pedal free travel is part of adjusting a clutch.
a. Clutch slippage is more noticeable in the higher, not the lower, gears.
b. Inspection of the transmission input shaft can help indicate the condition of a pilot
bushing. Listening for the sound of a pilot bushing is not a valid diagnostic procedure.

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Chapter 35

19. c. The surface of the pressure plate contacts the clutch disc.
20. b. Release bearing noise is most noticeable when the pedal is depressed and should
stop when the pedal is released.

TECH MANUAL
The following procedures are included in Chapter 35 of the Tech Manual:
1.
2.
3.
4.

Troubleshooting a clutch assembly.

Removing the clutch.
Inspecting and servicing the clutch.
Reassembling and installing a clutch.

ADDITIONAL TEACHING HINTS

Demonstrate how to adjust a cable or mechanical linkage clutch.
Demonstrate how to remove and reinstall the clutch, T.O. bearing, pressure plate,
and pilot bearing using an alignment tool, pilot bearing remover, and torque wrench.
Demonstrate the proper way to handle older clutch materials containing asbestos.

ANSWERS TO TECH MANUAL QUESTIONS

1. a. shaft and lever
b. cable
c. hydraulic
2. Yes
3. a
4. To prevent clutch cover distortion
5. a. Oil-soaked or worn disc facing
b. warped pressure plate
c. weak diaphragm
d. release bearing contacting and applying pressure to the release levers
6. c
7. Clutch disc dust may contain asbestos, which should be removed only with a special,
approved vacuum collection system or an approved liquid cleaning system.
8. To check clutch pedal free travel, use a tape measure or ruler. Place the tape measure
or ruler beside the clutch pedal with one end against the floor. Note the reading, and
then depress the clutch pedal to take up the free travel. The difference in readings is
the clutch pedal free travel.
9. c
10. a. worn clutch bearing
b. weak pressure plate springs
c. loose pilot bearing/bushing in the crankshaft

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36
MANUAL TRANSMISSIONS
AND TRANSAXLES
CHAPTER OVERVIEW
Understanding the major parts of manual transmissions and transaxles is the key to being
able to diagnose these units. The complexity of these parts and units is emphasized in this
general discussion.

CHAPTER OBJECTIVES
Explain the design characteristics of the gears used in manual transmissions and
transaxles.
Explain the fundamentals of torque multiplication and overdrive.
Describe the purpose, design, and operation of synchronizer assemblies.
Describe the purpose, design, and operation of internal and remote gearshift
linkages.
Explain the operation and power flows produced in typical manual transmissions
and transaxles.

INSTRUCTIONAL OUTLINE WITH TEACHING HINTS

I. Transmission Versus Transaxle
A. Transmission Designs
II. Gears
A. Gear Design
1. Gear Pitch
2. Spur Gears
3. Helical Gears
4. Idler Gears
Hint: Show examples of spur and helical gears.
III. Basic Gear Theory
A. Transmission Gear Sets
B. Reverse Gear Ratios
Hint: Calculate gear ratios through a mock-up transmission and then check
the results in practice by shifting through the gears and counting revolutions
of the input and output shaft.

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Chapter 36

IV. Transmission/Transaxle Design

A. Transmission Features
B. Transaxle Features
V. Synchronizers
A. Synchronizer Design
B. Operation
Hint: Show several common synchronizer designs. Show the areas where
wear is most likely to be found.
VI. Gearshift Mechanism
A. Gearshift Linkages
B. Automatic Manuals
1. Direct Shift Gearbox
VII. Transmission Power Flow
A. Neutral
B. First Gear
C. Second Gear
D. Third Gear
E. Fourth Gear
F. Fifth Gear
G. Reverse
Hint: Use a mock-up transmission to show power flow through each range.
VIII. Transaxle Power Flows
A. Neutral
B. First
C. Second
D. Third
E. Fourth
F. Reverse
Hint: Use a mock-up transaxle to show how power flows in each range.
IX. Final Drive Gears and Overall Ratios
Hint: Calculate final drive ratio and discuss how this affects the overall gear ratio
and driveability factors such as acceleration, top road speed, and fuel economy.
X. Electrical Systems
A. Reverse Lamp Switch
B. Vehicle Speed Sensor
C. Upshift Lamp Circuit
D. Shift Blocking

ANSWERS TO TEXTBOOK REVIEW QUESTIONS

1. Whether a vehicle uses a transmission or a transaxle depends on the type of drive system used, such as whether the differential gearing is included in the same assembly
as the transmission, and the location of the drive wheels.
2. When output speed is decreased through a set of gears, torque is proportionally
increased; the opposite is true when speed is increased.
3. True.
4. A final drive gear is a set of gears that provides an additional torque increase at the
wheels.

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149

5. Shift rails and shift forks are used to control the movement of the synchronizers, with
each synchronizer being able to engage or disengage two gear ratios by selecting which
gear is locked to the main shaft.
6. d. All of the above
7. b. Gear pitch refers to the number of gear teeth per given unit of measure, such as
diameter.
8. c. 0.85:1 is an overdrive ratio.
9. a. Spur gears are noisier at higher speeds.
10. a. The gears that produce the different speeds freewheel around the mainshaft until
they are locked to it.
11. a. With an idler gear, the drive and driven gears rotate in the same direction instead
of in opposite directions, such as would be the case without an idler.
12. a. A synchronizer matches the speed of the mainshaft and the gear selected to be
engaged.
13. c. Both technicians are correct.
14. b. The ring gear is driven by the pinion gear.
15. True. A synchronizer blocking ring functions as a cone clutch.
16. b. A collar shift transmission is one type of transmission design currently used.
17. d. The highest numerical ratio produces the most torque increase.
18. d. Neither technician is correct. Transaxle designs typically have an input shaft and
an output shaft that is driven directly by the input shaft. The countershaft is in motion
only when the clutch is engaged while the engine is running.
19. a. Reverse lamp switches may be operated by the gearshift lever. Reverse lamp switches are not operated by a sensor on the input shaft.
20. b. Technician B is correct. An idler gear enables the transmission output shaft to turn
in the opposite direction of the input shaft. The size and number of teeth of an idler
gear do not affect the gear ratio, only the direction of rotation.
Chapters 36 and 37 are combined in the Text Manual. The Text Manual Procedures,
Additional Teaching Hints, and answers to the Text Manual Review Questions for both
chapters are at the end of Chapter 37.

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37
MANUAL TRANSMISSION/
TRANSAXLE SERVICE
CHAPTER OVERVIEW
This chapter develops an understanding of the importance of transmission/transaxle lubrication. It focuses on maintenance, cleaning, and inspection guidelines, and typical disassembly and assembly procedures.

CHAPTER OBJECTIVES
Perform a visual inspection of transmission/transaxle components for signs of
damage or wear.
Check transmission oil level correctly, detect signs of contaminated oil, and change
oil as needed.
Describe the steps taken to remove and install transmission/transaxles, including
the equipment and safety precautions used.
Identify common transmission problems and their probable causes and solutions.
Describe the basic steps and precautions taken during transmission/transaxle
disassembly, cleaning, inspection, and reassembly procedures.

INSTRUCTIONAL OUTLINE WITH TEACHING HINTS

I. Lubricant Check
A. Lubricant leaks
B. Lubricant Replacement
C. Fluid Changes
Hint: Look up the type of lubricant used and the change interval for a variety
of vehicles. Discuss why they are different.
II. In-Vehicle Service
A. Rear Oil Seal and Bushing Replacement
B. Linkage Adjustment
C. Backup Light Switch Service
D. Speedometer Drive Gear Service
III. Diagnosing Problems
A. Visual Inspection

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IV.

V.
VI.
VII.

151

B. Transmission Noise
1. Rough, Growling Noise
2. Clicking or Knocking Noise
C. Gear Clash
D. Hard Shifting
E. Jumping Out of Gear
F. Locked in Gear
G. Shift Linkage
Hint: Describe the common transmission-associated problems and their
probable causes. Talk about how nontransmission problems may be falsely
attributed to the transmission.
Transmission/Transaxle Removal
A. RWD Vehicles
B. FWD Vehicles
Cleaning and Inspection
A. Aluminum Case Repair
Disassembly and Reassembly of the Differential Case
A. Shim Selection
Reassembly/Reinstallation of Transmission/Transaxle
A. Installing the Transmission/Transaxle

ANSWERS TO TEXTBOOK REVIEW QUESTIONS

1. Shiny metallic particles in the oil indicate internal bearing or gear wear.
2. A visual inspection should include (1) checking for lubricant leaks, (2) inspecting the
transmission mount, (3) checking the clutch and transmission linkage, (4) checking
the transaxle drive axle boots for cracks, deterioration, and damage, and (5) inspecting the constant velocity joints
3. Some noises that appear to be transmission related but are not, include improperly
aligned engines, improperly torqued mounting bolts, damaged or missing rubber
mounts, cracked brackets, and loose objects in the engine compartment.
4. Use a gear puller to remove gears, bearings, and synchronizer assemblies.
5. When removing or installing bearings using a press, the force should always be applied
to the tight bearing race instead of the loose one.
6. c. Both technicians are correct.
7. b. The reverse gear in most transmissions is nonsynchronized, and typically the
reverse idler gear is shifted into engagement with another gear. Some clashing can
occur, causing small chips on its engagement side.
8. a. Damaged input shaft bearings would be the most likely cause.
9. d. A clicking noise is most likely caused by chipped or damaged gear teeth.
10. c. Insufficient lubrication usually results in seizure and gear lockup.
11. b. Using the wrong lubricant causes hard shifting.
12. a. Technician A is correct. Under this condition, the gears and bearings inside the
transmission have stopped rotating, causing the noise to disappear.
13. a. If the synchronizer dog teeth are rounded, the synchronizer should be replaced.
The synchronizer sleeve moves on the hub, not on the shaft.
14. b. Technician B is correct; spinning bearings with compressed air is unsafe and damaging to the bearings.
15. d. All of the above.

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Chapter 37

16. a. Technician A is correct. The transmission rear seal is a common source of leaks.
Some up-and-down movement of the transmission case is normal; a transmission
mount needs replacement when the rubber separates from the metal plate.
17. b. Technician B is correct. Technician A is describing a failure that would most likely produce noise while the transmission is in neutral. The noise in question is encountered while the transmission is under load and would most likely be related to the
output shaft or main shaft bearings.
18. b. Technician B is correct. When the vehicle is moving, the countershaft gears and
bearings are loaded.
19. c. Both technicians are correct.
20. d. Neither technician is correct. A test drive can uncover a variety of nontransmissionrelated noises. If the noise disappears when the clutch is disengaged, it is most likely
in the transmission, not in the clutch.

TECH MANUAL
The following procedures are included in Chapters 36/37 of the Tech Manual:
1. Checking the fluid level in a manual transmission and transaxle.
2. Inspecting and adjusting shift linkage.
3. Road testing a vehicle for transmission problems.

ADDITIONAL TEACHING HINTS FROM CHAPTERS 36/37

Discuss and demonstrate precision measuring techniques such as determining
runout, or measuring parts to see if they fall within specifications.
Have the students install and remove bearings using a bearing press.
Discuss the importance of replacing sets of gears rather than a single gear to
prevent a new part from failing prematurely.
Emphasize neat and orderly work areas and using the technical literature to ensure
parts are reassembled correctly.

ANSWERS TO TECH MANUAL REVIEW QUESTIONS FOR

CHAPTERS 36/37
1. a.
b.
c.
d.
2. a.
b.
c.
d.
e.
f.
3. a.
b.

clutch linkage
lubricant too thick
badly worn bearings
damaged clutch gears
transmission not aligned
bad bearings
low oil level
broken gears
excess end play
bad clutch
clutch not releasing
stuck interlock

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4.
5.
6.
7.

8.
9.
10.

153

c. misaligned linkage
d. bad synchronizer
e. low lube level
a. Using a pry bar and a feeler gauge set
b. using a pry bar and a dial indicator
d
c
Gears on the main shaft are interlocked with gears on the countergear assembly. Power
is transferred through the constant mesh gears when the gear on the main shaft is
locked to the main shaft by the synchronizer assembly
a
c
The speedometer drive gear is typically located in the transaxle or transmission case
so that it is in mesh with a gear on the output shaft.

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38
DRIVE AXLES AND
DIFFERENTIALS
CHAPTER OVERVIEW
This chapter develops the understanding of drive axles and differentials using illustrations
to identify the many parts of these complex units. Also included are drive axle and differential diagnosis and service.

CHAPTER OBJECTIVES
Name and describe the components of a front-wheel-drive axle.
Describe the operation of a front-wheel-drive axle.
Diagnose the problems in CV joints.
Perform preventive maintenance on CV joints.
Explain the difference between CV joints and universal joints.
Name and describe the components of a rear-wheel-drive axle.
Describe the operation of a rear-wheel-drive axle.
Explain the function and operation of a differential and drive axles.
Describe the various differential designs including complete, integral carrier,
removable carrier, and limited slip.
Describe the three common types of driving axles.
Explain the function of the main driving gears, drive pinion gear, and ring gear.
Describe the operation of hunting, nonhunting, and partial nonhunting gears.
Describe the different types of axle shafts and axle shaft bearings.

INSTRUCTIONAL OUTLINE WITH TEACHING HINTS

I. Front-Wheel-Drive (FWD) Axles
II. Types of CV Joints
A. Inboard and Outboard Joints
B. Fixed and Plunge Joints
C. Ball-Type Joints
1. Fixed Ball-Type CV Joints
2. Plunging Ball-Type Joints
D. Tripod CV Joints
1. Tripod Plunging Joints

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Drive Axles and Differentials

III.
IV.

V.

VI.

VII.

VIII.
IX.

X.

XI.

XII.

XIII.

155

2. Fixed Tripod Joints

Hint: Show examples of different types of CV joints. Disassemble several
CV joints and show how they operate differently from a U-joint.
Front-Wheel-Drive Applications
A. Other Applications
CV Joint Service
A. Diagnosis and Inspection
B. Obtaining CV Repair Parts
C. CV Joint Service Guidelines
D. CV Shaft and Rubber Boot Care Tips
Hint: Show how to examine a boot. Show how to replace a boot.
Rear-Wheel Drive Shafts
A. Slip Yoke
B. Drive Shaft and Yokes
Operation of U-Joints
A. Speed Variations (Fluctuations)
B. Phasing of Universal Joints
C. Canceling Angles
Hint: Explain why phasing and U-joint canceling angles are important.
Describe the symptoms of incorrect installation. Show examples of early
failure caused by incorrect service.
Types of U-Joints
A. Single Universal Joints
B. Double-Cardan Universal Joint
Diagnosis of Drive-Shaft and U-Joint Problems
Differentials and Drive Axles
A. Differential Components
1. Hunting Gearset
2. Nonhunting Gearset
3. Partial Nonhunting Gearset
B. Rear Axle Housing and Casing
C. Differential Operation
Limited-Slip Differentials
A. Clutch-Based Units
B. Gear-Based Units
Axle Shafts
A. Semifloating Axle Shafts
B. Three-Quarter Floating Axle
C. Full-Floating Axle Shafts
D. Independently Suspended Axles
E. Axle Shaft Bearings
F. Diagnosis
Servicing the Final Drive Assembly
A. Basic Diagnosis
B. Disassembly
C. Assembly
D. Maintenance
Diagnosing Differential Noises
Hint: Explain how attention to different noises can narrow or pinpoint the failed
component.
A. Vibration Problems

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Chapter 38

ANSWERS TO TEXTBOOK REVIEW QUESTIONS

1. CV joints may be classified by (1) position, (2) function, or (3) design.
2. An axle with a removable carrier resembles a banjo; sometimes its housing is called
the banjo housing.
3. An axle that merely supports the weight of the vehicle and provides a mounting place
for the wheels is called a dead axle, as compared to a driving axle, which is called a
live axle.
4. A floating axle with only one bearing per wheel located outside of the axle housing is
classified as a three-quarter floating axle. The axle shaft only supports 25% of the
weight; the rest is supported by the axle housing.
5. Differential problems usually appear as either a noise or a leak.
6. d. CV Joints are used in each of these applications.
7. d. The inner joint is usually referred to as the inboard joint.
8. a. The plunge joint can move in and out as well as operate at an angle.
9. b. The recommended method for identifying ring gear runout is with a dial indicator,
not with a gear tooth pattern. When ring gear runout is excessive, the resulting gear
tooth pattern is inaccurate.
10. a. A double-offset joint has greater plunge capacity and can operate at larger operating angles.
11. c. A cross-groove joint is flatter than other plunge joint designs.
12. d. To determine which CV joint is noisy, spin the shaft at different operating angles.
13. c. A single Cardan joint is also called a four-point or a cross joint.
14. c. The yoke is used to connect two or more shafts together.
15. b. A double-Cardan is a constant velocity type U-joint.
16. a. Semifloating axle designs carry the weight and transmit torque to the wheel.
17. c. Both technicians are correct.
18. c. Both technicians are correct.
19. b. With a hunting gearset, one pinion gear tooth would contact each of the ring gear
teeth. An example of a partial nonhunting gearset is one in which each pinion gear
tooth would contact the same six ring teeth instead of the three it would normally contact if it were a nonhunting gearset.
20. d. Double-Cardan universal joints, found mostly on RWD luxury cars, use a centering ball socket and two universal joints and are commonly called constant-velocity
joints.

TECH MANUAL
The following procedures are included in Chapter 38 of the Tech Manual:
1.
2.
3.
4.
5.
6.

Inspecting and diagnosing a drive axle.

Servicing outer CV joints.
Servicing inner CV joints.
Inspecting U-joints and the driveshaft.
Road testing differential noises.
Measuring and adjusting pinion depth, bearing preload, and backlash.

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157

ADDITIONAL TEACHING HINTS

Discuss methods of isolating drive axles and differential gear noises.
Make sure students know how to install oil seals and dust seals.
Discuss ball bearing inspection and evaluation techniques.
Demonstrate how to set up a differential for pinion gear depth, backlash, and gear
patterns.

ANSWERS TO TECH MANUAL REVIEW QUESTIONS

1. Inspect the CV joint and replace the boot and grease.
2. Wipe clean with shop towels; solvent can damage the needle bearings and contaminate the lubricant.
3. Measuring driveshaft angles
4. Out-of-balance vibration
5. Nonhunting and partial nonhunting
6. Press them off; never burn them loose with a torch.
7. Inside the axle housing
8. By installing shims
9. c
10. c

SECTION 5
Answers to ASE Prep Test Questions
1.
2.
3.
4.
5.

c
a
c
d
b

6.
7.
8.
9.
10.

b
c
c
d
c

11.
12.
13.
14.
15.

c
c
b
c
d

16.
17.
18.
19.
20.

b
d
b
a
d