ATG 344 - GM Manual Drivetrains

1. Demonstrate safe work habits.
   1. Apply work area safety skills.
   2. Demonstrate safe personal working habits.
   3. Practice safe tool and equipment usage.
   4. Follow manufacturer’s repair procedures.
   5. Follow manufacturer and government warnings and regulations.
2. General Drivetrain Diagnosis - Manual Drivetrain and Axle Diagnosis.
   1. Identify and interpret drive train concerns; determine necessary action.
   2. Research applicable vehicle and service information, fluid type, vehicle service history, service precautions, and technical service bulletins.
   3. Check fluid condition; check for leaks; determine necessary action.
   4. Drain and refill manual transmission/transaxle and final drive unit.
3. Clutch Diagnosis and Repair.
   1. Diagnose clutch noise, binding, slippage, pulsation, and chatter; determine necessary action.
   2. Inspect clutch pedal linkage, cables, automatic adjuster mechanisms, brackets, bushings, pivots, and springs; perform necessary action.
   3. Inspect and replace clutch pressure plate assembly, clutch disc, release (throw-out) bearing and linkage, and pilot bearing/bushing (as applicable).
   4. Bleed clutch hydraulic system.
   5. Check and adjust clutch master cylinder fluid level; check for leaks.
   6. Inspect flywheel and ring gear for wear and cracks; determine necessary action.
   7. Measure flywheel runout and crankshaft end play; determine necessary action.
4. Manual Transmission/Transaxle Diagnosis and Repair.
   1. Inspect, adjust, and reinstall shift linkages, brackets, bushings, cables, pivots, and levers.
   2. Describe the operational characteristics of an electronically-controlled manual transmission/transaxle.
   3. Diagnose noise concerns through the application of transmission/transaxle power flow principles.
   4. Diagnose hard shifting and jumping out of gear concerns; determine necessary action.
   5. Diagnose transaxle final drive assembly noise and vibration concerns; determine necessary action.
   6. Disassemble, inspect clean, and reassemble internal transmission/transaxle components.
   7. Inspect transmission/transaxle case, extension housing, case mating surfaces, bores, bushings, and vents; determine necessary actions.
   8. Inspect and replace gaskets, seals, and sealants; inspect sealing surfaces.
   9. Measure endplay or preload on transmission/transaxle shafts; determine necessary action.
   10. Inspect and re-install synchronizer hub, sleeves, keys (inserts), springs, and blocker rings.
5. Constant Velocity Shaft/Drive Shaft and Universal Joint Service.
   1. Identify types of constant velocity (CV) joints and explain their operation.
   2. Identify types of universal joints and explain their operation
   3. Diagnose constant-velocity (CV) joint noise and vibration concerns; determine necessary action.
   4. Diagnose universal joint noise and vibration concerns; perform necessary action.
   5. Inspect, service, and replace shaft center support bearings.
   6. Inspect, service, and replace shafts, yokes, boots, and universal/CV joints.
   7. Check shaft balance and phasing; measure shaft runout; measure and adjust driveline angles.
6. Drive Axle and Differential operation.
   1. Identify the components of a differential and explain their operation.
   2. Define the different types of axle designs.
   3. Explain differential operation.
   4. Determine the operation of limited-slip and locking differentials.
7. Drive Axle and Differential Diagnosis And Repair.
   1. Diagnose noise and vibration concerns; determine necessary action.
   2. Inspect and replace companion flange and pinion seal; measure companion flange runout.
   3. Inspect ring gear and measure runout; determine necessary action.
   4. Remove, inspect, and reinstall drive pinion and ring gear, spacers, sleeves, and bearings.
   5. Measure and adjust drive pinion depth.
   6. Measure and adjust drive pinion bearing preload.
   7. 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).
   8. Check ring and pinion tooth contact patterns; perform necessary action.
   9. Disassemble, inspect, measure, and adjust or replace differential pinion gears (spiders), shaft, side gears, side bearings, thrust washers, and case.
   10. Reassemble and reinstall differential case assembly; measure runout; determine necessary action.
   11. Diagnose limited slip differential noise, slippage, and chatter concerns; determine necessary action.
   12. Measure limited slip differential rotating torque; determine necessary action.
   13. Inspect and replace drive axle wheel studs.
   14. Remove and replace drive axle shafts.
   15. Inspect and replace drive axle shaft seals, bearings, and retainers.
   16. Measure drive axle flange runout and shaft end play; determine necessary action.
   17. Diagnose drive axle shafts, bearings, and seals for noise, vibration, and fluid leakage concerns; determine necessary action.
8. Four-wheel Drive/All-wheel Drive System Operation.
   1. Identify and explain the operation of four-wheel drive systems.
   2. Name the major components of conventional four-wheel-drive systems.
   3. Discuss the purpose and operation of 4WD locking/unlocking mechanisms.
   4. Name the components of a transfer case.
   5. Explain the difference between four-wheel-drive (4WD) and all-wheel-drive (AWD).
   6. Explain the operation of viscous clutches used in all-wheel-drive systems.
9. Four-wheel Drive/All-wheel Drive Component Diagnosis and Repair.
   1. Inspect, adjust, and repair shifting controls (mechanical, electrical, and vacuum), bushings, mounts, levers, and brackets.
   2. Inspect front-wheel bearings and locking hubs; perform necessary action(s).
   3. Check for leaks at drive assembly seals; check vents; check lube level.
   4. Identify concerns related to variations in tire circumference and/or final drive ratios.
   5. Diagnose noise, vibration, and unusual steering concerns; determine necessary action.
   6. Diagnose, test, adjust, and replace electrical/electronic components of four-wheel drive systems.
   7. Disassemble, service, and reassemble transfer case and components.