Automotive Service Technology Section a /Automotive Special Problems s2

Remove and replace drive axle shafts; Inspect and replace drive axle shaft seals, bearings, and retainers. Lesson Plan for AUT 182-183/AUT 290 Automotive Service Technology Section A /Automotive Special Problems

Course HS Title: Automobile Service Technology/Special Problems Program: KCTCS Courses included in HS Title: (Lesson is prepared for course highlighted.) KCTCS Course No. KCTCS Course Title

Introduction/Conte This lesson will instruct the student on how to remove and replace drive axle xt shafts, and inspect and replace drive axle shaft seals, bearings, and retainers. Knowledge of these techniques and the skills required to correct problems associated with this task are necessary for a student to acquire if they wish to compete for high paying, high skilled jobs in an Automotive Repair Facility. Entry level technicians need to be able to perform this task to 100% accuracy. Incorrectly performing this task can lead to an automobile accident or create customer satisfaction issues. Prepared By School Date:

Lesson Grade Level No. Students No.IEP's: Length:

Task Remove and replace drive axle shafts; Inspect and replace drive axle shaft seals, bearings, and retainers.

N Objective o. Given the proper tools and instruction, the student will be able to remove and replace drive axle 1 shafts, inspect and replace drive axle shaft seals, bearings, and retainers, and pass a written test covering the task with 100% accuracy.

Connections: Skills Standards: OH 001 OH 002 OH 003 OD 002 OD 003 OD 005 Common Core Technical Standards: TD-SYS-2 New Common Core Standards: RST 11-12.2 RST 11-12 3 INSTRUCTIONAL MATERIALS/TECHNOLOGY

Teacher Designed Materials and Other Handouts

Textbooks and Workbooks Autho Editio Page Title/ISBN No. Publisher r n s Variou Motor Age ASE Test Prep Manual Drivetrains and Axles 2010 Motor Age 59-61 s

Web Addresses Title Publisher URL Today's Class Melior www.todaysclass.com

Equipment Quantity Item Source As Needed Puller/Seal Removal Tool Various

Content/Presentation/Demonstration Outline Tell students that to remove an axle shaft, they should first raise and safely support the vehicle, then remove the wheels and the brake drums or rotors. Instruct students that if the axle shafts are retained at the ends of the axle tubes, they should remove the retaining nuts and pull the axle shafts from the axle housing. Tell them it may be necessary to use a slide hammer to remove the axle shafts. Have them use a puller or seal removal tool to remove the axle seal from the axle housing. Instruct students that if the axle shafts are retained with C-clips, they should clean the area around the differential housing cover and position a drain pan under the cover. Have them loosen the cover bolts and drain the fluid from the differential, then remove the cover. Tell them to rotate the differential case until the differential case pinion shaft lock bolt is accessible. Tell students to remove the lock bolt and slide the pinion shaft out of the case. Have them push the axle shafts in enough to access the C-clips, then remove the C-clips and the axle shafts. Instruct them to reinstall the pinion shaft and lock bolt once the axle shafts are removed. Axle shafts with retainer plates use bearings that are pressed onto the shaft. Let them know that a retaining ring is used to help secure the bearing to the shaft and this ring must be removed before the old bearing can be pressed off. Have them grind a notch in the retaining ring and use a chisel to split it, and then remove the retaining ring from the axle. Instruct students that axle shafts that use C-clips are supported by bearings that are pressed into the axle housing. Tell them to use a seal removal tool or puller to remove the axle seal, then use a puller and slide hammer to remove the axle bearing from the housing. Tell students to inspect the axle shaft bearings for pitting, galling, spalling, brinelling, roughness or other damage. Have them replace bearings as required. Instruct them to inspect the axle shaft splines for wear and damage and inspect the seal contact area for damage. Replace axles that are damaged. To press on a new axle shaft bearing, tell students to install the retainer plate, oil seal, if equipped, and bearing onto the axle shaft. Have them position the axle shaft in a press, and press the bearing onto the shaft, making sure the bearing is supported on the inner race. Next, tell them to remove the axle shaft from the press and install a new retaining ring, and reposition the axle shaft in the press. Instruct them to press the retaining ring onto the shaft, making sure the retaining ring is properly supported. Instruct students to press a new axle shaft seal into the axle housing and lubricate the lips of the seal with gear lubricant. Have them lubricate the axle shaft splines and install the axle shaft with a new gasket. Tell them to align the axle shaft splines with the differential side gear splines and slide the axle shaft into position, and then install the retaining nuts and torque to specification. Have them check the axle shaft endplay using a dial indicator. Let them know that endplay that is not within specification is usually changed with shims, but they should refer to the vehicle service manual for specific instructions. On C-clip axles, tell students to lubricate a new bearing with gear lubricant and install it in the axle housing using a suitable driver. Have them install a new axle shaft seal and lubricate the lips of the seal with gear lubricant. They should then lubricate the axle shaft splines, align the splines with the differential side gear splines and slide the axle shaft into position. Instruct students to install the C-clip on the end of the axle shaft and then pull the axle shaft outward until the C- clip seats in the recess in the differential side gear, and then install the differential pinion shaft. Have them apply thread-locking compound to the pinion shaft lock bolt and install the lock bolt through the differential case and into the pinion shaft, and then torque the pinion shaft lock bolt to specification. Tell students to install the differential housing cover with a new gasket, and then remove the filler plug and fill the differential carrier with the proper type of lubricant until it begins to come out the filler plug hole. Instruct them to consult the vehicle service manual to see if a limited slip additive should be used. Install the filler plug, and then install the brake drums or rotors and the wheels and lower the vehicle.

Applications/Practice 1 Refer to content

Evaluation and feedback Prior to Testing or Lab Work Objective 1. / Formative assessment / Instructor will observe students as they practice the procedure to assure correct procedure and safety practices are being followed. A checklist will be utilized to chart 1 student progress on the task. Questioning techniques will be utilized as necessary to demonstrate student comprehension / Adaptations and/or accommodations for special needs students will be added if required.

STUDENT ASSESSMENT: (Assess student progress with performance criteria.) Objective 1 / Summative assessment / written test questions on stated objective / adaptation and / or 1 accommodations for special needs students will be added if required

IMPACT--Reflection/Analysis of Teaching and Learning: (How did students’ progress in relation to the state objectives? Was the instruction successful? Analyze samples of student work particularly that which is unsatisfactory, for the purpose of planning further instruction.)

REFINEMENT--Lesson Extension and Follow-up: (To be filled in as the lesson is modified during initial planning and/or during the teaching learning process.)