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Grade 10 Learner's Manual

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Grade 10 Learner's Manual Grade 10 Learner’s Manual 0 QUARTER I LESSON: PERFORM UNDERCHASSIS PREVENTIVE MAINTENANCE INTRODUCTION: This module contains information and practices in performing Under- chassis Preventive Maintenance. It includes instructions on how to check clutch, brake fluid and lines, inspect and change transmission and differential gear oil, inspect and replace power steering fluid, check and refill automatic transmission fluid, inspect fluid air tank, check tire and tire pressure, and check under chassis body bolts and nuts. This module also consists of learning outcomes which contains learning activities for both knowledge and skills, supported with information sheets, self-check, and job and operation sheets, gathered from different sources. LO 1.1: CHECK TRANSMISSION/DIFFERENTIAL OIL AND LEAKS ▪ Check transmission and differential oil leaks on joining member of engine and transmission, oil seal and gaskets. ▪ Refill transmission and differential oil to the specified level. ▪ Identify oil viscosity for gear oil, engine oil and automatic transmission oil 1 PRE - ASSESSMENT LO 1 MULTIPLE CHOICE Directions: Answer the statements/questions by writing the letter of the best option. 1. Oil used in transmission and differential is called _______. A. Engine oil C. Machine oil B. Gear oil D. Penetrating oil 2. Gear oil is heavier than motor oil and has a very low _______. A. Ability C. Velocity B. Porosity D. Viscosity 3. Usually, gear oil leak comes from __________ gasket and oil seal. A. Good C. Quality B. Dilapidated D. Worn-out 4. Gears must be continuously separated by a thin film of lubricant to prevent ____________ wear. A. Excessive C. Normal B. Minimum D. Optimum 5. As gear teeth mesh, there is a sliding or swiping action between the contact ___. A. Edges C. Films B. Faces D. Toes 6. Gearboxes must have lubricants or gear oil in them. Gear oil has different jobs to do except _______. A. To lubricate all moving parts and prevent wear B. To reduce friction and power loss C. To protect against rust and corrosion D. To keep the interior parts shiny, clean and fragrant 7. Oil that has additives in it to increase the load-carrying capacity is called ________________ lubricant. A. Extreme power C. Extreme quality B. Extreme pressure D. Extreme reliability 8. Gear oil level should be checked as specified in the service _______. A. Center C. Shop B. Manual D. Station 2 9. Allow the lubricant to drain into a clean catch _______. A. Ban C. Pan B. Can D. Van 10. Test running the vehicle and checking for oil leak after repair is a good _______. A. Analysis C. Practice B. Credo D. Try 11. Changing the gear oil is an important maintenance activity for a car. A. True C. Not at all B. False D. Sometimes 12. The gear oil inside the transmission and differential _________ the gears while the engine is running. A. Butts C. Cuts B. Coats D. Dots 13. The gear oil if not __________, will turn like a thick dark molasses. A. Changed C. Refreshed B. Converted D. Revived 14. Proper gear oil __________ grade must be followed when replacing transmission/differential gear oil. A. Color C. Viscosity B. Mixture D. Weight 15. When lifting a vehicle, place _____________ under the cross member for safety. A. Jack board C. Jack stone B. Jack stand D. Jack tool 16. Drained _______ must be disposed properly to avoid chemical pollution of the environment. A. Lubricant C. Urine B. Manure D. Water 17. Tighten the drain plug with the recommended torque. A. Always C. Rarely B. Not at all D. Sometimes 18. Right amount and grade of gear oil must be _______. A. Disregarded C. Guesses B. Followed D. Tried 3 19. When refilling gear oil, use _______. A. Oiler C. Oil gun B. Oil filler tool D. Oil pump 20. Metal particles in the transmission and differential gear can be traced in the _______ due to wear. A. Drain plug C. Filler plug B. Expansion plug D. Spark plug INFORMATION SHEET 1.1 CHECK TRANSMISSION/DIFFERENTIAL FOR LEAKAGE Oil used in transmission and differential is called gear oil. It is totally different from the one used in motor engine. Gear oil is heavier than motor oil and has a very low viscosity. When gear oil leaks, it causes a very untidy appearance, very slippery and fatal when accidentally stepped-on. That is why, gear oil should be maintained safe without finding its way dripping under the floor. 4 Fig. 43. Phantom view of transmission assembly (Auto Repair Illustrated Deluxe Ed.) Transmission and differential gear oil must be checked regularly for leaks. This can be done by visual inspection and recording the location where the leak originates. The location of leak will give the idea where the leak originates. Usually, gear oil leak comes from worn-out gasket and oil seal. This kind of leak openly comes from natural tear and wear of frequent used. Other source of leak is due to loosed drain plug or its shim gasket not squarely seated properly. If this condition is observed, it must be brought immediately to the service station at once to avoid further damage to the internal, working parts. Inadequate gear oil will tend the gears to heat up and if totally neglected friction between two metals contacting surfaces result thus giving a growling sound during operation. 5 The following are the parts that must be inspected when checking for leaks. Fig. 44.The differential axle housing Differential/Axle housing Differential axle oil seal ( located inside ) Filler plug Drain plug PROCEDURES AND WAYS ON CHECKING TRANSMISSION/DIFFERENTIAL FOR LEAKAGE SUPPLIES AND MATERIALS • Rags TOOLS • Open/Box wrench – appropriate mm. size EQUIPMENT • Hydraulic jack 6 • Jack stand • Live vehicle PROCEDURE: NOTE: Drive the vehicle before proceeding to the work station. 1. Jack up the front and rear (if necessary) of the vehicle and place jack stand for safety. 2. Inspect and clean the transmission and differential unit area. 3. Run the engine from 1 to 3 minutes with transmission shifted in gear position. 4. Bring transmission to NEUTRAL position and turn-off the engine. NOTE: Wait for 3 to 5 minutes. (It will take a longer time for the gear oil to flow because of its thick viscosity compared with engine oil which has a thinner viscosity). 5. Check if there is leak in the transmission and differential unit. 6. If leak is observed near the bolt (drain plug, front, side , rear and underside) area try to tighten it with the use of appropriate wrench. 7. Clean the unit and repeat steps 3 to 5. NOTE: If leak still persists, pull down the unit for repair. Possible trouble may come from worn-out gasket, drain plug shim, front and rear oil seals. 7 ACTIVITY SELF-CHECK 1.1 Identification: Identify the parts of the vehicle, Find the answer on the box provided. 1 2 3 4 5 Drain Plug Location of Differential Oil seal Filler Plug Tire ACTIVITY SELF CHECK 1.2 Differential Housing Shock Absorber Arrange the letters to create words pertaining to automobile parts or tools 1. REWNHC __________________________ 2. LPIRES __________________________ 3. FIDFENRTEIAL ______________________ 4. RTASNMSISONI _____________________ 5. XLEA __________________________ 6. LPGU ___________________________ 7. RDIAN ___________________________ 8. LRELFI ___________________________ 9. NGEIEN ___________________________ 10. SSVCIITYO __________________________ 8 INFORMATION SHEET 2.2 CHECKING TRANSMISSSION/DIFFERENTIAL GEAR OIL LEVEL GEAR OIL AND OIL VISCOSITY A. GEAR OIL Manual transmissions, transaxles, and transfer cases are all various types of gearboxes. They are very similar in three ways: 1. Gears that transmit power 2. Splinted shafts that rotate while other parts are sliding down on them. 3. Bearings that support the shafts and transfer the load to the case or housing. In the gearbox, the moving metal parts must not touch each other. They must be continuously separated by a thin film of lubricant to prevent excessive wear and premature failure. As gear teeth mesh, there is a sliding or wiping action between the contact faces. This action produces friction and heat. Without lubrication, the gears would wear quickly and fail. However, lubrication provides a fluid film between contact faces. This prevents metal-to-metal contact. Therefore, all gearboxes must have lubricants or gear oil on them. Gear oil has five jobs to do. These are: 1. To lubricate all moving parts and prevent wear 2. To reduce friction and power loss 3. To protect against rust and corrosion 4. To keep the interior clean 5. To cool the gearbox In addition, the oil must have adequate load-carrying capacity to prevent puncturing of the oil film. Chemical additives are mixed with gear oil to improve its load-carrying capacity. An oil that has an additive in it to increase the loadcarrying 9 capacity is called an extreme-pressure (EP) lubricant. Other additives are also added to the oil to improve the viscosity (thickness), to prevent channeling (solidify), to improve stability and oxidation resistance, to prevent foaming, to prevent rust and corrosion, and to prevent damage to the seals. The typical gear oil is a straight mineral oil (refined crude oil) with the required additives in it. Today, some oils are made from synthetic oil. Regardless of type, gear oils intended for most cars and light trucks have these classification, SAE 75W, 75W-80, 80W-90, 85W-90, 90, or 140. Gear oil is not recommended for use in all gearboxes by the manufacturers. Gears which are lightly loaded, like the planet-pinion gears in a planetary gear set of the automatic transmission do not require high viscosity (thick) oil. Therefore, some transfer cases are filled with SAE 10W engine oil. Other transfer cases use automatic transmission fluid (ATF).
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