Grade 10 Learner's Manual

Grade 10

Learner’s Manual

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

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

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

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.

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.

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

• 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.

ACTIVITY SELF-CHECK 1.1

Identification: Identify the parts of the vehicle, Find the answer on the box provided.

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 ______

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).

To prevent the lubricant from leaking out, the gearbox has an oil tight case. Seals are used around each cover and shaft. In addition, seals are provided around the input and the output shafts. The clutch shaft in many transmissions does not have a separate seal. Instead, an oil slinger is used to throw back any oil that reaches it. Other designs have a passage in the clutch-shaft-bearing retainer that bring back to the case any oil passing through the bearing.

B. OIL VISCOSITY

Viscosity is a measure of an oil's resistance to flow. A low-viscosity oil is thin and flows easily. A high-viscosity oil is thicker and flows more slowly. As engine oil should have the proper viscosity so it flows easily to all moving parts, so as oil used in transmission and differential gears as well. Gear oil must withstand heavy duty operation in all driving range. Low viscosity reduces the ability of the oil to stay in place between moving engine parts. If the oil is too thin (low viscosity), it is forced out of the moving parts. Rapid wear results then.

In some modern light vehicle, oil used in transmission and differential is the same as that of engine oil.

When properly operated and maintained, a manual transmission or transaxle normally lasts the life of the vehicle without a major breakdown. All units are designed so the internal parts operate in a bath of oil circulated by the motion of the gears and shafts. Some units also use a pump to circulate oil to critical wear areas that require more lubrication than the natural circulation provides.

Maintaining good internal lubrication is the key to the long life of transmission or transaxle. If the amount of oil falls below minimum levels, or if the oil becomes too dirty, problems result.

CHECKING OF LEVEL AND REFILL TRANSMISSION/DIFFERENTIAL GEAR OIL

SUPPLIES AND MATERIALS

• Rags

TOOLS

• Box/Socket wrench ( or special tool ) – appropriate mm. size

EQUIPMENT

• Hydraulic jack

• Jack stand

• Live vehicle

PROCEDURE:

A. CHECK GEAR OIL LEVEL

The transmission and transaxle gear oil level should be checked at the intervals specified in the service manual. Normally, these ranges from every 7,500 to 30,000 miles (12,000 to 48,000 kilometers). For service convenience, many units are now designed with a dipstick and filler tube accessible from beneath the hood.

Note:

Check the oil with the engine off and the vehicle resting on level grade. If the engine has been running, wait 2 to 3 minutes before checking the gear oil level. If the vehicles have no dipstick for easy determination of gear oil level, do the following steps: 1. Place the vehicle on level ground. (Checking can be done if the vehicle lift is high enough to go under the vehicle). If not; 2. Jack-up the vehicle and place jack stand for safety under the cross member. (If hydraulic lifter is available, vehicle must be raised enough to have access when checking gear oil level). 3. Locate the filler plug. (It is usually placed at the side of the transmission/differential unit). 4. Clean the filler plug area and remove the plug with appropriate wrench. 5. Insert finger or bent rod through the filler opening and check the gear oil level. (Lubricant should be level with, or not more than 1/2 inch below specified level). 6. Refill gear oil if necessary. 7.

Filler hole

FULL level LOW

Level

Fig.45. Transmission gear oil level

Filler7. hole

LOW FULL level level

Fig.46. Differential/Axle housing oil level

NOTE: If the oil level is adequate, reinstall the filler plug and gasket. Tighten with appropriate wrench. Raise the vehicle slightly to remove the jack stand. Slowly drop down the hydraulic jack until all four wheels have been safely dropped on the ground.

B. REFILLING GEAR OIL

SUPPLIES AND MATERIALS • Utility rags • Flexible plastic /rubber tube • Plastic funnel

TOOLS • Box/Socket wrench ( or special tool ) – appropriate mm. size • Oil filler (if available) EQUIPMENT • Hydraulic jack • Jack stand • Live vehicle

PROCEDURE:

After checking the oil level of transmission/differential and found needing refill, follow the procedure: 1. With filler plug removed, place a flexible tube in the filler opening (long enough with right diameter for it to insert in the filler opening).

Note: Oil filler pump is better to use if available. 2. Place a funnel on the other end of flexible tube. 3. Pour slowly a right amount of appropriate gear oil intended for transmission/differential. Stop pouring gear oil when it overflows in the filler plug.

Note: Some vehicles recommend a certain type and grade of gear oil. Manual transmission or transaxle lubricants in use today include single and multiple

13 viscosity gear oils, engine oils, and automatic transmission fluid. Always refer to the service manual to determine the correct lubricant and viscosity range for the vehicle and its operational conditions.

4. Check oil level, reinstall filler plug, tighten to specifications and test run for oil leak. 5. Jack-down the vehicle by slightly jacking it up, removing the jack stand, and slowly lifting down the vehicle. 6. Test run the vehicle for any unwanted noise and oil leak.

ACTIVITY SELF CHECK 2.2

FINDING WORDS: Encircle the words that you can see inside the box , words to

find can be seen below the box.

T R A N S M I S S I O N G E A R L O R I

R H D W R E N C H H V R X A X E L L

A Y V I S C O S I T Y O I L L G B D I I

N D E F I L T E R O D U S W E R U E P D

S R V F T O P E L A R I C A S E I C O I

I A Y E E A U T O M O B I L E N L A S F

T U T R C H M A C A N O T O Y E D D I F

F L R E H O P I O C A R Y F O R I E T E

I I E N V U A D M A H L H I Y C N A I R

L C N T O B R I O M A O O N O V G G O E

T O S I C U E G T O M V L D C E P O N N

O M L A H S K O I T M E Y M R D O R S C

E M O L T H O N V E E L T E G E O F G E

R E A R V E H G E D D I F F I C U L T S

HYDRAULIC GEAR TRANSMISSION AUTOMOBILE OIL DIFFERENTIAL AXLE VISCOSITY PUMP WRENCH FILTER

INFORMATION SHEET 2.3

CHANGING TRANSMISSION/DIFFERENTIAL GEAR OIL

GEAR OIL REPLACEMENT

Changing the gear oil is an important maintenance activity for a car. According to some car owner's manual, it should be changed every two years or 5000 kilometers. The gear oil inside the transmission and differential coats the gears while the vehicle is running. The gears and bearings rely on the gear oil to reduce the metal stress and fatigue. Gear oil breaks down over time and usage. If not changed, it will turn into a thick dark molasses-like dirt. Eventually, the gears and bearings could seize resulting in a untimely deterioration. Changing the gear oil is fairly simple and can be accomplished in an hour.

Proper gear oil viscosity grade must be followed when replacing transmission/differential gear oil.

Fig. 47. Gear oil viscosity and temperature

SUPPLIES AND MATERIALS • Rags • Oil filler tool with flexible tube • Funnel TOOLS • Box/Socket wrench ( or special tool ) – appropriate mm. size • Oil filler (if available) EQUIPMENT • Hydraulic jack • Jack stand • Live vehicle PROCEDURE:

Drive the vehicle to warm the lubricant before placing the vehicle on the lifter/hoist. 1. Place the vehicle on level ground. Jack-up the front and rear of the vehicle and place jack stand under the cross member for safety. (If hydraulic lifter is available, vehicle must be raised enough to have access when checking gear oil level) 2. Remove and clean the drain plug (usually located underneath the transmission/differential unit) with appropriate wrench.

Fig. 48. Removing drain plug using appropriate wrench

3. Allow the lubricant to drain into a clean catch pan. (Inspect the lubricant for metal particles, which may appear as a shiny, metallic color in the lubricant. Large amounts of metal particles indicate severe bearing, synchronizer, gear, or housing wear).

Fig. 49. The metallic particles attached to the magnetic drain plug

4. If all lubricants are drained, replace the plug washer and apply a recommended sealant to the threads on the drain plug.

5. Tighten the drain plug with the recommended torque.

Fig. 50.Replacing of drain plug before refilling gear oil.

6. Fill the transmission/differential with appropriate gear oil

a. Remove transmission/differential filler bolt/plug.

Fig. 51. Location of refill bolt/plug

b. Pour a right amount of gear oil.

Fig. 52.Refilling gear oil using oil filler tool.

c. Reinstall and tighten filler plug to specifications.

7. Test run the vehicle and check for oil leak.

ACTIVITY SELF CHECK 2.3

IDENTIFY AND NAME :

1. What is this part? a. Transmission b. Differential c. Engine 2. What tools are used to manipulate this part? a. Socket wrench b. Extension of socket wrench c. Pliers 3. Where can you find this part in the vehicle? a. Underchassis b. Under the hood c. Under the drivers seat 4. Name the two plug that will be loosen and tighten during change gear oil. a. Sensor & Wire b. Cap & cover c. Filler & drain 5. To lift a vehicle , what tools is used a. Hydraulic Jack b. Lumber Jack c. Jack and Stone

SUMMATIVE ASSESSMENT LO 1

A. Written Assessment

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 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 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

B. Oral Assessment Directions: Answer the question. Your answer will be assessed based on the following criteria: 1. As a car owner, how would you react when the automotive technician deviates from the manufacturer’s instruction in changing the transmission/differential gear oil ?

Criteria 3 ( Better ) 2 ( Good ) 1 ( Poor ) Mastery of the Manifested a Manifested some Manifested few concept working knowledge working knowledge working knowledge of the concept with of the concept with of the concepts no error. few errors. with many errors. Level of Manifested Manifested Manifested comprehension evidence of evidence of evidence of comprehension comprehension comprehension with critical analysis with average with indefinite of the subject. analysis of the analysis with subject. significance of the subject.

Level of Demonstrated Demonstrated Demonstrated confidence communication communication communication skills correctly and skills correctly but skills but made easily with not easily. some mistakes. confidence.

C. Performance Assessment ( This can be done in Face to face approach)

Directions: Below is the performance assessment that serves as your guide in assessing the following skills you need to perform. Please be guided with the tasks with the corresponding score and the performance level.

Name : ______Year & Section : ______Course: ______Time Allotment: ______Module Title:______Grading Period : ______

Unit of Competency Time Performa Tasks Dat Begu Finishe Scor nce e n d e Level LO2 Inspect 2.1 Check and change transmission transmission / differential /differential for leakage. gear oil 2.2 Check

transmission /differential gear oil level. 2.3 Change transmission /differential gear oil in accordance with manufacturer’s specification.

2.4 Refill transmission/ differential gear oil to specified level.

Average: ______

LEVEL OF PERFORMANCE

RATING SCALE TOTAL SCORE NUMERICAL DESCRIPTIVE RATING RATING 21 – 25 91 – 100 Outstanding 16 – 20 86 – 90 Very Good 11 – 15 81 – 85 Good 06 – 10 76 – 80 Fair 01 - 05 71 – 75 Needs Improvement

WHAT IS YOUR SCORE? ______PERFORMANCE LEVEL ______

LO 3 : CHECK/REFILL AUTOMATIC TRANSMISSION FLUID

• Check automatic transmission for leakage. • Check automatic transmission fluid in accordance with service manual. • Refill transmission fluid to specified level.

PRE/DIAGNOSTIC ASSESSMENT LO 3

A. WRITTEN ASSEMENT

MULTIPLE CHOICE

Directions: Answer the statements/questions by writing the letter of the best option.

1. One of the several additives of automatic transmission fluid (ATF) is ______. A. Dexron C. Silicon B. Lime D. Viscosity-index improvers 2. The color of the automatic transmission fluid (ATF) is usually ______. A. Amber C. Dye red B. Black D. Brown 3. To prevent the fluid from overheating, automatic transmission has ______. A. Brake Fluid cooler C. Silicon cooler B. Fluid cooler or Oil cooler D. Water cooler 4. The hot transmission fluid flows through the tube, the engine coolant carries away excess ______. A. Air C. Moisture B. Heat D. Oxidation 5. The automatic transmission comprises a set of ______. A. Bolts and nuts C. Planetary gears B. Hydraulic Valves D. Splines 6. When the dipstick shows a low fluid level, look for ______. A. Bends C. Restrictions B. Leaks D. Twists

7. Placing the vehicle on level ground when checking the fluid level is _____ a good practice. A. Always C. Seldom B. Rarely D. Sometimes 8. When lifting a vehicle, placing jack stands for safety must be observed ______. A. Always C. Some other time B. Not at all D. Sometimes 9. Gum or varnish on the dipstick, discolored fluid, and particles or specks on the paper towel indicate the condition of ______in the pan. A. Fluid C. Plasma B. Gasoline D. Water 10. If leak is obvious, be it minor or major troubles, it must be immediately ______. A. Refreshed C. Repaired B. Renewed D. Replaced

INFORMATION SHEET 3.1

AUTOMATIC TRANSMISSION FLUID

Automatic transmission fluid is a special lubricant with about the same viscosity as an SAE 20 engine oil. It has several additives such as viscosity-index improvers, oxidation and corrosion inhibitors, extreme-pressure and antifoam agents, detergents, dispersants, friction modifiers, pour-point depressants, and fluidity modifiers. Automatic transmission fluid is usually dyed red. The color makes a leak easily identifiable.

A. TRANSMISSION FLUID COOLER

Overhead automatic-transmission fluid can damage the friction elements (bands and multiple-disc clutches) in an automatic transmission or transaxle. The heat develops in an unlocked torque converter and in other moving parts.

To prevent the fluid from overheating, automatic transmissions and transaxles have transmission-fluid cooler or oil cooler. It is usually a tube on the bottom or side of the engine radiator.

The engine coolant runs at a lower temperature than the automatic transmission fluid. As the hot transmission fluid flows through the tube, the engine coolant carries away excess heat. Cooler lines similar to steel fuel lines carry the transmission fluid between the case and the radiator.

B. HYDRAULIC SYSTEM

Functions of the Hydraulic System

Figure 63 shows the complete hydraulic system of a 4-speed automatic transmission. The hydraulic system provides the pressurized fluid to operate an automatic transmission or transaxle.

Fig. 64. The Hydraulic system which uses a special transmission fluid. (www.google.com.ph)

Planetary gear set with clutch engaged. One set of clutch plates is splined to the sun-gear drum. The other set is fixed at the planet-pinion carrier. When fluid pressure from the pump acts on the apply side of the clutch piston, the clutch plates are forced together. This locks the sun gear to the planet carrier and the planetary gear set rotates as a single unit. The functions of the system are as follows:

1. Supplies fluid to the torque converter

2. Directs pressurized fluid to the band servos and multiple-disc clutches

3. Lubricates the internal parts

4. Removes heat generated by the torque converter and other moving parts

These four jobs are possible because the automatic transmission or transaxle is fitted with automatic-transmission fluid (ATF). Without the proper amount of fluid, the transmission may not shift and the vehicle may not move. Major components in the hydraulic system include the oil pump, band servos, and multiple disc clutches. Other major components are the valve body and governor.

C. NORMAL MAINTENANCE

Normal maintenance of an automatic transmission or transaxle includes:

1. Checking fluid level, color, and condition

2. Adding fluid, if necessary

3. Changing fluid and filter

4. Checking shift and throttle linkage

5. Adjusting neutral safety switch

6. Adjusting bands, if possible

The level of the automatic-transmission fluid (ATF) should be checked with every change of engine oil. Many vehicle manufacturers recommend changing the transmission fluid and filter at periodic intervals. The length of the intervals depends on how the vehicle is used. For example, Chevrolet recommends changing the fluid and filter every 100,000 miles [160,000 km] for normal service. In severe situation, Chevrolet recommends changing the fluid and filter every 15,000 miles [25,000 km]. Severe service includes using the vehicle as trailer, towing or as a delivery vehicle, police car, and even taxi.

ACTIVITY 2.1

Identification: Identify the parts of the automatic transmission, write the answer on

the box provided, choose your answer below the picture.

12 10

3 9

4 7

5 6

Ring Gear Band Clutch Piston Clutch Pack

Sun Gear Planet Gear Input shaft Oil line

Output shaft Drum Connected to Sun Gear

INFORMATION SHEET 2.2

CHECKING, DRAINING AND REFILLING AUTOMATIC TRANSMISSION FLUID

SUPPLIES AND MATERIALS • Automatic transmission fluid (ATF) • Rag • Empty container • Rubber tube – appropriate to the size of steering fluid reservoir outlet

TOOLS • Jack stand • Special ATF tool – drain plug wrench EQUIPMENT • hydraulic lifter/Crocodile jack • Automatic Transmission - equipped vehicle

PROCEDURE:

A. CHECK FLUID LEVEL

Checking the fluid level, its color and conditions should be made every change of engine oil. To check the fluid level, drive the vehicle for 15 minutes or until the engine and transmission are at normal operating temperature. Park the vehicle on level ground and firmly apply the parking brake. Let the engine idle. Place the transmission selector lever in PARK (or NEUTRAL, if specified by the manufacturer).

1. Clean any dirt found around the dipstick cap.

2. Pull out the ATF dipstick from the tube, wipe, and reinsert it,

3. Pull out again the dipstick and observe the oil level.

Note: The fluid level on the dipstick. Touch the fluid on the end of the dipstick to get an indication of fluid temperature. If the fluid feels cool, the fluid level should be on the low side of the dipstick. If the fluid level feels warm or hot (too hot to hold), the dipstick level is on the high side.

Fluid level will vary under normal operating conditions as much as 19 mm from cold to hot. For example, as the temperature of the fluid goes from 16°C to 82°C, the level of the fluid may rise to as much as 19 mm. Some dipsticks are marked to show proper levels at different fluid temperatures.

Note that in some automatic transaxles, the fluid level goes down as temperature increases. The COLD mark on the dipstick is above the FULL

32 mark. If the fluid level is low, add a sufficient amount of the specified fluid to bring the level within the marks for the fluid temperature. Do not overfill an automatic transmission or transaxle. Too much fluid will cause foaming. Foaming fluid cannot operate bands and clutches properly. They will slip and probably burn. This may need an overhaul of the transmission or transaxle.

B. CHECK FLUID CONDITION

Fluid color and odor can be checked to determine the condition of the fluid. Look at the color and smell the fluid at the end of the dipstick. If the fluid is brown or black and has a strong burnt odor, bands and clutch plates may have slipped, overheated, and burned. Particles of friction materials from the bands and clutch plates have probably circulated through the torque converter, transmission, and fluid cooler.

These particles can cause valves in the valve body to stick. This may cause noisy, rough or missed shifts. Slipping may occur because the servos and clutches cannot work properly. A quick check of fluid condition can be made by placing one or two drops of fluid on a paper towel. As the towel absorbs the fluid, examine the stain for specks or particles. This indicates solid material in the fluid.

If the stain spreads and is red or light brown in color, the fluid probably is good. If the stain is dark and remains small, the fluid is oxidized and should be changed. Oxidized fluid has combined with oxygen in the air and no longer has its original properties.

Fig. 65. Checking the fluid condition using dipstick. (http://www.google.com.ph.)

CHECKING FLUID COLOR

Automatic transmission fluid is normally red in color, however if found out that the ATF changes its color, it indicates that a problem occurs in the system.

1. PINK FLUID – This indicates that the fluid cooler in the radiator is leaking. Engine coolant has contaminated the fluid. Repair or replace the fluid cooler and remove and overhaul the transmission or transaxle. Replace the seals, bands, lined clutch plates, nylon washers, and speedometer and governor gears. Coolant can affect these parts. Clean all other parts and passages. Flush the cooler lines and flush or replace the torque converter.

2. BROWN FLUID. ATF may turn dark in normal use. However, contaminated fluid may also have a brown color. If the fluid appears contaminated, drain it, then remove and inspect the pan. A small amount of metal particles and friction material at the bottom of the pan is normal. Replace the filter, and refill with new fluid. Large pieces of metal or other materials indicate excessive wear or failure. The transmission or transaxle should be removed and overhauled. Flush the cooler lines, and flush or replace the torque converter.

Fig. 66. ATF color determine its internal condition. (http://www.google.com.ph.)

C. CHECK OIL PAN CONDITION

Gum or varnish on the dipstick, discolored fluid, and particles or specks on the paper towel indicate the condition of the pan. It should be removed and inspected. A small amount of materials in the pan is normal. Look for large pieces of metal and large amounts of friction material. These indicate abnormal wear or failure. The unit then requires rebuilding or overhaul.

D. CHECK FOR FLUID LEAKS

When the dipstick shows a low fluid level, look for a fluid leak. Some fluid can be lost through the case vent if the fluid has foamed. To locate the source of a leak, see if the automatic transmission fluid is dyed red. The dyed red helps in detecting and identifying easily the leak. Another method of detecting a leak is to use an ultraviolet leak detector. If a leak detector is not available, do the following procedure:

Fig. 67.Checking the fluid leaks. (www.google.com.ph.)

1. Place the vehicle on level ground. (Lift the vehicle if necessary with the use of appropriate hydraulic lifter. Place jack stand for safety).

2. Clean the suspected area with solvents to remove any traces of fluid.

3. Run the engine for 15 minutes with automatic transmission on DRIVE range and observe for oil leak in the transmission area.

4. Turn off the engine. Place the transmission on PARK range and observe again the area if there are leaks.

NOTE: If leak is obvious whether it be minor or major troubles such as leak in oil pan gasket, drain plug and shim, and oil seal must be brought immediately to the automatic transmission specialist for repair.

E. DRAIN AND REFILL AUTOMATIC TRANSMISSION FLUID

After the automatic transmission fluid had been checked or drained, it must be refilled. Take note great care must be observed when refilling ATF (automatic transmission fluid) because of its intricate construction and sensitive parts. Manufacturer’s specifications must be consulted and performed when doing the job.

PROCEDURE:

1. Apply hand brake, put the transmission in PARK position, place wood chock on the rear wheels. Jack the vehicle (if necessary).

2. Place oil catch basin. Loosen and completely remove the automatic transmission drain plug and washer with the use of appropriate drain plug tool.

3. Allow the ATF to completely drain.

4. Reinstall the drain plug with washer and remove the oil catch basin.

5. Remove the ATF dipstick and install oil funnel to dipstick tube where the ATF dipstick was removed .

6. Pour a right grade and amount of ATF. (See owner’s manual for specific grade and amount of ATF).

7. Remove the oil funnel and reinstall the ATF dipstick.

8. Check the ATF level based on the dipstick markings (Cold check).

9. Jack up and place jack stand on the rear of the vehicle.

10. With handbrake applied and transmission in “PARK” position;

11. Start the engine and shift automatic transmission in different driving range.

12. Turn- off the engine.

13. Jack up the vehicle, remove jack stand and totally lift down the vehicle.

14. Remove the ATF dipstick and recheck the ATF level (Hot check).

15. Add ATF if necessary. Do not overfill the ATF because it easily expands and

may cause fire.

16. Recheck ATF level and reinstall dipstick.

ACTIVITY 2.2

Arrange the procedure in correct order on how to check ATF (automatic transmission fluid), Write your answer on the blanks provided.

______Pull out again the dipstick and observe the oil level. ______Pull out the ATF dipstick from the tube, wipe, and reinsert it,

______Clean any dirt found around the dipstick cap.

ACTIVITY 2.3

Arrange the scrambled letter to form a word related to this topic. Automatic Transmission.

1. UAOTAMCTI ______2. FDIUL ______3. SDPIICTK ______4. XIDOIZE ______5. KGTAES ______

SUMMATIVE ASSESSMENT LO 2

A. Written Assessment

MULTIPLE CHOICE

Directions: Answer the statement/question by writing the letter of the best option. 1. One of the several additives of automatic transmission fluid (ATF) is ______. A. Dexron C. Silicon B. Lime D. Viscosity-index improvers 2. The automatic transmission fluid (ATF) is usually colored ______. A. Amber C. Dye red B. Black D. Brown 3. To prevent the fluid from overheating, automatic transmission has ______. A. Brake Fluid cooler C. Silicon cooler B. Fluid cooler or Oil cooler D. Water cooler 4. The hot transmission fluid flows through the tube, the engine coolant carries away excess ______. A. Air C. Moisture B. Heat D. Oxidation 5. The automatic transmission comprises set of ______. A. Bolts and nuts C. Planetary gears B. Hydraulic Valves D. Splines 6. When the dipstick shows a low fluid level, look for ______. A. Bends C. Restrictions B. Leaks D. Twists 7. Placing the vehicle on level ground when checking the fluid level is _____ a good practice. A. Always C. Seldom B. Rarely D. Sometimes 8. When lifting a vehicle, placing jack stands for safety must be observed ______. A. Always C. Some other time B. Not at all D. Sometimes

9. Gum or varnish on the dipstick, discolored fluid, and particles or specks on the paper towel indicate the condition of ______in the pan. A. Fluid C. Plasma B. Gasoline D. Water 10. If leak is obvious, be it minor or major troubles, it must be immediately ______. A. Refreshed C. Repaired B. Renewed D. Replaced

B. Oral Assessment

Directions: Explain your answer on the question below.

1. You are driving in a remote place. You felt that you have difficulty in handling your steering. You found out that your power steering fluid is way below the minimum level. The only available power steering fluid does not match the required fluid by the manufacturer’s specifications? What would you do? Explain your answer. You will be assessed based on the following criteria:

Criteria 3 ( Better ) 2 ( Good ) 1 ( Poor ) Mastery of the Manifested a Manifested some Manifested few concept working knowledge working knowledge working knowledge of the concept with of the concept with of the concept with no error. few errors. many errors. Level of Manifested Manifested Manifested comprehension evidence of evidence of evidence of comprehension comprehension comprehension with critical analysis with average with indefinite of the subject. analysis of the analysis and subject. significance of the

subject. Level of Demonstrated Demonstrated Demonstrated confidence communication communication communication skills correctly and skills correctly but skills but made easily with not easily. some mistakes. confidence.

C. Performance Assessment

Name : ______Year & Section: ______

Course: ______Time Allotment: ______

Module Title: ______Grading Period ______

Unit of Competency Time Performance UNDERCHASSIS Tasks Date Begun Finished Score Level PREVENTIVE MAINTENANCE LO 4 Check/ refill 4.1 Check automatic automatic transmission fluid transmissio . n for leakage. 4.2 Check automatic transmissio n fluid in accordance with service manual. 4.3 Refill transmissio n fluid to specified level.

Average: ______

L E V E L O F P E R F O R M A N C E

WHAT IS YOUR SCORE?______PERFORMANCE LEVEL ______

Disclaimer: All information and activities were copied from CBLM Automotive Y4 of the Department of Education published in 2008. The publisher makes no warranties with respect to the accuracy, applicability, and completeness of the contents of this module. All information and activities contained in this module were reviewed and refined for distance learning. The publisher does not claim ownership over them.