diesel technology: drive trains - jones & bartlett...

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NATEF Crosswalk The following NATEF Drive Trains tasks (Rev. 2004) are covered in this publication. The chart shows where each task is located within the publication. The first column indentifies the NATEF task by name and number. The second column identifies the exact location by unit number and assignment sheet or job sheet. NATEF Tasks A. Clutch Diagnosis and Repair—Unit 6 1. Diagnose clutch noise, binding, slippage, pulsation, vibration, grabbing, and chatter problems; determine needed action. P-1 2. Inspect and adjust clutch linkage, cables, levers, brackets, bushings, pivots, springs, and clutch safety switch (includes push and pull-type assemblies); check pedal height and travel; perform needed action. P-1 3. Inspect, adjust, repair, or replace hydraulic clutch slave and master cylinders, lines, and hoses; bleed system. P-2 4. Inspect, adjust, or replace release (throw-out) bearing, sleeve, bushings, springs, housing, levers, release fork, fork pads, rollers, shafts, and seals. P-2 5. Inspect, adjust, and replace single-disc clutch pressure plate and clutch disc. P-1 6. Inspect, adjust, and replace two-plate clutch pressure plate, clutch discs, intermediate plate, and drive pins/lugs. P-1 7. Inspect and/or replace clutch brake assembly; inspect input shaft and bearing retainer; perform needed action. P-3 8. Inspect, adjust, and replace self-adjusting/ continuous-adjusting clutch mechanisms. P-3 9. Inspect and replace pilot bearing. P-2 10. Inspect flywheel mounting area on crank- shaft, rear main oil seal, and measure crank- shaft end play; determine needed action. P-2 11. Inspect flywheel, starter ring gear and measure flywheel face and pilot bore runout; determine needed action. P-2 MAVCC Tasks Assignment Sheet 1 — Diagnose clutch noise, binding, slippage, pulsation, vibration, grabbing, and chatter problems; determine needed repairs. Job Sheet 1 — Inspect and adjust clutch linkage, cables, levers, brackets, bushings, pivots, springs, and clutch safety switch (includes push and pull-type assemblies), and check pedal height and travel. Job Sheet 2 — Inspect, adjust, repair, or replace hydraulic clutch slave and mater cylinders, lines and hoses; bleed system. Job Sheet 6 — Inspect, adjust, or replace release (throw-out) bearing, sleeve, bushings, springs, housing, levers, release fork, fork pads, rollers, shafts, and seals. Job Sheet 5 — Inspect a single-disc and two-plate clutch pressure plate clutch disc(s), intermediate plate, and drive pins/lugs. Job Sheet 5 — Inspect a single-disc and two-plate clutch pressure plate clutch disc(s), intermediate plate, and drive pins/lugs. Job Sheet 7 — Inspect and/or replace clutch brake assembly; inspect input shaft and bearing retainer. Job Sheet 3 — Inspect, adjust, and replace, self-adjusting/continuous-adjusting clutch mechanisms. Job Sheet 8 — Inspect and replace pilot bearing. Job Sheet 11 — Inspect flywheel mounting area on crankshaft, rear main oil seal, and measure crankshaft end play. Job Sheet 10 — Inspect flywheel, starter ring gear and measure flywheel face and pilot bore runout. xxv Diesel Technology: Drive Trains

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NATEF CrosswalkThe following NATEF Drive Trains tasks (Rev. 2004) are covered in this publication. The chart shows where each task is located within the publication. The first column indentifies the NATEF task by name and number. The second column identifies the exact location by unit number and assignment sheet or job sheet.

NATEF TasksA. Clutch Diagnosis and Repair—Unit 61. Diagnose clutch noise, binding, slippage,pulsation, vibration, grabbing, and chatterproblems;determineneededaction.P-12. Inspect and adjust clutch linkage, cables,levers, brackets, bushings, pivots, springs, andclutch safety switch (includes push and pull-typeassemblies);checkpedalheightandtravel;perform needed action. P-13. Inspect, adjust, repair, or replace hydraulicclutch slave and master cylinders, lines, andhoses;bleedsystem.P-24. Inspect, adjust, or replace release (throw-out)bearing, sleeve, bushings, springs, housing,levers, release fork, fork pads, rollers, shafts,and seals. P-25. Inspect, adjust, and replace single-disc clutchpressure plate and clutch disc. P-1

6. Inspect, adjust, and replace two-plate clutchpressure plate, clutch discs, intermediate plate,and drive pins/lugs. P-17. Inspect and/or replace clutch brake assembly;inspectinputshaftandbearingretainer;performneeded action. P-38. Inspect, adjust, and replace self-adjusting/continuous-adjusting clutch mechanisms. P-3

9. Inspect and replace pilot bearing. P-210. Inspect flywheel mounting area on crank-shaft, rear main oil seal, and measure crank-shaftendplay;determineneededaction.P-211. Inspect flywheel, starter ring gear andmeasure flywheel face and pilot bore runout;determine needed action. P-2

MAVCC Tasks

Assignment Sheet 1 — Diagnose clutch noise,binding, slippage, pulsation, vibration, grabbing,andchatterproblems;determineneededrepairs.Job Sheet 1 — Inspect and adjust clutch linkage,cables, levers, brackets, bushings, pivots,springs, and clutch safety switch (includes pushand pull-type assemblies), and check pedalheight and travel.Job Sheet 2 — Inspect, adjust, repair, or replacehydraulic clutch slave and mater cylinders, linesandhoses;bleedsystem.Job Sheet 6 — Inspect, adjust, or replacerelease (throw-out) bearing, sleeve, bushings,springs, housing, levers, release fork, fork pads,rollers, shafts, and seals.Job Sheet 5 — Inspect a single-disc andtwo-plate clutch pressure plate clutch disc(s),intermediate plate, and drive pins/lugs.Job Sheet 5 — Inspect a single-disc andtwo-plate clutch pressure plate clutch disc(s),intermediate plate, and drive pins/lugs.Job Sheet 7 — Inspect and/or replace clutchbrakeassembly;inspectinputshaftandbearingretainer.Job Sheet 3 — Inspect, adjust, and replace,self-adjusting/continuous-adjusting clutchmechanisms.Job Sheet 8 — Inspect and replace pilot bearing.Job Sheet 11 — Inspect flywheel mounting areaon crankshaft, rear main oil seal, and measurecrankshaft end play.Job Sheet 10 — Inspect flywheel, starter ringgear and measure flywheel face and pilot borerunout.

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Diesel Technology:Drive Trains

xxvi

NATEF Crosswalk

NATEF Tasks12. Inspect flywheel housing(s) to transmissionhousing/engine mating surface(s) and measureflywheel housing face and bore runout;determine needed action. P-2B. Transmission Diagnosis and Repair1. Diagnose transmission noise, shifting, lockup,jumping-out-of-gear, overheating, and vibrationproblems;determineneededaction.P-12. Diagnose transmission component failurecause, both before and during disassemblyprocedures;determineneededaction.P-23. Inspect, adjust, service, repair, or replacetransmission remote shift linkages, brackets,bushing, pivots, and levers. P-2

4. Inspect, test, repair, or replace air shiftcontrols, lines, hoses, valves, regulators, filters,and cylinder assemblies. P-15. Inspect and replace transmission mounts,insulators,andmountingbolts;determineneeded action. P-3

6. Inspect for leakage and replace transmissioncoverplates,gaskets,seals,andcapbolts;inspectsealsurfacesandvents;repairasneeded. P-17.Checktransmissionfluidlevelandcondition;determineneededservice;addpropertypeoflubricant. P-18. Inspect, adjust, and replace transmission shiftlever, cover, rails, forks, levers, bushings,sleeves, detents, interlocks, springs, and lockbolts/safety wires. P-39. Remove and reinstall transmission. P-2

MAVCC TasksJob Sheet 9 — Inspect flywheel housing(s) totransmission housing/engine mating surface(s)and measure flywheel housing face and borerunout.

Unit 4, Assignment Sheet 1 — Diagnose causesof transmission noise, shifting, lockup, jumping-out-of-gear, overheating, and vibration.Throughout

Unit 4, Job Sheet 5 — Inspect, adjust, service,repair, or replace remote shift linkages andcontrol assembly, brackets, bushings, pivots,and levels.Unit 4, Job Sheet 3 — Inspect, test, adjust,repair, or replace air shift controls, lines, valves,regulators, filters, and cylinder assemblies.Unit4,JobSheet4—Removethetransmission;check condition of transmission mounts,insulators, and mounting bolts.Unit5,JobSheet1—Removetransmission;check condition of transmission mounts,insulators, and mounting boltsUnit 4, Job Sheet 1 — Inspect for leakage andreplace transmission cover plates, gaskets,seals,andcapbolts;inspectsealsurfacesandvents.Unit 1. Job Sheet 1 — Perform drive trainlubrication and replace grease fittings.

Unit 4, Job Sheet 6 — Inspect, adjust, andreplace transmission shift lever assembly, topcover, and shift bar housing.

Unit4,JobSheet4—Removethetransmission;check condition of transmission mounts,insulators, and mounting bolts.Unit 4, Job Sheet 12 — Reinstall transmissionUnit5,JobSheet1—Removetransmission;check condition of transmission mounts,insulators, and mounting boltsUnit 5, Job Sheet 3 — Reinstall transmission

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NATEF Tasks10. Inspect input shaft, gear, spacers, bearings,retainers,andslingers;replaceasneeded.P-3

11. Inspect and adjust main shaft, gears, slidingclutches, washers, spacers, bushings, bearings,auxiliarydriveassemblies,retainers,andkeys;replace as needed. P-312. Inspect countershafts, gears, bearings,retainers,andkeys;adjustbearingpreloadandtimemultiplecountershaftgears;replaceasneeded. P-3

13. Inspect output shafts, gears, washers,spacers, bearings, retainers, and keys, replaceas needed. P-314. Inspect reverse idler shafts, gears, bushings,bearings,thrustwashers,andretainers;checkreverse idler gear and end play (whereapplicable);replaceasneeded.P-315. Inspect synchronizer hub, sleeve, keys(inserts), springs, blocking rings, synchronizerplates, blocker pins, and sliding clutches;replace as needed. P-316. Inspect transmission cases includingsurfaces, bores, bushings, pins, studs, andmagnets;replaceasneeded.P-317. Inspect transmission lubrication systempumps,troughs,collectors,andslingers;serviceor replace as needed. P-3

18.Inspecttransmissionoilfiltersandcoolers;replace as needed. P-219. Inspect mechanical and electronicspeedometercomponents;determineneededaction. P-320. Inspect and adjust power take-off (PTO)assemblies,controls,andshafts;performneededaction. P-321. Inspect and test function of backup light,neutralstart,andwarningdevicecircuits;repairas needed. P-1.

MAVCC TasksUnit 4, Job Sheet 9 — Remove, inspect, andreinstall input shaft gear, spacers, bearing,retainers, and slingers.Unit 4, Job Sheet 8 — Remove, disassemble,inspect, assemble, and reinstall the main shaftand auxiliary drive assembly.

Unit 4, Job Sheet 7 — Remove, disassemble,inspect, assemble, and reinstall the auxiliarycase and its componentsUnit 4, Job Sheet 10 — Remove, inspect, and/orreplace main countershafts, reverse indlerassembly,andoilpump;timemultiplecountershafts.Unit 4, Job Sheet 7 — Remove, disassemble,inspect, assemble, and reinstall the auxiliarycase and its componentsUnit 4, Job Sheet 10 — Remove, inspect, and/orreplace main countershafts, reverse indlerassembly,andoilpump;timemultiplecountershafts.Unit 4, Job Sheet 7 — Remove, disassemble,inspect, assemble, and reinstall the auxiliarycase and its components

Unit 4, Job Sheet 11 — Inspect transmissioncases

Unit 4, Job Sheet 10 — Remove, inspect, and/orreplace main countershafts, reverse indlerassembly,andoilpump;timemultiplecountershafts.Unit 4, Job Sheet 14 — Inspect transmission oilfilter and coolerUnit 4, Job Sheet 7 — Remove, disassemble,inspect, assemble, and reinstall the auxiliarycase and its componentsUnit 3, Job Sheet 1 — Inspect the PTO.Unit 3, Job Sheet 2 — Remove, install andadjust a PTOUnit 4, Job Sheet 2 — Inspect and test functionof backup lamp, neutral start, and warningdevice circuits

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NATEF Crosswalk

NATEF Tasks22. Inspect and test transmission temperaturegaugesendingunit/sensor;determineneededaction. P-323. Inspect, test operation, adjust, repair, orreplace automated mechanical transmissionand manual electronic shift controls, shift, rangeand splitter solenoids, shift motors, indicators,speed and range sensors, electronic/transmissioncontrol units (ECU/TCU), neutral/in gear andreverse switches, and wiring harnesses. P-2

24. Inspect, test operation, repair, or replaceelectronic shift selectors, air and electricalswitches, displays and indicators, wiringharnesses, and air lines. P-2

25. Use appropriate diagnostic tools andprocedures to diagnose automated mechanicaltransmissionproblems;checkandrecorddiagnostic codes, clear codes, and interpretdigitalmultimeter(DMM)readings;determineneeded repairs. P-2

26. Inspect, test operation, adjust, repair, orreplace automatic transmission electronic andmanual shift controls, shift solenoids, shiftmotors, indicators, speed and range sensors,electronic/transmission control units (ECU/TCU),neutral/in gear and reverse switches, andwiring harnesses. P-3

27. Inspect, test operation, repair, or replaceautomatic transmission electronic shift selectors, switches, displays and indicators, wiringharnesses. P-3

MAVCC TasksUnit 4, Job Sheet 15 — Inspect and testtransmission temperature gauge.

Unit 4, Job Sheet 17 — Inspect, adjust, repair,or replace electronic shift controls, sensors,solenoids, shift motors, indicators, control units,and wiring harnesses.Unit 5, Job Sheet 4 — Inspect, adjust, repair, or replace electronic shift controls, electroniccontrol unit, wiring harnesses, sensors, controlmodule, vehicle interface module, and relatedcomponents.Unit 4, Job Sheet 18 — Inspect, adjust, repair,or replace electronic shift selectors, air andelectrical switches, displays and indicators, andwiring harnesses.Unit 5, Job Sheet 4 — Inspect, adjust, repair, or replace electronic shift controls, electroniccontrol unit, wiring harnesses, sensors, controlmodule, vehicle interface module, and relatedcomponents.Unit4,JobSheet16— Useadiagnostictooland procedure to diagnose automatedtransmission problems.Unit 5, Job Sheet 4 — Inspect, adjust, repair, or replace electronic shift controls, electroniccontrol unit, wiring harnesses, sensors, controlmodule, vehicle interface module, and relatedcomponents.Unit 4, Job Sheet 17 — Inspect, adjust, repair,or replace electronic shift controls, sensors,solenoids, shift motors, indicators, control units,and wiring harnesses.Unit 5, Job Sheet 4 — Inspect, adjust, repair, or replace electronic shift controls, electroniccontrol unit, wiring harnesses, sensors, controlmodule, vehicle interface module, and relatedcomponents.Unit 4, Job Sheet 18 — Inspect, adjust, repair,or replace electronic shift selectors, air andelectrical switches, displays and indicators, andwiring harnesses.Unit 5, Job Sheet 4 — Inspect, adjust, repair, or replace electronic shift controls, electroniccontrol unit, wiring harnesses, sensors, controlmodule, vehicle interface module, and relatedcomponents.

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NATEF Tasks28. Use appropriate diagnostic tools and procedures to diagnose automatic transmissionproblems;checkandrecorddiagnosticcodes,clear codes, and interpret digital multimeter(DMM)readings;determineneededrepairs.P-3

C. Drive and Universal Joint Diagnosis and Repair—Unit 21. Diagnose driveshaft and universal joint noiseandvibrationproblems;determineneededaction. P-12. Inspect, service, or replace driveshaft, slipjoints,yokes,driveflanges,anduniversaljoints;check phasing of all yokes. P-13. Inspect and replace driveshaft center supportbearingsandmounts;determineneededaction. P-14. Measure and adjust drive line angles. P-2

D. Drive Axle Diagnosis and Repair—Unit 71. Diagnose drive axle(s) drive unit noise andoverheatingproblems;determineneededaction. P-22.Checkandrepairfluidleaks;inspectandreplace drive axle housing cover plates, gaskets,sealants, vents, magnetic plugs, and seals. P-1

3.Checkdriveaxlefluidlevelandcondition;determineneededservice;addpropertypeoflubricant. P-14. Remove and replace differential carrierassembly. P-2

5. Inspect and replace differential case assemblyincluding spider gears, cross shaft, side gears,thrust washers, case halves, and bearings. P-3

6. Inspect and replace components of lockingdifferential case assembly. P-3

MAVCC TasksUnit4,JobSheet16— Useadiagnostictooland procedure to diagnose automatedtransmission problems.Unit 5, Job Sheet 4 — Inspect, adjust, repair, or replace electronic shift controls, electroniccontrol unit, wiring harnesses, sensors, controlmodule, vehicle interface module, and relatedcomponents.

Assignment Sheet 1— Diagnose driveshaft andU-joint problems.

Job Sheet 1 — Inspect and service driveshaft,slipjoints,yokes,driveflanges,andU-joints;check phasing of all yokes.Job Sheet 2 — Remove and reinstall thedriveshaft and center support bearing andmounts.Job Sheet 5 — Measure and adjust drivelineangles.

Assignment Sheet 1 — Diagnose drive axle(s)drive unit noise and overheating problems.

JobSheet2—Checkforandrepairfluidleaks;inspect and replace drive axle drive unit coverplates, gaskets, sealants, vents, magnetic plugs,and seals.Job Sheet 1 — Check axle fluid level andcondition;addpropertypeoflubricant.

Job Sheet 6 — Remove and replace differentialcarrier, inspect case and caps, side bearingbores, and pilot bearing bore.Job Sheet 7 — Inspect and replace differentialcase assembly including spider gears, crossshaft, side gears, thrust washers, case halves,and bearing.Job Sheet 17 — Inspect and replacecomponents of locking differential caseassembly

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NATEF Crosswalk

NATEF Tasks7. Inspect differential carrier case and caps,side bearing bores, and pilot (spigot, pocket)bearingbores;determineneededaction.P-38.Measureringgearrunout;determineneededrepairs. P-39. Inspect and replace ring and drive piniongears, spacers, sleeves, bearing cages, andbearings. P-310. Measure and adjust drive pinion bearingpreload. P-311. Measure and adjust drive pinion depth. P-3

12. Measure and adjust side bearing preloadand ring gear backlash. P-313. Check and interpret ring gear and piniontoothcontactpattern;determineneededaction. P-314. Inspect, adjust, or replace ring gear thrustblock/bolt. P-315. Inspect, adjust, repair, or replace planetarygear-type 2-speed axle assembly including: case,idler pinion, pins, thrust washers, sliding clutchgear, shift fork, pivot, seals, cover, and springs.P-316. Inspect, repair, or replace 2-speed axle shiftcontrol system, speedometer adapters, motors,axle shift units, wires, air lines, and connectors.P-317. Inspect power divider (inter-axle differential)assembly;determineneededaction.P-3

18. Inspect, adjust, repair, or replace airoperated power divider (inter-axle differential)lockout assembly including diaphrams, seals,springs, yokes, pins, lines, hoses, fittings, andcontrols. P-219. Inspect, repair, or replace drive axlelubricationsystem;pump,troughs,collectors,slingers, tubes, and filters. P-320. Inspect and replace drive axle shafts. P-1

MAVCC TasksJob Sheet 6 — Remove and replace differentialcarrier, inspect case and caps, side bearingbores, and pilot bearing bore.Job Sheet 12 — Measure ring gear runout.

Job Sheet 8 — Inspect and replace ring anddrive pinion gears, spacers, sleeves, bearingcage, and bearings.Job Sheet 10 — Measure and adjust drivepinion bearing preload.Job Sheet 9 — Measure and adjust drive piniondepth.Job Sheet 11 — Measure and adjust sidebearing preload and ring gear backlash.Job Sheet 13 — Check and interpret ring gearand pinion tooth contact pattern.

Job Sheet 14 — Inspect, adjust, or repair ringgear thrust block/screw.Job Sheet 15 — Inspect, adjust, repair, orreplace planetary gear-type 2-speed axleassembly.

Job Sheet 16 — Inspect, repair, or replace2-speed axle shift control system, speedometeradapters, motors, axle shift units, wires, air lines and connectors.Job Sheet 18 — Inspect, adjust, repair, orreplace air-operated power divider (inter-axledifferential) lockout assembly.Job Sheet 18 — Inspect, adjust, repair, orreplace air-operated power divider (inter-axledifferential lockout assembly.

Job Sheet 19 — Inspect, repair, or replace rearaxle lubrication system

Job Sheet 4 — Inspect and replace drive axleshafts

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NATEF Tasks21.Removeandreplacewheelassembly;checkrearwheelsealandaxleflangegasketforleaks;perform needed action. P-122. Diagnose drive axle for wheel bearing noiseanddamage;performneededaction.P-223. Inspect and test drive axle temperaturegaugesendingunit/sensor;determineneededaction. P-324. Clean, inspect, lubricate and replace wheelbearings;replacesealsandwearrings;adjustdrive axle wheel bearings. P-125. Inspect and test drive axle temperaturesendingunit/sensor;determineneededaction.P-1

MAVCC TasksJob Sheet 3 — Remove, clean, inspect,lubricate, replace, and adjust wheel bearingsand seals.Assignment Sheet 2 — Diagnose drive axle forwheel bearing noise and damage.Job Sheet 5 — Inspect and test rear axletemperature gauge and sensor

Job Sheet 3 — Remove, clean, inspect,lubricate, replace, and adjust wheel bearingsand seals.Job Sheet 5 — Inspect and test rear axletemperature gauge and sensor