Clutch and Manual Transmission Diag Examples

Presentation

•

Instructional Technology

•

12th Grade

•

Practice Problem

•

Easy

Brandon Spiller

Used 36+ times

FREE Resource

16 Slides • 6 Questions

Clutch and Manual Transmission Diag Examples

Auto Occupations

In this lesson, we will discuss a couple of manual transmissions and clutch symptoms and diagnostics.

First the General Inspection

What are some things I can quickly inspect on a manual transmission and clutch system?

Open Ended

What are some things I can quickly inspect on a manual transmission and clutch system?

Type response here

General Inspections Points

1. Transmission Fluid Level and Condition (We can review this if needed)
Clutch Hydraulic Fluid (if equipped)
Evaluate the clutch
Inspect Gear Shift Mechanism (Binding, Bent, Broken)
Evaluate the Transmission (Hard Shift, Grinding Gears, Excessive Noise)

The Road Test (Do not drive with low transmission fluid)

1. Start the engine
2. Evaluate the noise in NEUTRAL while parked
Is there a noise with the clutch pressed/released?
Noise with a change in RPM?
Does it go through all gears smoothly?
Noise in a specific gear/speed?
Noise only under load, coasting, clutch in/out?

Typical Clutch Concerns

Clutch Slippage
Clutch chatter or shudder
The clutch pedal feels spongy or excessive travel or does not disengage
Clutch drag hard to shift
Clutch pedal pulsation
Clutch-related vibration
Excessive noise

Let's work through an example...

2015 Ford Mustang 5.0L MT
Customer States Transmission is difficult to shift when cold
The transmission starts to shift normally when it warms up.

Open Ended

What are your initial thoughts on the concern? Any test or inspections you would start with?

Type response here

Ford Mustang Transmission Symptom Chart Link:

I will send it to you all now.

Look through this page and look for the symptom described by the customer.

3 Mins: Starting Now

Multiple Choice

What is the possible source of this concern based on the symptom chart?

Normal Condition (Manual Transmission fluid is thick when cold)

Internal Shift Mechanism

Lubricant Issue

Housing or shafts

When the transmission is cold the fluid is thicker and requires more effort to shift.

Let's do one more example

2015 Ford Mustang 5.0L MT
The customer states there is a high-pitched whine or squeal coming from the transmission.
The car has over 200k miles and has had regular transmission fluid changes.

Open Ended

What are your initial thoughts on the concern? Any tests or inspections you would like to start with?

Type response here

First, look at the symptom chart and see if any of the symptoms listed match the concern described.

Look under the NVH part of the symptom chart
Noise Vibration and Harshness = NVH

Multiple Select

Select all of the possible causes below.

Transmission gears are worn (high mileage vehicle)

Mismatched gear sets

Damaged or worn transmission bearing

Axle howl or whine

Worn countershaft gears

Multiple Choice

True or False: Since the concern is related to the internals of the transmission it must be removed and dissembled for proper inspection.

True

False

In order to inspect the transmission for damage, it must be disassembled.

Conclusion

There are several concerns related to transmissions and clutches best practice to start is to use a symptom chart and base diagnostic decisions on the chart.

Most faults will require the removal and disassembly of the transmission.

Extra Credit: Watch a manual transmission teardown video on YouTube (5 Points/One Assignment)

Once you watch the video write one paragraph summarizing the video and information you learned.
Good Example: https://www.youtube.com/watch?v=4cBKjbobwec

Clutch and Manual Transmission Diag Examples

Auto Occupations

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