This unit describes the performance outcomes required to return a manual transmission to original manufacturer tolerances and clearances. It involves preparing for the task, dismantling and evaluating the transmission, carrying out the overhaul procedures, reassembling and testing the transmission, and completing workplace processes and documentation.
It applies to those working on manual transmissions in vehicles from all sectors of the industry.
No licensing, legislative, regulatory or certification requirements apply to this unit at the time of publication.
You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)
Evidence Required
List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.
Elements
Elements describe the essential outcomes.
Performance Criteria
Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold and italicised text is used, further information is detailed in the range of conditions section.
1. Prepare to dismantle manual transmission
1.1 Job requirements are determined from workplace instructions
1.2 Dismantling information is sourced and interpreted
1.3 Dismantling options are analysed and those most appropriate to the circumstances are selected
1.4 Hazards associated with the work are identified and risks are managed
1.5 Dismantling tools and equipment are selected and checked for serviceability
2. Dismantle and evaluate manual transmission and components
2.1 Transmission is dismantled in a logical sequence according to manufacturer and workplace procedures, and safety and environmental requirements, and without causing unnecessary damage to components or systems
2.2 Components are cleaned for evaluation according to workplace procedures and safety and environmental requirements
2.3 Components are measured and compared with manufacturer specifications and serviceability is determined
2.4 Component repair method is determined
2.5 Unserviceable parts are identified and replacement parts sourced
3. Carry out overhaul
3.1 Overhaul information is sourced and interpreted
3.2 Overhaul options are analysed and those most appropriate to the circumstances are selected
3.3 Overhaul tools and equipment are selected and checked for serviceability
3.4 Components are machined, repaired and replaced as required, and adjustments are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and without causing damage to components or systems
4. Assemble transmission and components
4.1 Transmission is assembled according to manufacturer specifications, workplace procedures, and safety and environmental requirements
4.2 Tolerances and clearances are measured against manufacturer specifications and necessary adjustments are made
4.3 Assembly of transmission is completed within workplace timeframes and without causing damage to other components or systems
4.4 Post-assembly testing is carried out according to workplace procedures and safety and environmental requirements, and any problems detected as having been introduced during the assembly process are rectified
5. Complete work processes
5.1 Final inspection is made to ensure work is to workplace expectations and transmission is presented ready for use or storage
5.2 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
5.3 Tools and equipment are checked and stored according to workplace procedures
5.4 Workplace documentation is processed according to workplace procedures
Before competency can be determined, individuals must demonstrate they can perform the following according to the standards defined in this unit’s elements, performance criteria, range of conditions and foundation skills:
overhaul three different manual transmissions, one of which must include a transaxle transmission.
Individuals must be able to demonstrate knowledge of:
work health and safety (WHS) and occupational health and safety (OHS) requirements relating to overhauling manual transmissions, including procedures for using:
specialised manual transmission overhaul tools, equipment and machinery
chemicals and toxic substances
manual and mechanical lifting equipment
environmental requirements, including procedures for trapping, storing and disposing of fluids released from manual transmissions
types, characteristics and operating principles of manual transmissions, including transaxles and conventional transmissions
methods for cleaning and preparing manual transmissions for overhaul
transmission dismantling procedures
transmission component inspection, measuring and evaluation procedures, including:
non-destructive testing procedures, including dye penetrant testing and magnetic particle testing
assessing transmission case damage and alignment to engine
measuring tolerances and clearances of components, including extension housing seal and bushing, bearings, gear wear and damage, synchroniser units and baulk rings, shift rails and forks, detents and interlock systems, and input, main, counter and output shafts
transmission component repair and adjustment procedures, including:
bearings and shims
seals and bushings
speedometer drive gears
transmission assembly procedures, including procedures for adjusting component tolerances, including:
bearing preload
shaft end float
final drive bearing preload
post-overhaul testing procedures for manual transmissions.
Assessors must satisfy NVR/AQTF assessor requirements.
Competency is to be assessed in the workplace or a simulated environment that accurately reflects performance in a real workplace setting.
Assessment must include direct observation of tasks.
Where assessment of competency includes third-party evidence, individuals must provide evidence that links them to the manual transmissions that they have worked on, e.g. repair orders.
Assessors must verify performance evidence through questioning on skills and knowledge to ensure correct interpretation and application.
The following resources must be made available:
mechanical repair workplace or simulated workplace
workplace instructions
manufacturer manual transmission specifications
three different manual transmissions requiring overhaul, one of which must be a transaxle
tools, equipment and materials appropriate for overhauling and adjusting manual transmissions.
Submission Requirements
List each assessment task's title, type (eg project, observation/demonstration, essay, assingnment, checklist) and due date here
Assessment task 1: [title] Due date:
(add new lines for each of the assessment tasks)
Assessment Tasks
Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.
Elements
Elements describe the essential outcomes.
Performance Criteria
Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold and italicised text is used, further information is detailed in the range of conditions section.
1. Prepare to dismantle manual transmission
1.1 Job requirements are determined from workplace instructions
1.2 Dismantling information is sourced and interpreted
1.3 Dismantling options are analysed and those most appropriate to the circumstances are selected
1.4 Hazards associated with the work are identified and risks are managed
1.5 Dismantling tools and equipment are selected and checked for serviceability
2. Dismantle and evaluate manual transmission and components
2.1 Transmission is dismantled in a logical sequence according to manufacturer and workplace procedures, and safety and environmental requirements, and without causing unnecessary damage to components or systems
2.2 Components are cleaned for evaluation according to workplace procedures and safety and environmental requirements
2.3 Components are measured and compared with manufacturer specifications and serviceability is determined
2.4 Component repair method is determined
2.5 Unserviceable parts are identified and replacement parts sourced
3. Carry out overhaul
3.1 Overhaul information is sourced and interpreted
3.2 Overhaul options are analysed and those most appropriate to the circumstances are selected
3.3 Overhaul tools and equipment are selected and checked for serviceability
3.4 Components are machined, repaired and replaced as required, and adjustments are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and without causing damage to components or systems
4. Assemble transmission and components
4.1 Transmission is assembled according to manufacturer specifications, workplace procedures, and safety and environmental requirements
4.2 Tolerances and clearances are measured against manufacturer specifications and necessary adjustments are made
4.3 Assembly of transmission is completed within workplace timeframes and without causing damage to other components or systems
4.4 Post-assembly testing is carried out according to workplace procedures and safety and environmental requirements, and any problems detected as having been introduced during the assembly process are rectified
5. Complete work processes
5.1 Final inspection is made to ensure work is to workplace expectations and transmission is presented ready for use or storage
5.2 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
5.3 Tools and equipment are checked and stored according to workplace procedures
5.4 Workplace documentation is processed according to workplace procedures
This section specifies work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included. Bold italicised wording, if used in the performance criteria, is detailed below.
Safety and environmental requirements must include:
work health and safety (WHS) and occupational health and safety (OHS) requirements, including procedures for using:
specialised manual transmission overhaul tools, equipment and machinery
chemicals and toxic substances
manual and mechanical lifting equipment
environmental requirements, including procedures for trapping, storing and disposing of fluids released from manual transmissions.
Before competency can be determined, individuals must demonstrate they can perform the following according to the standards defined in this unit’s elements, performance criteria, range of conditions and foundation skills:
overhaul three different manual transmissions, one of which must include a transaxle transmission.
Individuals must be able to demonstrate knowledge of:
work health and safety (WHS) and occupational health and safety (OHS) requirements relating to overhauling manual transmissions, including procedures for using:
specialised manual transmission overhaul tools, equipment and machinery
chemicals and toxic substances
manual and mechanical lifting equipment
environmental requirements, including procedures for trapping, storing and disposing of fluids released from manual transmissions
types, characteristics and operating principles of manual transmissions, including transaxles and conventional transmissions
methods for cleaning and preparing manual transmissions for overhaul
transmission dismantling procedures
transmission component inspection, measuring and evaluation procedures, including:
non-destructive testing procedures, including dye penetrant testing and magnetic particle testing
assessing transmission case damage and alignment to engine
measuring tolerances and clearances of components, including extension housing seal and bushing, bearings, gear wear and damage, synchroniser units and baulk rings, shift rails and forks, detents and interlock systems, and input, main, counter and output shafts
transmission component repair and adjustment procedures, including:
bearings and shims
seals and bushings
speedometer drive gears
transmission assembly procedures, including procedures for adjusting component tolerances, including:
bearing preload
shaft end float
final drive bearing preload
post-overhaul testing procedures for manual transmissions.
Assessors must satisfy NVR/AQTF assessor requirements.
Competency is to be assessed in the workplace or a simulated environment that accurately reflects performance in a real workplace setting.
Assessment must include direct observation of tasks.
Where assessment of competency includes third-party evidence, individuals must provide evidence that links them to the manual transmissions that they have worked on, e.g. repair orders.
Assessors must verify performance evidence through questioning on skills and knowledge to ensure correct interpretation and application.
The following resources must be made available:
mechanical repair workplace or simulated workplace
workplace instructions
manufacturer manual transmission specifications
three different manual transmissions requiring overhaul, one of which must be a transaxle
tools, equipment and materials appropriate for overhauling and adjusting manual transmissions.
Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.
Observation Checklist
Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice
Yes
No
Comments/feedback
Job requirements are determined from workplace instructions
Dismantling information is sourced and interpreted
Dismantling options are analysed and those most appropriate to the circumstances are selected
Hazards associated with the work are identified and risks are managed
Dismantling tools and equipment are selected and checked for serviceability
Transmission is dismantled in a logical sequence according to manufacturer and workplace procedures, and safety and environmental requirements, and without causing unnecessary damage to components or systems
Components are cleaned for evaluation according to workplace procedures and safety and environmental requirements
Components are measured and compared with manufacturer specifications and serviceability is determined
Component repair method is determined
Unserviceable parts are identified and replacement parts sourced
Overhaul information is sourced and interpreted
Overhaul options are analysed and those most appropriate to the circumstances are selected
Overhaul tools and equipment are selected and checked for serviceability
Components are machined, repaired and replaced as required, and adjustments are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and without causing damage to components or systems
Transmission is assembled according to manufacturer specifications, workplace procedures, and safety and environmental requirements
Tolerances and clearances are measured against manufacturer specifications and necessary adjustments are made
Assembly of transmission is completed within workplace timeframes and without causing damage to other components or systems
Post-assembly testing is carried out according to workplace procedures and safety and environmental requirements, and any problems detected as having been introduced during the assembly process are rectified
Final inspection is made to ensure work is to workplace expectations and transmission is presented ready for use or storage
Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
Tools and equipment are checked and stored according to workplace procedures
Workplace documentation is processed according to workplace procedures
Job requirements are determined from workplace instructions
Dismantling information is sourced and interpreted
Dismantling options are analysed and those most appropriate to the circumstances are selected
Hazards associated with the work are identified and risks are managed
Dismantling tools and equipment are selected and checked for serviceability
Transmission is dismantled in a logical sequence according to manufacturer and workplace procedures, and safety and environmental requirements, and without causing unnecessary damage to components or systems
Components are cleaned for evaluation according to workplace procedures and safety and environmental requirements
Components are measured and compared with manufacturer specifications and serviceability is determined
Component repair method is determined
Unserviceable parts are identified and replacement parts sourced
Overhaul information is sourced and interpreted
Overhaul options are analysed and those most appropriate to the circumstances are selected
Overhaul tools and equipment are selected and checked for serviceability
Components are machined, repaired and replaced as required, and adjustments are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and without causing damage to components or systems
Transmission is assembled according to manufacturer specifications, workplace procedures, and safety and environmental requirements
Tolerances and clearances are measured against manufacturer specifications and necessary adjustments are made
Assembly of transmission is completed within workplace timeframes and without causing damage to other components or systems
Post-assembly testing is carried out according to workplace procedures and safety and environmental requirements, and any problems detected as having been introduced during the assembly process are rectified
Final inspection is made to ensure work is to workplace expectations and transmission is presented ready for use or storage
Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
Tools and equipment are checked and stored according to workplace procedures
Workplace documentation is processed according to workplace procedures
Forms
Assessment Cover Sheet
AURTTX008 - Overhaul manual transmissions
Assessment task 1: [title]
Student name:
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I declare that the assessment tasks submitted for this unit are my own work.
Student signature:
Result: Competent Not yet competent
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Date:
Assessment Record Sheet
AURTTX008 - Overhaul manual transmissions
Student name:
Student ID:
Assessment task 1: [title] Result: Competent Not yet competent
(add lines for each task)
Feedback to student:
Overall assessment result: Competent Not yet competent