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Elements and Performance Criteria

1. Prepare to dismantle manual transmission
   • 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
2. Dismantle and evaluate manual transmission and components
   • 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
3. Carry out overhaul
   • 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
4. Assemble transmission and components
   • 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
5. Complete work processes
   • 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
6. Prepare to dismantle manual transmission
   • 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
7. Dismantle and evaluate manual transmission and components
   • 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
8. Carry out overhaul
   • 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
9. Assemble transmission and components
   • 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
10. Complete work processes
    • 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

Range Statement

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.

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Performance Evidence

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.

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Knowledge Evidence

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

manual transmission overhaul procedures, including:

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.

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