AURLTX101 Task 1

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Feb 20, 2024

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RTO No: 91223 Assessment Task 1 AURLTX101 Diagnose and Repair Light Vehicle Manual Transmissions

AURLTX101 Diagnose and repair light vehicle manual transmissions Assessment 1 – Questioning – Written Assessment Student Name JAYVEE RYEE JAYME Student ID Number SCM3144 Unit Start Date AUGUST 14, 2023 Unit End Date AUGUST 27, 2023 Assessment Due Date AUGUST 27, 2023 Date Submitted AUGUST 27, 2023 This cover sheet is to be completed by the student and assessor and used as a record to determine student competency in this assessment task The assessment process and tasks were fully explained. Yes / No I am aware of which evidence will be collected and how. Yes / No I am aware of my right to appeal an assessment decision. Yes / No I am aware of the Complaints and Appeals Policy and Procedure Yes / No I have discussed any additional educational support or reasonable adjustments I require in order to undertake this assessment with the Student Support Services Officer and Trainer / Assessor Yes / No I have access to all required resources? Yes / No Cheating & Plagiarism Declaration Student Declaration: I hereby acknowledge by signing this declaration that I have not cheated or plagiarised any work regarding the assessment tasks undertaken in this unit of competency except where the work has been correctly acknowledged. NOTE: Student MUST sign this prior to submitting their assessments to the assessor Signature JAYVEE RYEE JAYME Date: 13 / 08 / 2023 Assessment Results Satisfactory or Not Yet Satisfactory (Please circle the assessment result for this task) Feedback to Student - Please provide general feedback on the Student’s performance Student Declaration: - I verify that the work completed is my own and that I was adequately informed of the assessment process prior to commencing this assessment task. Assessor Declaration: - I verify that I have adequately explained and negotiated the assessment tasks with the student prior to commencing assessment. Student Name: JAYVEE RYEE JAYME Assessor’s Name: Student Signature Date Assessor Signature Date Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 2 of 26

AURLTX101 Diagnose and repair light vehicle manual transmissions JAYVEE RYEE JAYME 13 / 08 / 2023 Student Guide for Written Knowledge Assessment Overview of Assessment This is a written assessment task you will be assess on your knowledge of diagnosing and repairing light vehicle manual transmissions. The topics that will be covered in the assessment are: 1. Prepare to diagnose and repair light vehicle manual transmission 2. Diagnose manual transmission 3. Repair manual transmission 4. Complete work processes This assessment will ensure that the elements, performance criteria, performance evidence and knowledge evidence required, and conditions are adhered to demonstrate competency in this unit assessment task. 1. Read the assessment carefully before commencing. 2. Your Assessor will use the assessment criteria in this document and will provide feedback / comment. 3. You MUST answer all the questions in the assessment tasks in your own words and own handwriting. 4. This is an “Open Book” assessment, and students can use the resources listed in the “Resources Required” section below. Task/s to be assessed To complete this written assessment, you will need to answer the 85 questions comprising of Multiple Choice, True and False, Fill-in the Gap and Short Answer questions. Time allowed On average, the Assessment should take 4 – 6 hours to complete. Location This theory assessment will be completed in a classroom under the supervision of a trainer/assessor. Decision making rules The candidate must be able to demonstrate knowledge to complete the tasks outlined in the elements, performance criteria and foundation skills of this unit, including knowledge of:  Methods to locate and interpret information required to diagnose and repair light vehicle manual transmissions, including: o Information provided by customer and supervisors o Manufacturer specifications and procedures or equivalent documentation  Workplace procedures required to diagnose and repair light vehicle manual transmissions, including: o Establishing serviceability of tools and equipment o Documentation and diagnosis reporting procedures, including: o Recommendations for required repairs or adjustments o Housekeeping procedures, including:  Examination of tools and equipment  Storage of equipment  Identification, tagging and isolation of faulty equipment  Disposal of excess materials  Recycling procedures  Work health and safety (WHS) requirements relating to diagnosing and repairing light vehicle manual transmissions, including procedures for lifting, Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 3 of 26

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AURLTX101 Diagnose and repair light vehicle manual transmissions supporting and manual handling light vehicle manual transmissions  Environmental requirements, including procedures for trapping, storing and disposing of fluids released from transmissions  Operating principles light vehicle manual transmissions, including: o Gear types o Gear ratios and torque reduction and multiplication o Simple gear trains o Compound gear trains o Lubricant types  Application, purpose and operation of light vehicle manual transmissions and components, including: o Power flows, including:  Longitudinal manual transmissions  Transaxles  Transfer cases o Synchromesh operation o Gearshift mechanisms o Transfer cases, including:  Part-time four-wheel drives  Full-time four-wheel drives  All-wheel drives  Diagnostic testing procedures for light vehicle manual transmissions, including: o Abnormal noise diagnosis o Shift diagnosis  Repair procedures for light vehicle manual transmissions, including procedures for removing, replacing and adjusting them  Post-repair testing procedures for light vehicle manual transmissions Assessment conditions Competency is to be assessed in the 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 light vehicle 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:  Automotive simulated workplace  Workplace instructions  Manufacturer light vehicle manual transmission specifications  Two [2] different light vehicles with faults in the manual transmission components specified in the performance evidence  Diagnostic equipment for light vehicle manual transmissions  Tools, equipment and materials appropriate for repairing light vehicle manual transmissions Assessors of this unit MUST satisfy the requirements for assessors in applicable vocational education and training legislation, frameworks and/or standards. Resources required Learning Resources available to students include:  Automotive Technology (A System Approach) 7 th Edition – Chapters 2, 5, 6, 7, 38, 39 & 44  Websites  Trainer Handouts Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 4 of 26

AURLTX101 Diagnose and repair light vehicle manual transmissions Results/Re-assessment  The Assessor will grade the assessment and record the result on the front page of this document (S) – Satisfactory if all observable behaviours are correct and (NS) not satisfactory if any areas are left incorrect  Feedback will be provided on either result  Where a student receives a ‘NS – Not Satisfactory’ result, the assessor will discuss the area of the non-compliant observable behaviour and an opportunity given for re-assessment. This may be through direct observation or a different method of assessment e.g. verbal/oral questioning, problem solving exercise.  If the outcome is again not satisfactory the student result will be deemed (NYC) not yet competent. Additional feedback will be given, and a time agreed upon for further assessment after additional training and skills practice has taken place, this information will be recorded, dated and signed in the re-assessment area on the last page of this document  Where all the assessment tasks have been graded (S) Satisfactory, the student will be deemed C – Competent for the practical component and the result recorded and signed in the area indicated on the last page of this document Reasonable Adjustment If the participant is unable to undertake the written assessment as designed, an interview (verbal questioning) may be used as an alternate approach. Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 5 of 26

AURLTX101 Diagnose and repair light vehicle manual transmissions Assessment 1 – Questioning Written Assessment 1. Identify some important items of personal safety or PPE when diagnosing and repairing light vehicle manual transmissions? Safety glasses, Gloves, Protective clothing, Respirator, Hearing protection, Steel toed boots, Hair and beard restraints, Apron, Head Protection, Knee pads, Fire resistant clothing, Face shield Multiple Choice question. Selected the correct answer. 2. Which of the following statements about safety glasses is true? A. They should offer side protection. B. The lenses should be made of a shatterproof material. C. Some service operations require additional eye protection to be worn with safety glasses. D. All the answers are correct. True or False question 3. When lifting and moving heavy light vehicle manual transmissions, twist at the waist to change direction. ☐ True or ☐ False Multiple Choice question. Select the correct answer. 4. When lifting and moving heavy light vehicle manual transmissions, you must ________. A. Place your feet close to the heavy wheel and tyres assemblies. Position your feet so you will be able to maintain a good balance. B. Keep your back and elbows as straight as possible. Bend your knees until your hands reach the best place to get a strong grip on the object. C. Keep the heavy wheel and tyres assemblies close to your body and lift it up by straightening your legs. Use your leg muscles, not your back muscles. D. All the answers are correct. Multiple Choice question. Select the correct answer. 5. What should you be aware of before using a jack and jack stand to Isolate, stabilise, lift and support the vehicle or machinery? A. Always check the capacity of the jack before lifting a vehicle. If the end of the vehicle is heavier than that, or if the vehicle is loaded, you will need to use a vehicle jack with a larger lifting capacity. Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 6 of 26

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AURLTX101 Diagnose and repair light vehicle manual transmissions B. Make sure the stands are in good condition and that their size and capacity are adequate before you use them to support the vehicle. C. Always use matched pairs of jack stands. D. All these answers are correct. True or False question 6. Place wheel chocks in front of and behind the wheels that are not going to be raised off the ground. ☐ True or ☐ False Fill in the Missing Words 7. Place the missing word to complete the following statement about safely Isolating and stabilising vehicles or machines using the following words? Missing Words: hoist, parking, surface Park the vehicle on a clean, level ______ surface_________. Next, make sure that the engine compartment can be accessed by whatever _______ hoist________ you are planning to carry out diagnosing and repairing procedures on the vehicle. Engage the vehicle ______ parking_________ brakes and block the wheels. 8. Referring to the VACC Automotive Environmental Guide, explain the four [4] step procedure for trapping, storing and disposing of hazardous oils released from the vehicle when diagnosing and repairing light vehicle manual transmissions. 1 Trapping and Containment - Before beginning any work, place appropriate absorbent materials, such as absorbent pads or spill containment mats, under the vehicle's transmission area. - These materials will help trap and absorb any oil leaks or spills that might occur during the maintenance process. - Trapping the oil prevents it from spreading and contaminating the surrounding environment. 2 Collection and storage - Use oil drip pans or containers to collect any oil that is drained during the maintenance process. - Make sure these containers are specifically designed for collecting and storing hazardous materials like oil. - Ensure the containers have lids or covers to prevent leaks and spills during storage. - Clearly label the containers as "Hazardous Waste" or "Used Oil" to indicate their contents. 3 Proper Labeling and Identification - Clearly label all containers with the type of oil and its potential hazards (flammable, toxic, etc.). - If your local regulations require specific labeling or identification, make sure to adhere to those guidelines. 4 Disposal - Contact a licensed waste disposal facility or recycling center that handles hazardous materials, including used oils. Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 7 of 26

AURLTX101 Diagnose and repair light vehicle manual transmissions - Follow the disposal guidelines provided by your local environmental agency or regulatory body. - Transport the collected oil in a secure and sealed container to the disposal facility. - Do not dispose of used oil in regular trash, storm drains, or sewers, as this can lead to environmental contamination. Multiple Choice question. Selected the correct answer. 9. When working on light vehicle manual transmissions, which document should you use to find how to handle, trap, store and dispose of new or waste hazardous oils? A. Safety Data Sheet (SDS) . B. Technical Service Bulletin (TSB). C. Product Information Letter (PIL). D. All the answers are correct. Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 8 of 26

AURLTX101 Diagnose and repair light vehicle manual transmissions Multiple Choice question. Selected the correct answer. 10. When working on light vehicle manual transmissions, trapping and storing wasted hazardous oils by setting up equipment such as: A. Drip table or screen table with a used-oil collection bucket. B. Place drip pans underneath vehicles that are leaking fluid. C. Do not mix other waste with waste hazardous oils. D. All the answers are correct. 11. What are the three (3) different types of gears in a manual transmission/transaxle? 1 Spur Gears (Straight-Cut Gears) 2 Helical Gears 3 Synchromesh Gears (Synchronized Gears) Multiple choice. Circle all the correct answer 12. Gears can _____. A. Transfer speed and torque. B. Decrease speed and increase torque. C. Increase speed and decrease torque. D. All answers are correct. Multiple choice. Circle all the correct answer 13. Which of the following is NOT a function of gears? A. Multiply torque while increasing speed. B. Multiply speed while decreasing torque. C. Multiply torque while decreasing speed. D. Transfer torque leave speed unchanged. Multiple choice. Circle all the correct answer 14. To reduce gear whine, manufacturers use _____ gears. A. Spur. B. Helical. C. Ellipsoidal. D. Parabolic. Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 9 of 26

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AURLTX101 Diagnose and repair light vehicle manual transmissions Fill in the Missing Words 15. Place the missing word to complete the following statement about gear ratios and torque reduction and multiplication using the following words. Missing Words: dividing, driven, gear, number, larger, multiplication, ratios Gear ______ ratios_________ express the mathematical relationship of one gear to another. ______ gear_________ ratios can vary by changing the diameter and _______ number________ of teeth of the gears in mesh. A gear ratio also expresses the amount of torque ______ multiplication_________ between two gears. The ratio is obtained by _______ dividing________ the diameter or number of teeth of the _______ driven________ gear by the diameter or teeth of the drive gear. If the smaller driving gear had eleven teeth and the _____ larger__________ gear had forty-four teeth, the ratio is 4:1. Multiple choice. Circle all the correct answer 16. When a large gear drives a smaller gear, the output speed _____. A. Decreases and torque decreases. B. Decreases and torque increases. C. Increases and torque increases. D. Increases and torque decreases. Multiple choice. Circle all the correct answer 17. When a small gear drives a larger gear, the output speed _____. A. Decreases and torque decreases. B. Decreases and torque increases. C. Increases and torque increases. D. Increases and torque decreases. Multiple choice. Circle all the correct answer 18. When an idler gear is placed between the driving and driven gear, the driven gear _____. A. Rotates in the same direction as the driving gear. B. Rotates in the direction opposite to the driving gear. C. Remains stationary. D. Rotates faster. Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 10 of 26

AURLTX101 Diagnose and repair light vehicle manual transmissions Multiple choice. Circle all the correct answer 19. Which of the following gear ratios generates the highest torque or power output? A. 0.85:1. B. 2.67:1. C. 5.23:1. D. 11.12:1. Multiple choice. Circle all the correct answer 20. A gear ratio of 0.80:1 is a(n) _____ ratio A. Reduction. B. Overdrive. C. Direct drive. D. Geometric. True or False question 21. A 2.85:1 ratio represents a gear reduction. ☐ True or ☐ False 22. Why are overdrive gear ratios used in most modern transmissions? Overdrive gear ratios are used in most modern transmissions for several reasons, primarily aimed at improving fuel efficiency, reducing engine wear, and enhancing overall driving comfort. An overdrive gear ratio refers to a gear where the output shaft of the transmission turns faster than the input shaft, resulting in lower engine RPM for a given vehicle speed. 23. What does the term “constant mesh” mean? The term "constant mesh" refers to a type of manual transmission design used in vehicles. In a constant mesh transmission, the gears on the input and output shafts are always in contact with each other, which allows for smoother and more efficient gear shifting. This design is in contrast to non-constant mesh transmissions, where gears have to be synchronized before they can engage. 24. What is the purpose of the transmission/transaxle in a light vehicle? Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 11 of 26

AURLTX101 Diagnose and repair light vehicle manual transmissions The transmission (or transaxle, in certain configurations) in a light vehicle serves a crucial role in managing and optimizing power delivery from the engine to the wheels. Its primary purpose is to allow the driver to control the vehicle's speed and torque output by selecting different gear ratios. Fill in the Missing Words 25. Place the missing word to complete the following statement about transmission gearsets using the following words. Missing Words: axle, calculated, final, first, fourth, gears, increased, large, meshes, multiplying, ratio, second, shaft, torque, transmission Power is moved through the ______ transmission_________ via four gears (two sets of two gears). Speed and torque are altered in steps. To explain how this works, let us assign numbers to each of the ________ gears_______. The small gear on the input shaft has twenty teeth. The gear it ______ meshes_________ with has forty. This provides a gear ratio of 2:1. The output of this gearset moves along the ______ shaft_________ of the forty-tooth gear and rotates other gears. The gear involved with _____ first__________ gear has fifteen teeth. This gear rotates with the same speed and with the same _______ torque________ as the forty-tooth gear. However, the fifteen-tooth gear is meshed with a ______ large_________ gear with thirty-five teeth. The gear _____ ratio__________ of the fifteen-tooth and the thirty-five-tooth gearset is 2.33:1. However, the ratio of the entire gearset (both sets of two gears) is 4.67:1. The driveline’s gear ratios are further _____ increased__________ by the gear ratio of the ring and pinion gears in the drive axle assembly. Typical ______axle_________ ratios are between 2.5 and 4.5:1. The final (overall) drive gear ratio is calculated by _______ multiplying________ the transmission gear ratio by the final drive ratio. If a transmission is in first gear with a ratio of 3.63:1 and has a _______ final________ drive ratio of 3.52:1, the overall gear ratio is 12.78:1. If ______ fourth_________ gear has a ratio of 1:1, using the same final drive ratio, the overall gear ratio is 3.52:1. The overall gear ratio is ______ calculated_________ by multiplying the ratio of the first set of gears by the ratio of the ______ second_________ (3.63 times 3.52 equals 12.78). Multiple choice. Circle all the correct answer 26. Manual transmission/transaxle lubricants in use today include ______. A. Automatic transmission fluids. B. Engine oils. C. Multiple viscosity gear oils. D. All answers are correct. 27. Describe the power-flow through a transaxle when it is in second gear. When the transaxle is in second gear, the power-flow is characterized by a reduction in speed and an increase in Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 12 of 26

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AURLTX101 Diagnose and repair light vehicle manual transmissions torque, which is advantageous for situations requiring moderate acceleration and the ability to handle higher loads, such as driving uphill or towing. Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 13 of 26

AURLTX101 Diagnose and repair light vehicle manual transmissions Multiple choice. Circle all the correct answer 28. The power flow through a five-speed transmission while it is in first gear: A. Power enters on the input shaft, which rotates the countershaft that is engaged with first gear. B. The first gear synchronizer engages with the clutching teeth of first gear and locks the gear to the main shaft, allowing power to flow from the input gear through the countershaft and to first gear and the main shaft. C. Both “ Power enters on the input shaft, which rotates the countershaft that is engaged with first gear” and “The first gear synchronizer engages with the clutching teeth of first gear and locks the gear to the main shaft, allowing power to flow from the input gear through the countershaft and to first gear and the main shaft”. D. Neither “Power enters on the input shaft, which rotates the countershaft that is engaged with first gear” and “The first gear synchronizer engages with the clutching teeth of first gear and locks the gear to the main shaft, allowing power to flow from the input gear through the countershaft and to first gear and the main shaft”. True or False question 29. Third gear powerflow happens when the shift from second to third gear is made, the shift fork returns the first/second synchronizer to its neutral position. A second shift fork slides the third/fourth synchronizer until it locks the third speed gear to the mainshaft. Power flow now goes through the third gear of the countergear to the third speed gear, through the synchronizer to the mainshaft, and driveline. ☐ True or ☐ False Multiple choice. Circle all the correct answer 30. In fourth gear, the third/fourth synchronizer is moved to lock the clutch gear on the input shaft to the mainshaft. This means power flow is ______. A. Directly from the input shaft to the mainshaft (output shaft) at a gear ratio of 1:1. B. Large gear on the countershaft to drive a smaller gear on the mainshaft. C. Through the fourth gear of the countergear to the fourth speed gear, through the synchronizer to the mainshaft, and driveline. D. None of these answers are correct. 31. How is reverse speed obtained in most transmissions? Reverse speed in most transmissions is typically achieved through the use of an additional gear arrangement that changes the direction of power flow. The gear setup used for reverse is specifically designed to enable the vehicle to move backward. It's important to note that the design of reverse gears and their engagement mechanisms can vary between different types of transmissions (manual, automatic, dual-clutch, etc.). However, the fundamental principle remains consistent: the presence of specific gear arrangements and mechanisms that allow for power to be transmitted in the reverse direction, enabling the vehicle to move backward. Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 14 of 26

AURLTX101 Diagnose and repair light vehicle manual transmissions 32. What movement occurs inside a transmission when the vehicle is stopped, the engine is running, and the transmission is in neutral? Fill in the Missing Words 33. Place the missing word to complete the following statement about transaxle power flow using the following words. Missing Words: differential, gear, output, rotate, selected, shaft, shift, synchronizer When first gear is ______ selected_________, the first/second gear synchronizer engages with first gear. Because the synchronizer hub is splined to the ______ output_________ shaft, first gear on the input shaft drives its mating gear (first gear) on the output shaft. This causes the output shaft to ________ rotate_______ at the ratio of first gear and to drive the differential ring ______ gear_________ at that same ratio. As the other forward gears are selected, the appropriate ______ shift_________ fork moves to engage the selected ______ synchronizer_________ with the gear. Because the synchronizer’s hub is splined to the output shaft, the desired gear on the input shaft drives its mating gear on the output ______ shaft_________. This causes the output shaft to rotate at the ratio of the selected gear and drive the ______ differential_________ ring gear at that same ratio. Multiple choice. Circle all the correct answer 34. Transfer cases power flow, two-wheel drive – high range, the transfer selector lever is moved to the 2H position, the front sleeve is moved ________. This connects the transmission main output shaft to the transfer rear output shaft. In the transfer case, this is a straight-through drive. A. Forwards. B. Back. C. Sideways. D. None of these answers are correct. Multiple choice. Circle all the correct answer 35. Transfer cases power flow, four-wheel drive – high range, the ________ sleeve is moved forwards. This connects the chain drive sprocket to the rear output shaft. Drive is taken through the transfer chain to the sprocket on the front output shaft. A. Front. B. Rear. C. Left. D. Right. Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 15 of 26

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AURLTX101 Diagnose and repair light vehicle manual transmissions True or False question 36. In a conventional transmission, the speed gears freewheel around the mainshaft until they are locked to it by the synchronizer. ☐ True or ☐ False True or False question 37. During a gear shift, the blocking ring is pushed into the speed gear cone by the shifter plates or keys. ☐ True or ☐ False True or False question 38. The blocking ring eliminates friction between the cone-shaped surface on the speed gear and the synchronizer assembly. ☐ True or ☐ False Multiple choice. Circle all the correct answer 39. When fourth gear is selected on a five-speed manual transmission, the synchronizer couples the ______. A. Fourth speed gear to the mainshaft. B. Clutch [input] gear to the mainshaft. C. Both “fourth speed gear to the mainshaft” and “clutch [input] gear to the mainshaft”. D. Neither “fourth speed gear to the mainshaft” nor “clutch [input] gear to the mainshaft”. Multiple choice. Circle all the correct answer 40. Which of the following is not part of a synchronizer assembly? A. Blocking ring. B. Synchronizer hub. C. Shifting plates or keys. D. Interlock pin. 41. What is the function of a synchronizer? The function of a synchronizer (also known as a synchromesh or synchronizer assembly) in a manual transmission is to facilitate smooth and seamless engagement of gears during gear shifts. It achieves this by equalizing the speeds of the gears being engaged, allowing them to mesh without clashing or grinding. The synchronizer's primary function is to synchronize the speeds of the gears being shifted, allowing for smooth engagement without grinding or clashing. This enhances the longevity of the transmission and improves the overall driving experience by making gear shifts seamless and comfortable for the driver. Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 16 of 26

AURLTX101 Diagnose and repair light vehicle manual transmissions 42. Explain the role of shift rails and shift forks in the operation of transmissions and transaxles. Shift rails are rods or shafts that run parallel to the main input and output shafts of the transmission or transaxle. They are responsible for guiding the movement of shift forks, which in turn control the position of the gears on the shafts. Shift forks are movable components that slide along the shift rails. Each fork is designed to engage with a specific gear on the transmission's main shaft or countershaft. When the driver shifts gears using the gear shift lever, the movement of the shift fork causes the selected gear to move into its desired position, either engaging or disengaging from its mating gear. Shift rails and shift forks work together to translate the driver's gear selection into the physical movement of gears within the transmission or transaxle. Their precise coordination ensures that the selected gear is engaged smoothly and accurately, facilitating efficient power transfer and providing the driver with control over the vehicle's speed and torque. Multiple choice. Circle all the correct answer 43. When the 1-2 shift rail is moved into first gear, the 3-4 and 5-R shift rails are prevented from moving by the ______. A. Detent ball and spring. B. Shifter plate. C. Shift fork. D. Interlock pin. True or False question 44. Cables are used to connect the shift lever to the transmission. ☐ True or ☐ False True or False question 45. Rods are used to connect the shift lever to the transmission. ☐ True or ☐ False 46. Nearly all part-time 4WD systems have a transfer case that not only allows for 2WD or 4WD, but also offers? Nearly all part-time 4WD systems have a transfer case that not only allows for 2WD or 4WD operation but also offers a low-range gear ratio for enhanced off-road capability. This low-range gear ratio provides increased torque Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 17 of 26

AURLTX101 Diagnose and repair light vehicle manual transmissions output at the wheels, allowing the vehicle to handle challenging terrain and obstacles more effectively. It's particularly useful for slow-speed crawling and steep inclines where additional torque is needed. True or False question 47. In a part-time four-wheel drive system, 4WD [4 HI or 4 LO] should not be selected when the vehicle is traveling on dry surfaces. ☐ True or ☐ False Multiple choice. Circle all the correct answer 48. Which of the following components is (are) NOT found in a transfer case? A. Drive chain. B. Shifter forks. C. Blocking rings. D. Planetary gearset. Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 18 of 26

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AURLTX101 Diagnose and repair light vehicle manual transmissions Multiple choice. Circle all the correct answer 49. Full-time four-wheel drive _____. A. Is never disconnected. B. Must be disconnected by a technician. C. Is disconnected during off-road use only. D. Is used with manual transmissions only. Multiple choice. Circle all the correct answer 50. A 4WD vehicle may be shifted into four-wheel drive _____. A. Only while stopped. B. Only while moving. C. At any time. D. Only according to the owner's manual instructions. Multiple choice. Circle all the correct answer 51. _____ are often used to link the input and output shafts in a transfer case and serve as a link that does not influence gear ratios. A. Drive chains. B. Sprockets. C. Locking hubs. D. Pin and rocker joints Multiple choice. Circle all the correct answer 52. Which of the following components is NOT part of a viscous clutch assembly? A. Sealed drum. B. Hydraulic piston. C. Externally splined steel plates. D. Internally splined steel plates. Multiple choice. Circle all the correct answer 53. In a viscous clutch, when the silicone fluid is heated, it ______. A. Becomes a very thin fluid. B. Boils to a vapour. C. Thickens to a solid mass. D. Stiffens. Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 19 of 26

AURLTX101 Diagnose and repair light vehicle manual transmissions Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 20 of 26

AURLTX101 Diagnose and repair light vehicle manual transmissions Multiple choice. Circle all the correct answer 54. In an automatic AWD vehicle, normally one axle receives all the torque; when slippage occurs, 50 percent of the torque can be sent to the other axle by _____ means. A. Hydraulic. B. Mechanical. C. Electrical. D. All answers are correct. True or False question 55. If a noise stops with the engine at idle and the clutch disengaged, the noise is probably coming from the inside of the transmission. ☐ True or ☐ False Multiple choice. Circle all the correct answer 56. A clicking noise during transmission/transaxle operation may be an indication of ______. A. Worn main shaft (input shaft) bearings. B. Faulty synchronizer operation. C. Failed oil seals. D. Worn, broken, or chipped gear teeth. True or False question 57. A rough growling noise occurs when the engine is running, the transmission is in neutral, the clutch is engaged, and the vehicle is not moving. The input shaft bearing may be faulty. ☐ True or ☐ False Multiple choice. Circle all the correct answer 58. Gold-coloured particles in the transmission fluid are an indication of worn ______. A. Blocking rings. B. Gear teeth. C. Roller bearings. D. Shifter forks. Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 21 of 26

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AURLTX101 Diagnose and repair light vehicle manual transmissions Multiple choice. Circle all the correct answer 59. A growling noise that occurs when the transaxle is in neutral, the vehicle is not moving, the engine is running, and the clutch is engaged is most likely caused by ______. A. Clutch pilot bearing. B. Differential carrier bearing. C. Output shaft bearing. D. Input shaft bearing. True or False question 60. A rough growling noise occurs when the vehicle is moving and the transmission is in forward or reverse gears. The noise is not heard when the transmission is in neutral. The output or mainshaft bearings may be faulty. ☐ True or ☐ False 61. What do shiny metallic particles in the oil indicate? Shiny metallic particles in oil can indicate various types of mechanical wear occurring within the engine or transmission. The presence of these particles often suggests that metal components are experiencing friction, abrasion, or deterioration. True or False question 62. A plugged transmission vent may cause a seal to leak. ☐ True or ☐ False Multiple choice. Circle all the correct answer 63. An excessively low lubricant level will most likely cause ______. A. Gear clash. B. Hard shifting. C. Gear lockup or seizure. D. Gear jump-out. Multiple choice. Circle all the correct answer 64. Using a lubricant that is thicker than service manual specifications can lead to ______. A. Gear jump-out. B. Hard shifting. Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 22 of 26

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AURLTX101 Diagnose and repair light vehicle manual transmissions C. Gear lockup. D. Gear slippage. Multiple choice. Circle all the correct answer 65. A poorly adjusted shift linkage can cause which of the following problems? A. Gear clash. B. Hard shifting. C. Jumping out of gear. D. All answers are correct. Multiple choice. Circle all the correct answer 66. Which of the following will NOT cause gear clash? A. Incorrect lubricant. B. Incorrect clutch adjustment. C. Worn countergear bearings. D. Worn synchronizer blocking rings. Multiple choice. Circle all the correct answer 67. An engine support fixture is used to hold the engine in place while removing a ______. A. FWD transaxle. B. RWD transmission. C. Both “FWD transaxle” and “RWD transmission”. D. Neither “FWD transaxle” nor “RWD transmission”. True or False question 68. On some vehicles, the engine and transmission must be removed as a unit. ☐ True or ☐ False 69. Explain the four [4] steps to replace the rear extension housing seal on an RWD manual transmission. 1 Step 1: Preparation and Safety 2 Step 2: Access and Removal 3 Step 3: Seal Removal 4 Step 4: Seal Replacement and Reassembly Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 23 of 26

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AURLTX101 Diagnose and repair light vehicle manual transmissions True or False question 70. Manual transmission/transaxle internal shift linkage should be adjusted if a shift linkage problem is identified. ☐ True or ☐ False Fill in the Missing Words 71. Place the missing word to complete the following statement about linkage adjustment using the following words. Missing Words: adjustments, Linkage, provision, service Transmissions with internal linkage have no ________ provision_______ for adjustments. However, external linkages can be adjusted. ______ Linkage_________ are adjusted at the factory but worn parts may make adjustments necessary. Also, after a transmission has been reassembled, ______ Adjustments_________ may be necessary. To begin the adjustment procedure, raise the car and support it on jack stands. Then follow the procedure given in the _____ service__________ information. 72. Consider the various post repair checks that you would make during a road test on the vehicle manual transmissions? During a road test after repairing a vehicle with a manual transmission, several post-repair checks are important to ensure that the transmission is functioning properly and that the repair was successful. Here are some key checks to make during the road test: Gear Engagement and Shifting, Clutch Operation, Synchronization, Clutch Slippage, Neutral and Idling, Vibration and Noise, Reverse Gear, Shift Linkage, Gearing, Final Checks, Fluid Leaks, Warning Lights , Multiple choice. Circle all the correct answer 73. Which source of information will give you the most detail about diagnosing and repairing light vehicle manual transmissions on the vehicle you are working on? A. Workshop manual. B. Owner’s manual. C. Google. D. Textbooks. 74. Why is it very important that the Job Card is completed correctly? Completing the Job Card correctly is vital for maintaining accurate records, facilitating communication, ensuring quality, supporting billing and warranty claims, and ultimately providing a high level of customer service. It's a Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 24 of 26

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AURLTX101 Diagnose and repair light vehicle manual transmissions foundational practice in the automotive repair industry that contributes to professionalism, efficiency, and accountability. True and False 75. An automotive technician must adhere to workshop safety guidelines and procedures when using all tools and equipment. ☐ True or ☐ False True and False 76. An automotive technician is required to document the work that was performed on a vehicle. Writing or typing in the description of the steps performed during the diagnosis of the vehicle should be worded as if the technician is talking to the customer. ☐ True or ☐ False True and False 77. Inspect your tools for cracks, broken parts, or other dangerous conditions before you use them. Never use broken or damaged tools. ☐ True or ☐ False True and False 78. For best results and long tool life, each tool used must be cleaned and checked before placing it back into the toolbox. ☐ True or ☐ False Multiple Choice question. Select the correct answer. 79. Lockout/tagout practices and procedures are intended to reduce the risk of automotive technicians’ inadvertently using tools, equipment or materials that have been determined to? A. Be unsafe or potentially unsafe. B. That are in the process of being serviced. C. Both “ Be unsafe or potentially unsafe” and “That are in the process of being serviced” . D. Neither “Be unsafe or potentially unsafe” and “That are in the process of being serviced”. True and False Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 25 of 26

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AURLTX101 Diagnose and repair light vehicle manual transmissions 80. Disposing of excess oil, can be dispose into their correct sealed recycling drum. ☐ True or ☐ False True and False 81. Second-hand manual transmissions components and manual transmissions assemblies etc that are in good condition can be reused on the other vehicles of the same make and model? ☐ True or ☐ False True and False 82. An automotive technician must adhere to workshop safety guidelines and procedures and follow the manufactures procedures in the workshop manual when diagnosing faults in manual transmissions. ☐ True or ☐ False 83. You are diagnosing a fault in the manual transmission on Mitsubishi Pajero and require the lubrication and quantities specifications. Referring to the Mitsubishi Pajero “Manual Transmission” Workshop Manual, locate and interpret the lubrication and quantities specification for the manual transmission and transfer case: Manual Transmission: 75W/90 Quantity: 2.5L Transfer Case: 75W/90 Quantity: 2.3L 84. You are diagnosing a fault in the manual transmission on Mitsubishi Pajero and require the torque specifications for the drain and filler plug. Referring to the Mitsubishi Pajero “Manual Transmission” Workshop Manual, locate and interpret the lubrication and torque specifications for the drain and filler plug: Drain Plug: 70NM Filler Plug: 70MN Multiple Choice question. Select the correct answer. 85. A work order is selected or assigned to a service technician who then performs the listed tasks. The work order should be written so that the technician knows exactly what needs to be done. However, if there is any doubt, the technician should clarify the needed task with the ________ or the person who spoke to the customer. A. Service advisor . B. Service technician. C. Spare parts manager. D. New car sales manager. Document Name: Student Written Questions – AURLTX101 Version: 2.0 © Strathfield College | RTO Code: 91223 | CRICOS Code: 02736K Page Sequence: Page 26 of 26

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AURLTX101 Task 1

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