Auto 111- Final Exam Notes

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Mechanical Engineering

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Jan 9, 2024

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A UTO 111 – D RIVELINES & T RANSMISSIONS N OTES & R EVIEW Q UESTIONS W / A NSWERS Notes Manual Transmissions Purpose: to change torque ratio Why? ● Engines work best between 1,500 and 2,000 rpm ○ After 2,500 rpm, engine does not put out more power Higher gear = ● Less torque ● Less energy ● Better fuel mileage 1st Gear has the most rear wheel torque 5th Gear ● Low gear ratio ● Overdrive ● Best fuel economy **1st gear & reverse have similar gear ratios (1st gear > ratio than reverse). Backing up doesn’t need speed, but may need high torque **Angle cuts on gears (helical gear) allow them to be quiet ➔ Reverse are straight cut gears (hence noise)

Torque x Speed = Power *Gears on counter shaft are fixed to counter shaft *Fourth Gear usually “direct drive” aka 1:1 ratio ➔ Straight line on a power flow diagram

Gear Ratios NV1500 Manual Transmission (S-10 Pickups) 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear Reverse Ratios 3.96 2.37 1.49 1.00 0.83 3.54 Saturn SCI Transmission Ratio= Driven Gear (output shaft)/Drive Gear 1st Gear 2nd gear 3rd Gear 4th Gear 5th Gear 6th Gear 39/12 39/20 34/29 30/37 26/43 38/13 Ratio 3.25 1.95 1.17 0.81 0.60 2.92 Rear Differential = 65/16……….. Ratio = 4.06 Ratio Explained 3.96:1 3.96 turns of input shaft = 1 turn of output shaft Final Drive = Gear Ratio x Rear Differential Ratio

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Drive Shafts Ductile Material ● Break @ 90 degrees (in half) ● “Soft material” ● Ex: drive shaft Brittle Material ● Break @ 45 degree angle ● Ex: axle **Aluminum Driveshafts are larger than steel to allow for more strength with lower weight** U-joint minimum angle: 0.5 degrees ● Preload to allow bearing rotation U-joint maximum angle: based on driveshaft RPM (3 degrees @6,000 RPM; redline above 6k) Angles RPM Angle 5,000 3.2 degrees 4,500 3.7 degrees 4,000 4.2 degrees 3,500 5.0 degrees 3,000 5.8 degrees 2,500 7.0 degrees 2,000 8.7 degrees 1,500 11.5 degrees End with tire is a fixed, constant velocity joint Other end is plunge joint (goes in/out to shorten/lengthen)

Clutch Clutch : engages & disengages engine from transmission Types ● Friction clutch ● Centrifugal clutch ● Vacuum clutch ● Semi-centrifugal clutch ● Conical spring clutch (diaphragm clutch) ● Dog & spline clutch ● Electromagnetic clutch ● Hydraulic clutch ● Freewheel unit (one way clutch) ○ Sprag in an automatic transmission **When disengaged (foot to floor), the clutch plate (disc) does not move** Clutch Diagram (Expanded) *Clutch set up is like a sandwich *If no springs on clutch (marcel springs), they will be on the flywheel *When diaphragm spring is up (elbows up), clutch is disengaged

Review Questions Chapter 102 1. Which type of automotive bearing can withstand radial and thrust loads, yet must be adjusted for proper clearance? a. Roller Bearing b. Tapered Roller Bearing c. Ball Bearings d. Needle Roller Bearing 2. Most sealed bearings used on the front wheels of front-wheel-drive vehicles are usually which type? a. Roller bearing b. Single tapered roller bearing c. Double-row ball bearing d. Needle roller bearing 3. The bearing grease most often specified is rated NLGI ________. a. #00 b. #0 c. #1 d. #2 4. Technician A says that a defective wheel or axle bearing often makes a growling or rumbling noise. Technician B says that a defective wheel or axle bearing often makes a noise similar to a tire with an aggressive mud or snow design. Which technician is correct? a. Technician A only b. Technician B only c. Both Technicians A and B d. Neither Technician A nor B 5. After a non-drive-wheel bearing has been properly adjusted, the wheel should have how much end play? a. Zero b. 0.001 to 0.005 inch c. 0.10 to 0.30 inch d. 1/16 to 3/32 inch

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6. What part(s) should be replaced when servicing a wheel bearing on a non-drive wheel? a. The bearing cup b. The grease seal c. The cotter key d. Both the grease seal and cotter key 7. Two technicians are discussing differentials. Technician A says all differentials are vented. Technician B says that a clogged vent can cause the rear axle seal to leak. Which technician is correct? a. Technician A only b. Technician B only c. Both Technicians A and B d. Neither Technician A nor B 8. Which type of drive axle would a heavy-duty truck tractor have? a. Full-floating b. Semi-floating c. Three-quarter floating d. Any of these 9. The differential cover must be removed before removing the rear axle on which type of axle? a. Retainer plate b. C-lock c. Press fit d. Welded tube 10. On a bearing that has been shock loaded, the race (cup) of the bearing can be dented. This type of bearing can be dented. This type of bearing failure is called ________. a. Spalling b. Arcing c. Brinelling d. Fluting

Chapter 126 1. What is the purpose and function of a clutch? a. To disconnect the engine from the transmission/transaxle b. To connect and transmit engine torque to the transmission/transaxle c. To dampen and absorb engine impulses and drive train vibration d. All of the above 2. What is the purpose and function of a dual-mass flywheel? a. Dampen engine vibrations b. Increase the torque of the engine c. Decrease the amount of force needed to depress the clutch pedal d. Eliminates the need for a throwout (release) bearing 3. Which part does not rotate when the engine is running and the clutch pedal is depressed? a. Clutch disc b. Pilot bearing c. Pressure plate d. Flywheel 4. What part is often not used on a front-wheel-drive vehicle with a manual transaxle? a. Flywheel b. Throwout (release) bearing c. Clutch fork d. Pilot bearing 5. What should be done to check to see if a clutch is slipping? a. Release the clutch at idle speed in gear to see if it causes the engine to stall b. Rapidly accelerate the vehicle in first or second gear and rapidly shift the vehicle into a higher gear c. Shift from first to reverse with the clutch pedal depressed and see if it goes into gear d. Place shifter into second gear and start the engine with the clutch pedal depressed

6. A manual transmission is difficult to shift or get into gear, especially reverse. Technician A says that the clutch may not be fully releasing. Technician B says that too much clutch pedal freeplay could be the cause. Which technician is correct? a. Technician A only b. Technician B only c. Both technicians A and B d. Neither technician A nor B 7. Before removing the transmission to replace a clutch, the ________ must be disconnected. a. Battery b. Shift linkage c. Reverse light switch wires d. All of the above 8. Technician A says that too much clutch pedal freeplay can cause the clutch to slip during acceleration. Technician B says that too little clutch pedal freeplay can cause the clutch to slip. Which technician is correct? a. Technician A only b. Technician B only c. Both technicians A and B d. Neither technician A nor B 9. What needs to be done before attaching the pressure plate to the flywheel? a. Align the clutch disc to the pilot bearing b. Have an assistant depress the clutch pedal c. Bleed the hydraulic clutch d. Adjust the freeplay 10. Two technicians are discussing bleeding a hydraulic clutch. Technician A says to open the bleeder and allow the fluid to gravity bleed. Technician B says to have an assistant slowly depress the clutch pedal as the bleeder valve is opened at the slave cylinder to bleed the air out of the system. Which technician is correct? a. Technician A only b. Technician B only c. Both technicians A and B d. Neither technician A nor B

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Chapter 128 1. Two technicians are discussing a dented driveshaft. Technician A says that it should be repaired. Technician B says that it should be replaced. Which technician is correct? a. Technician A only b. Technician B only c. Both technicians A and B d. Neither Technician A nor B 2. All driveshafts are balanced to within ____________. a. One oz b. 10 oz c. 15 oz d. 0.5% of the driveshaft weight 3. Drive axle shafts are also called ______. a. Double-Cardan shafts b. Half shafts c. Driveshafts d. Propeller shafts 4. The name most often used to describe the universal joints on a conventional rear-wheel drive vehicle driveshaft is _________. a. Trunnion b. Cardan c. CV d. Spider 5. A rear-wheel-drive vehicle vibrates when first accelerating from a stop. The vibration is less noticeable at higher speeds. The most likely cause is _________. a. Driveshaft unbalance b. Excessive U-joint working angles c. Unequal U-joint working angles d. Brinelling of the U-joint

6. The maximum difference between the front and rear working angle of a driveshaft is ___. a. ¼ degree b. ½ degree c. 1 degree d. 3 degrees 7. Which series U-joint has the greatest torque capacity? a. 1260 b. 1310 c. 1350 d. 1480 8. Two technicians are discussing torque steer on a front wheel drive vehicle. Technician A says that equal-length drive axle shafts help reduce torque steer. Technician B says that equal drive axle shaft angles help reduce torque steer. Which technician is correct? a. Technician A only b. Technician B only c. Both Technicians A and B d. Neither Technician A nor B 9. The outer CV joints used on front-wheel-drive vehicles are ________. a. Fixed type b. Plunge type c. Double Cardan d. Either B or C depending on the vehicle 10. The proper grease to use with a CV joint is ________. a. Black chassis grease b. Dark blue EP grease c. Red moly grease d. The grease that is supplied with the boot kit

Chapter 129 1. Two technicians are discussing U-joints. Technician A says that a defective U-joint could cause a loud clunk when the transmission is shifted between drive and reverse. Technician B says a worn U-joint can cause a clicking sound only when driving the vehicle in reverse. Which technician is correct? a. Technician A only b. Technician B only c. Both Technicians A and B d. Neither Technician A nor B 2. A Cardan-type U-joint may require what tool(s) to replace? a. A special tool b. A torch c. A press or vice d. May require any of the above 3. Incorrect or unequal U-joint working angles are most likely to be caused by _______. a. A bent driveshaft b. A collapsed engine or transmission mount c. A dry output shaft spline d. Defective or damaged U-joints 4. Front and rear driveshaft U-joint working angles should be within _______ degrees of each other. a. 0.5 b. 1.0 c. 3.0 d. 4.0 5. What could be a symptom of a defective U-joint? a. A vibration at highway speed b. A clicking sound c. A clunking sound d. Any of the above

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6. A defective outer CV joint will usually make a _________. a. Rumbling noise b. Growling noise c. Clicking noise d. Clunking noise 7. The last step after installing a replacement CV boot is to ______. a. “Burp the boot” b. Lubricate the CV joint with chassis grease c. Mark the location of the boot on the drive axle shaft d. Separate the CV joint before installation 8. What needs to be removed to replace a drive axle shaft from a front-wheel-drive vehicle? a. Tie rod end b. Lower control arm or ball joint c. Hub nut d. All of the above 9. The splines of the driveshaft yoke should be lubricated to prevent _______. a. A vibration b. Spline bind c. Rust d. Transmission fluid leaking from the extension housing 10. What is recommended to install the drive axle shaft to avoid damage to the hub bearing? a. Torque wrench b. Cordless impact wrench c. Pickle fork d. Hub bearing puller

Chapter 130 1. Inside the drive axle of a rear-wheel-drive vehicle, the ring gear is attached to the _____. a. Drive shaft b. Pinion gear c. Differential gear d. Spider gear 2. A limited-slip differential has ______ on the side gears that a standard (open) differential does not have. a. Sliders b. Clutch packs c. Slip teeth d. Slipper rings 3. A collapsible spacer is used in some differentials to provide ______. a. A lubrication path to the drive pinion bearing b. The proper preload for the side bearings c. The proper preload for the drive pinion bearings d. The proper amount of slippage in a limited-slip differential 4. The shim used on a drive pinion gear is used to properly position the gear so that it can correctly mesh with the _______. a. Ring gear b. Side gear c. Differential pinion gear d. Both B and C 5. Technician A says that the convex side of the ring gear is the drive side on most rear axle assemblies. Technician B says that the convex side of the ring gear is the drive side on differentials used in the front of many four wheel drive vehicles. Which technician is correct? a. Technician A only b. Technician B only c. Both Technicians A and B d. Neither Technician A nor B

6. A growling sound is heard from the rear of a rear wheel drive vehicle during cornering only. Technician A says that defective rear axle bearings may be the cause. Technician B says that defective drive pinion bearings may be the cause. Which technician is correct? a. Technician A only b. Technician B only c. Both Technicians A and B d. Neither Technician A nor B 7. Technician A says that if the backlash is okay, than the side bearing preload is also okay. Technician B says that a ring gear tooth pattern check will indicate if the drive pinion depth is correct. Which technician is correct? a. Technician A only b. Technician B only c. Both Technicians A and B d. Neither Technician A nor B 8. The backlash exceeds specifications. The technician should position the ring gear ____. a. Closer to the drive pinion gear b. Farther from the drive pinion gear c. Toward the heel d. Toward the toe 9. The backlash is less than specifications (too low). This will cause the ring gear tooth platform to be too close to the _______. a. Heel b. Flank c. Toe d. Face 10. Two technicians are discussing which lubricants are used in a limited-slip differential. Technician A says to use SAE 80W-140. Technician B says that most vehicle manufacturers usually specify SAE 80W-90 be used with or without special limited slip additives. Which technician is correct? a. Technician A only b. Technician B only c. Both Technicians A and B d. Neither Technician A nor B

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Chapter 132 1. A vibration or noise can be caused by all of the following except _____. a. Exhaust system b. Wheels and tires c. Incorrect driveshaft angles d. Exhaust smoke 2. An engine related vibration can be best detected by performing a ______. a. Neutral run-up test b. Test drive on a rough road c. Hard acceleration from a stop d. Any of the above 3. Driveline vibrations due to a bent or out-of-balance driveshaft on a rear-wheel-drive vehicle usually produce a vibration that is _____. a. Felt in the steering wheel b. Seen as a vibrating dash or hood c. Felt in the seat or all over the vehicle d. Felt by the rear passenger only 4. A vibration is felt in the steering wheel during braking only. A common cause of the vibration is ______. a. Worn idler arm b. Out-of-balance front tires c. Loose or defective wheel bearing(s) d. Warped or nonparallel front disc brake rotors 5. The rolling circumference of both tires on the same axle of a four-wheel-drive vehicle should be within _______. a. 0.1 inch (2.5mm) b. 0.3 inch (7.6mm) c. 0.6 inch (15mm) d. 1.2 inch (30mm)

6. Wheel/tire imbalance is the most common source of vibrations that occur in what frequency range? a. 5-20 Hz b. 20-50 Hz c. 50-100 Hz d. 100-150 Hz 7. The maximum allowable driveshaft runout is ______. a. 0.030 inch (0.8mm) b. 0.10 inch (2.5 mm) c. 0.50 inch (13 mm) d. 0.015 inch (0.4mm) 8. Measuring driveshaft U-joint phasing involves checking to see if the front and rear U-joints are ______ with each other. a. Parallel b. Crossed c. At an angle d. Opposite phased 9. A driveshaft can be checked for proper balance by marking the circumference of the shaft in four places and running the vehicle drive wheels to spot the point of imbalance using a _____. a. Reed tachometer b. Strobe light c. Electronic vibration analyzer d. Scan tool 10. A defective clutch release (throw-out) bearing is usually heard when the clutch is _____. a. Engaged in neutral b. Disengaged in a gear c. Depressed to take up any freeplay d. Engaged in first gear or reverse