KSKV Transmission System Repair

December Edition 2013
MINISTRY OF EDUCATION, MALAYSIA

VOCATIONAL COLLEGE STANDARD CURRICULLUM
COURSE INFORMATION
COURSE NAME
TRANSMISSION SYSTEM REPAIR
CODE NAME
GMA 303
LEVEL
1 SEMESTER 3
CREDIT UNIT
3.0
CONTACT HOUR
FACE TO FACE
: 5.0 HOURS/WEEK (1T+4P)
NON FACE TO FACE
COURSE TYPE
VOCATIONAL
PRE-REQUISITE
CORE REQUISITE
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COURSE OUTCOMES
At the end of the course, the students should be able to:
Overhaul manual gear box

Overhaul transfer box
Repair power take off assembly
Overhaul differential assembly
Overhaul final drive unit
Overhaul planetary gear system
Overhaul torque converter
Overhaul power shift transmission
COURSE DESCRIPTION
This unit identifies the competence required to overhaul manual gear box using hand tools set, gear box service manual, puller, lifting
equipment, measuring equipments, prussian blue, gasket, transmission oil, torque wrench and new oil seal so that gear box service manual
obtained, manual gear box removed, gear box components dismantled, gear box components checked, gear box components assembled, manual
gear box installed and gear box operations tested in accordance with manufacturers specification.
This unit identifies the competence required to overhaul transfer box using hand tools set, transfer box service manual, puller, lifting equipment,
measuring equipments, prussian blue, gasket, transmission oil, torque wrench and new oil seal so that transfer box service manual obtained,
manual transfer box removed, transfer box components dismantled, transfer box components checked, transfer box components assembled,
manual transfer box installed and transfer box operations tested in accordance with manufacturers specification.
This unit identifies the competence required to Repair power take off assembly using hand tools set, power take off service manual, puller,
lifting equipment, measuring equipments, Prussian blue, gasket, transmission oil, torque wrench and new oil seal so that power take off service
manual obtained, power take off assembly removed, power take off components dismantled, checked and assembled, power take off assembly
installed and power take off operations tested in accordance with manufacturers specification.
This unit identifies the competence required to overhaul differential assembly using hand tools set, hydraulic press, dial testing indicator (DTI),
marking blue, differential assembly service manual, differential oil, gasket, solvent and grease so that differential assembly service manual
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obtained, differential assembly removed, differential assembly dismantled, differential components checked, differential components
assembled, differential assembly installed and differential assembly operations tested in accordance with manufacturers specification
This unit identifies the competence required to overhaul final drive unit using hand tools set, transfer box service manual, special tools, puller,
grease, gasket, lubrication oil and solvent so that final drive service manual obtained, final drive assembly removed, final drive components
dismantled, final drive parts and components checked, final drive components assembled, final drive assembly installed and final drive
operations tested in accordance with manufacturers specification
This unit identifies the competence required to overhaul planetary gear system using hand tools set, planetary gear system service manual,
jack and support stand and lubrication oil so that planetary gear system service manual identified, planetary gear system removed, planetary
gear assembly dismantled, planetary gear components checked, planetary gear assembly assembled, planetary gear system installed and
planetary gear operations tested in accordance with manufacturers specification
This unit identifies the competence required to overhaul torque converter using hand tools set, torque converter service manual, dial testing
indicator, torque wrench, torque converter oil, gasket and log book so that torque converter service manual obtained, torque converter assembly
removed, torque converter components dismantled, torque converter components checked, torque converter components assembled, torque
converter assembly installed and torque converter performance tested in accordance with manufacturers specification.
This unit identifies the competence required to overhaul power shift transmission using hand tools sets, power shift transmission service
manual, special tools, lifting equipment, puller, torque wrench, measuring equipment, and log book so that power shift transmission service
manual obtained, power shift transmission assembly removed, power shift transmission components dismantled, components defect inspected,
power shift transmission components assembled, power shift transmission assembly installed and power shift transmission performance tested
in accordance with manufacturers specification
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CONTENT AND LEARNING STANDARDS
PROGRAM
AGRICULTURAL MECHANIZATION
COURSE NAME
CODE NAME
GMA 303
COMPETENCY
CONTENT
STANDARD
performance
1. OVERHAUL
MANUAL GEAR
BOX
Hrs
LEARNING STANDARD
performance , condition
1.1. Obtain Gear Box Service Manual
1.2. Remove Manual Gear Box
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PERFORMANCE CRITERIA
performance,condition, standard
1.1.1
Explain sources gear box service manual in

according standard of service manufactured
1.1.2
Explain procedures of acquiring gear box service
manual in according standard of service
manufactured
1.1.3
Identify gear box service manual in according with
standard of service manufactured
1.1.4
Determine source of gear box service manual in
according with standard of service manufactured
1.1.5
Acquire gear box service manual in according with
1.1.6
Interpret gear box service manual in according with
1.1.7
Identify precaution warnings given by service
manual in according with standard service
manufactured
1.2.1
List types of lifting transmission equipment
1.1.1. Explain procedure of removing transmission unit
with standard service manufactured.
1.1.2. Unscrew transmission bolt with standard service
manufactured.
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CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
1.1.3. Moving out transmission unit with standard service
manufactured.
1.1.4. Disconnect external attachment with standard
service manufactured.
1.1.5. Support transmission unit with wheel jack with
standard service manufactured.
1.1.6. Unscrew transmission bolt with standard service
manufactured.
1.1.7. Move out transmission unit with standard service
manufactured.
1.1.8. Use tools or equipment accordance with user tools
manual standard.
1.3. Dismantle Gear Box

Components
1.1.9. State gear box main components with standard

1.1.10. Explain procedure of disassembling gear box parts
and components with standard service
manufactured.
1.1.11. List types of solvent with standard service
manufactured.
1.1.12. Identify soaking parts and components with solvent
with standard service manufactured.
1.1.13. Disassemble transmission front cover with standard
1.3.1
Disassemble gear box parts and components such
as
Shifting fork assembly

Interlocking mechanism
Counter shaft assembly
Lay shaft assembly
1.1.14. Soak parts and components with solvent with

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CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
1.4. Check Gear Box Components
standard service manufactured.
1.1.15. Determine type of solvent with standard service
manufactured.
1.1.16. Use non-flammable non-toxic proprietary solvents as
cleaning agents with standard service manufactured.
1.4.1
State types of gear box components defect
accordance with service manual
1.4.2
Define checking gear box parts and components
procedure accordance with service manual
1.4.3
Explain measuring teeth contact accordance with
service manual
1.4.4
Determine types of gear box defect accordance with
service manual
1.4.5
Inspect gearbox component defect such as
1.4.6
1.4.7
1.5. Assemble Gear Box
Components
1.5.1
1.5.2
1.5.3
1.5.4
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Gear crack or worn-out

Synchronizer units wear or crack
Roughness of bearing
Oil seal broken
Measure teeth contact accordance with service
manual
Apply conscientious when measure wear parts
State operation of gear box assembly accordance
with service manual
List method of reassemble gear box parts and
components accordance with service manual
Identify technique of reassemble transmission front
cover accordance with service manual
State changing gear box defect parts and
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CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
1.5.5
1.5.6
1.5.7
1.5.8
1.5.9
1.6. Install Manual Gear Box
1.6.1
1.6.2
1.6.3
1.6.4
1.6.5
1.6.6
1.6.7
1.6.8
1.6.9
1.6.10
1.6.11
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Determine operation of gear box assembly

Change gear box defect parts and components
Apply method of reassemble gear box parts and
Reassemble transmission front cover accordance
with service manual
Meticulous when assembling gearbox parts and
List function of lifting equipment accordance with
service manual
List types of gear box oil accordance with service
manual
State function ability of gear box accordance with
service manual
Prepair lifter to place transmission assembly at
location accordance with service manual
List checking function ability of gear box
Explain method of tightening transmission bolt
Use lifter to place transmission assembly at location
Slot transmission shaft accordance with service
manual
Tighten transmission bolt accordance with service
manual
Connect external attachments accordance with
service manual
Top up gear box oil accordance with service manual
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CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
1.6.12
1.6.13
1.7. Test Gear Box Operations
1.7.1
1.7.2
1.7.3
1.7.4
1.7.5
1.7.6
1.7.7
1.7.8
1.7.9
1.7.10
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Inspect function ability of gear box accordance with

service manual
Assemble with meticulous when fixing gearbox
assembly accordance with service manual
Explaine engine starting procedure accordance with
service manual
Describe leakage inspect procedure accordance
with service manual
State gear box testing method accordance with
service manual
List Updating log book accordance with service
manual
State checking all level of gear accordance with
service manual
Apply engine starting procedure accordance with
service manual
Inspect engine leakage accordance with service
manual
Apply gear box testing method accordance with
service manual
Test all level of gear accordance with service
manual
Update log book accordance with service manual
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PROGRAM
COURSE NAME
CODE NAME
GMA 303
COMPETENCY
CONTENT
STANDARD
performance
2.
Overhaul
transfer box
Hrs
LEARNING STANDARD
2.1. Obtain Transfer Box Service
Manual
2.2. Remove Transfer Box Assembly
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2.1.1
Identify Sources of transfer box accordance with

manufactured specifications
2.1.2
Explain procedures of acquiring transfer box service
manual accordance with manufactured
specifications
2.1.3
Determine source of transfer box service manual
accordance with manufactured specifications
2.1.4
Acquire transfer box service manual accordance
with manufactured specifications
2.1.5
Interpret transfer box service manual accordance
with manufactured specifications
2.1.6
Use carefully read and observe precaution warnings
given by manual
1.1.17. List types of lifting equipment accordance with
service manual
2.2.1
List Method of removing transmission unit
2.2.2
Explain technique of unscrew transfer box bolt
2.2.3
Moving out transfer box unit accordance with
service manual
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CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
2.2.4
2.2.5
2.2.6
2.2.7
2.2.8
2.3. Dismantle Transfer Box

Assembly
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.4. Check Transfer Box Components
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
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Disconnect external attachment accordance with

service manual
Fix lifting shackles or support transfer box with jack
Unscrew transfer box bolt accordance with service
manual
Move out transfer box unit accordance with service
manual
Use tools or equipment an oder with purpose
designed accordance with service manual
Define Transfer main components accordance with
service manual
Explain procedure of disassembling transfer box
parts and components Types of solvent accordance
with service manual
Disassemble transfer box front cover accordance
with service manual
Disassemble transfer box parts and components
Soak parts and components with solvent
List of defect transfer box components accordance
with service manual
Define procedure of checking transfer box parts and
Explain procedure to measure of teeth contact
Determine of defect types on transfer box
Inspect defect of transfer box component such as
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CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
2.4.6
2.5. Assemble Transfer Box
Components
2.5.1
2.5.2
2.5.3
2.5.4
2.5.5
2.5.6
2.5.7
2.5.8
2.6. Install Transfer Box Assembly
2.6.1
2.6.2
2.6.3
2.6.4
2.6.5
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Gear crack or worm
Synchronizer units wear or crack
Roughness of bearing
Oil seal broken

Measuring of teeth contact accordance with service
manual
List of Operation transfer box assembly accordance
with service manual
Explain method of transferring box parts and
Explain technique of reassemble transfer front
cover accordance with service manual
Identify defect of transfer box parts and
Determine operation transfer box assembly
Changing the defect of transfer box parts and
Apply method of reassemble transfer box parts and
Apply procedure of reassemble transfer front cover
Explain function of lifting equipment accordance
with service manual
List types of transfer box oil accordance with
service manual
Describe method of installing transfer box assembly
Describe to connecting external attachments
Explain method of topping up transfer box oil
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CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
2.6.6
2.6.7
2.6.8
2.6.9
2.6.10
2.6.11
2.6.12
2.7. Test Transfer Box Operations
2.7.1
2.7.2
2.7.3
2.7.4
2.7.5
2.7.6
2.7.7
2.7.8
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Explain technique of tighten up transfer box bolt

Use lifter to place transfer box assembly at location
Slot transmission shaft accordance with service
manual
Tighten transfer box bolt accordance with service
manual
service manual
Top up transfer box oil accordance with service
manual
Apply method of installing transfer box assembly
Explain of engine starting procedure accordance
with service manual
Describe leakage inspect procedure accordance
with service manual
State Transfer box testing procedure accordance
with service manual
Apply procedure engine starting accordance with
service manual
Inspect engine leakage accordance with service
manual
Apply procedure transfer box testing accordance
with service manual
Test all level of transfer accordance with service
manual
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CONTENT
STANDARD
performance
Hrs
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LEARNING STANDARD
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PROGRAM
COURSE NAME
CODE NAME
GMA 303
COMPETENCY
CONTENT
STANDARD
performance
3.
Repair power
take off
assembly
Hrs
LEARNING STANDARD
3.1. Obtain Power Take Off Service
Manual
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.1.6
3.2. Remove power Take Off

Assembly
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
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Explain Source of power take off service manual

Identify procedures of acquiring power take off
service manual
Determine source of power take off service manual
Acquire power take off service manual
Interpret power take off service manual
Use Carefully and observe precaution warnings
given by service manual
List types of lifting equipment accordance with
services manual
Explain Method of removing transmission unit
accordance with services manual
Explain technique of unscrew power take off bolt
Describe to moving out power take off unit
services manual
Fix lifting shackles or support power take off with
jack accordance with services manual
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CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
3.2.7
3.2.8
3.3. Dismantle Power Take Off

Assembly
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
3.4. Check Power Take Off

Components
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
3.4.6
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Uunscrew bolt of power take off follow by technique

Move out power take off unit accordance with
services manual
Identify power take off main components
Explain procedure of disassembling transfer box
parts and components accordance with services
manual
List Types of solvent accordance with services
manual
Disassemble power take off front cover accordance
with services manual
Disassemble power take off parts and components
Soak parts and components with solvent
List types of power take off components defect
Explain procedure of checking power take off parts
and components accordance with services manual
Measuring teeth contact accordance with services
manual
Determine types of power take off defect
Inspect power take off component defect
Measure teeth contact accordance with services
manual
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CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
3.5. Assemble Power Take Off
Components
3.5.1
3.5.2
3.5.3
3.5.4
3.5.5
3.5.6
3.5.7
3.5.8
3.6. Install Power Take Off Assembly
3.6.1
3.6.2
3.6.3
3.6.4
3.6.5
3.6.6
3.6.7
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Explain operation of power take off assembly

Explain method of reassemble power take off parts
and components accordance with services manual
Justify technique of reassemble power take off front
cover accordance with services manual
Justify method to change power take off defect
parts and components accordance with services
manual
Determine operation of power take off assembly
Change power take off defect parts and
components accordance with services manual
Reassemble power take off parts and
componentsfollow by technique accordance with
services manual
Apply method of reassemble power take off cover
List Function of lifting equipment accordance with
services manual
List types of power take off oil accordance with
services manual
Explain function ability of power take off accordance
Use lifter to place power take off assembly at
location accordance with services manual
Slot transmission shaft accordance with services
manual
Tighten power take off bolt accordance with
services manual
services manual
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CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
3.6.8
3.6.9
3.7. Test Power Take Off Operations
3.7.1
3.7.2
3.7.3
3.7.4
3.7.5
3.7.6
3.7.7
3.7.8
3.7.9
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Top up power take off oil accordance with services

manual
Test function ability of power take off accordance
Identify procedure of Engine starting Leakage
inspect procedure accordance with services manual
Identify method of power take off testing
Explain to test all level of transfer accordance with
services manual
Prepare update log book accordance with services
manual
services manual
Inspect engine leakage accordance with services
manual
Apply power take off testing method accordance
Test all level of transfer accordance with services
manual
Update log book accordance with services manual
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PROGRAM
COURSE NAME
CODE NAME
GMA 303
COMPETENCY
CONTENT
STANDARD
performance
4. Overhaul
differential
assembly
Hrs
LEARNING STANDARD
4.1. Obtain Differential Assembly
Service Manual
4.1.1
4.1.2
4.1.3
4.1.4
4.2. Remove Differential Assembly
4.1.5
4.1.6
4.1.7
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
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Identify source of differential assembly service

manual
Explain procedures of acquiring differential
assembly service manual
Justify differential assembly service manual
Determine source of differential assembly service
manual
Acquire differential assembly service manual
Interpret differential assembly service manual
Read precaution warnings given by manual
Explain Disconnecting propeller shaft and
differential assembly accordance with services
manual
List Types of differential oil accordance with services
manual
List Types of differential unit accordance with
services manual
Explain technique of pulling out wheel shaft from
centre housing accordance with services manual
Explain procedure of removing differential assembly
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CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
4.2.6
4.2.7
4.2.8
4.2.9
4.2.10
4.2.11
4.2.12
4.3. Dismantle Differential Assembly
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
4.3.8
4.3.9
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Explain pulling out wheel shaft from centre housing

Disconnect propeller shaft and differential assembly
Drain out differential oil accordance with services
manual
Release external components with differential
assembly accordance with services manual
Determine types of differential unit accordance with
services manual
Pull out wheel shaft from centre housing accordance
Apply procedure of removing differential assembly
State function of hydraulic press accordance with
services manual
List differential unit parts and components
Explain procedure of dismantling differential
assembly accordance with services manual
Explain to taking out bearing cone from differential
by hydraulic press accordance with services manual
Explain Method of disassemble gear from spider
gear accordance with services manual
Justify Technique of disassemble case from bevel
gear accordance with services manual
Uninstall pinion shaft by pushing with hydraulic
press accordance with services manual
Mount carrier assembly on suitable stand
Disassemble differential unit from housing
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CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
4.3.10
4.3.11
4.3.12
4.4. Check Differential Components
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.4.6
4.4.7
4.4.8
4.5. Assemble Differential

Components
4.5.1
4.5.2
4.5.3
4.5.4
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Take out bearing cone from differential by hydraulic
Apply method of disassemble gear from spider gear
Disassemble case from bevel gear follow by
procedure accordance with services manual
List Types of differential components defect
Justify method of Inspecting gear back lash
Explain technique of Adjust pinion free load
adjusting accordance with services manual
Specify parts and components by visualize check
from crack and wear accordance with services
manual
Determine types of differential components defect
Visual check parts and components from crack and
wear accordance with services manual.
Inspect gear back lash accordance with services
manual
Adjust pinion free load accordance with services
manual
List function of hydraulic press accordance with
services manual
Explain differential unit parts and components
Describe procedure of assembling differential
components accordance with services manual
ExplainMethod of reassemble bevel gear to case
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CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
4.5.5
4.5.6
4.5.7
4.5.8
4.5.9
4.5.10
4.6. Install Differential Assembly
4.6.1
4.6.2
4.6.3
4.6.4
4.6.5
4.6.6
4.6.7
4.6.8
4.6.9
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Explain Method of reassemble spider gear to gear
Reinstall pinion shaft by pushing with hydraulic
Reassemble bevel gear to case accordance with
services manual
Reassemble spider gear to gear accordance with
services manual
Press bearing cone to differential accordance with
services manual
Apply assembling differential components
procedure accordance with services manual
List Function of differential unit accordance with
services manual
List Function of differential oil accordance with
services manual
Specify Technique of pressing in wheel shaft from
centre housing accordance with services manual
Explain Procedure of installing differential assembly
Demonstrate Explain connecting propeller shaft and
differential assembly accordance with services
manual
Demonstrate topping up differential oil accordance
Determine function of differential unit accordance
Press in wheel shaft from centre housing
Apply procedure of installing differential assembly
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CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
4.6.10
4.6.11
4.6.12
4.7. Test Differential Assembly

Operations
4.7.1
4.7.2
4.7.3
4.7.4
4.7.5
4.7.6
4.7.7
4.7.8
4.7.9
4.7.10
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Connect propeller shaft and differential assembly
Fix external components to differential assembly
Top up differential oil accordance with services
manual
Procedure Engine starting
Procedure Leakage inspect
Method of differential assembly testing
Updating log book
Apply procedure of engine starting
Inspect engine leakage
Apply testing differential performance method
Update log book
Never run the engine in confined spaces which are
not equipped with adequate ventilation for exhaust
gas extraction
Tidy up working area
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PROGRAM
COURSE NAME
CODE NAME
GMA 303
COMPETENCY
CONTENT
STANDARD
performance
5. Overhaul final
drive unit
Hrs
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LEARNING STANDARD
5.1. Obtain Final Drive Service

Manual
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6
5.1.7
Source of final drive service manual

Procedure of acquiring final drive service manual
Final drive service manual
Determine source of final drive service manual
Acquire final drive service manual
Interpret final drive service manual
Carefully read and observe precaution warnings
given by manual
5.2. Remove Final Drive Assembly
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5.2.7
5.2.8
5.2.9
Operation of final drive

Function of final drive
Procedure of removing final drive assembly
Draining lubrication oil
Determine operation of final drive
Determine function of final drive
Apply removing final drive assembly procedure
Drain lubrication oil
Patient when working at tight area
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CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
5.3. Dismantle Final Drive
Components
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5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
Operation of planetary gear

Function of planetary gear
Procedure of dismantling gear bearing and thrust
washers
Disassemble final drive cover
Disassemble final drive planetary gear
Uninstall gear bearing and thrust washers
5.4. Check Final Drive Parts And

Components
5.4.1
5.4.2
5.4.3
5.4.4
5.4.5
5.4.6
5.4.7
Types of final drive defects

Checking components for serviceability method
Checking components from crack and wear.
Determine types of final drives defects
Inspect components for serviceability
Inspect components from crack and wear.
Conscientious when measure wear parts
5.5. Assemble Final Drive

Components
5.5.1
5.5.2
5.5.3
5.5.4
5.5.5
5.5.6
5.5.7
Determine function of final drive components

Reassembling final drive planetary gear method
Procedure of assembling final drive components
Reassemble gear bearing and thrust washers
Reassemble final drive planetary gear
Reinstall final drive cover
Apply assembling final drive components procedure
5.6. Install Final Drive Assembly
5.6.1
5.6.2
5.6.3
5.6.4
5.6.5
5.6.6
5.6.7
5.6.8
Operation of final drive

Function ability of final drive
Procedure of installing final drive assembly
Types of lubrication oil
Determine operation of final drive
Determine function ability of final drive
Apply installing final drive assembly procedure
Top up lubrication oil
Document Page
24

CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
5.7. Test Final Drive Operations
5.7.1
5.7.2
5.7.3
5.7.4
5.7.5
5.7.6
5.7.7
5.7.8
5.7.9
5.7.10
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Engine starting procedure

Leakage inspect procedure
Final drive testing procedure
Updating log book
Apply engine starting procedure
Inspect engine leakage
Apply final drive testing procedure
Update log book
gas extraction
Document Page
25

PROGRAM
COURSE NAME
CODE NAME
GMA 303
COMPETENCY
CONTENT
STANDARD
performance
6. Overhaul
planetary gear
system
Hrs
LEARNING STANDARD
6.1. Obtain Planetary Gear System
Service Manual
6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
6.1.6
6.1.7
6.2. Remove Planetary Gear System
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6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.2.6
6.2.7
6.2.8
6.2.9
Sources of planetary gear system service manual

Procedure of acquiring planetary gear system
service manual
Planetary gear system service manual
Determine source of planetary gear system service
manual
Acquire planetary gear system service manual
Interpret planetary gear system service manual
given by manual
Operation of planetary gear system
Types of gear
Method of removing planetary gear system
Determine operation of planetary gear system
Determine types of gear
Determine function of planetary gear
Apply removing planetary gear system
Lift and handle all heavy components using lifting
equipment of adequate capacity
Document Page
26

CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
6.3. Dismantle Planetary Gear

Assembly
6.3.1
6.3.2
6.3.3
6.3.4
Types of gear
Method of dismantling planetary gear assembly
Disassemble planetary gear assembly
6.4. Check Planetary Gear

Components
6.4.1
6.4.2
Types of planetary gear components defect

Checking planetary gear parts and components
procedure
Measuring teeth contact
Determine types of planetary gear defect
Inspect planetary gear component defect
Measure teeth contact
Conscientious when measure teeth contact
6.4.3
6.4.4
6.4.5
6.4.6
6.4.7
6.5. Assemble Planetary Gear
Assembly
6.6. Install Planetary Gear System
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6.5.1
6.5.2
6.5.3
6.5.4
6.5.5
Function of gear
Procedure of assembling planetary gear assembly
Determine function of gear
Apply reassemble planetary gear assembly
procedure
Conscientious when measure teeth contact
6.6.1
6.6.2
6.6.3
6.6.4
6.6.5
6.6.6
6.6.7
6.6.8
Operation of planetary gear system

Types of gear
Procedure of installing planetary gear system
Trying function ability of gear box
Connecting external attachments
Determine operation of planetary gear system
Document Page
27

CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
6.7. Test Planetary Gear Operations
6.6.9
6.6.10
6.6.11
6.6.12
6.6.13
6.6.14
Determine function of planetary gear

Apply procedure of installing planetary gear system
Connect external attachments
Try function ability of gear box
Avoid splash gear box oil to skin, floor and eyes
Tidy up gear box oil
6.7.1
6.7.2
6.7.3
6.7.4
6.7.5
6.7.6
6.7.7
6.7.8
6.7.9
6.7.10
6.7.11
Engine starting procedure

Leakage inspect procedure
Planetary gear system testing procedure
Trying all level of gear
Updating log book
Inspect planetary gear system leakage
Apply planetary gear system testing procedure
Try all level of gear
Update log book
gas extraction
Keep work areas clean, uncluttered and free of spills
6.7.12
6.7.13
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Document Page
28

PROGRAM
COURSE NAME
CODE NAME
GMA 303
COMPETENCY
CONTENT
STANDARD
performance
7. Overhaul torque
converter
Hrs
LEARNING STANDARD
7.1. Obtain Torque Converter Service
Manual
7.1.1
7.1.2
7.1.3
7.1.4
7.1.5
7.1.6
7.1.7
7.2. Remove Torque Converter

Assembly
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7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
7.2.7
7.2.8
7.2.9
Sources of torque converter service manual

Procedure of acquiring torque converter service
manual
Torque converter service manual
Determine source of torque converter service
manual
Acquire torque converter service manual
Interpret torque converter service manual
given by manual
Principal of torque converter
Types of universal coupling
Procedure of removing torque converter assembly
Using lifter to move out torque converter
Disconnect external attachments
Uninstall universal coupling
Unscrew torque converter mounting bolts
Use lifter to move out torque converter
Lift and handle all heavy components using lifting
equipment of adequate capacity
Document Page
29

CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
7.3. Dismantle Torque Converter

Components
7.3.1
7.3.2
Torque converter parts and components

Procedure of dismantling torque converter
components
Disassemble torque converter parts and
components such as
7.3.3
7.3.4
7.4. Check Torque Converter
Components
7.4.1
7.4.2
7.4.3
7.4.4
7.4.5
7.4.6
7.4.7
7.4.8
7.4.9
7.4.10
7.4.11
7.4.12
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Impeller
Turbine
Stator
Bearing
Apply procedure of dismantling torque converter
components
Types of torque converter components default
Checking for reusability of torque converter
components
Measuring running clearance
Apply technique of checking bearing condition
Types of torque converter components default
Inspect reusability of torque converter components
Measure running clearance between:
Impeller and turbine
Stator and impeller
Apply technique of checking bearing condition
Do not use petrol, paraffin or other solvent to
remove oil from skin
Document Page
30

CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
7.5. Assemble Torque Converter
Components
7.5.1
7.5.2
7.5.3
7.5.4
7.5.5
7.5.6
7.6. Install Torque Converter

Assembly
7.6.1
7.6.2
7.6.3
7.6.4
7.6.5
7.6.6
7.6.7
7.6.8
7.6.9
7.6.10
7.6.11
7.6.12
7.6.13
7.7. Test Torque Converter

Performance
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7.7.1
7.7.2
7.7.3
7.7.4
7.7.5
Torque converter parts and components

Procedure of reassembling torque converter
components
Reassemble torque converter parts and components
Apply procedure of reassembling torque converter
components
Do not use petrol, paraffin or other solvent to
remove oil from skin
Describe Operation of torque converter
Justify Function ability of torque converter
Explain Procedure of installing torque converter
components
Connecting external attachments
Topping up torque converter oil
Trying function ability of torque converter
Determine operation of torque converter
Determine function ability of torque converter
Apply installing torque converter components
procedure
Connect external attachments
Top up torque converter oil
Try function ability of torque converter
Avoid splash torque converter oil to skin, floor and
eyes
Justify Procedure of engine starting
Justify Procedure of leakage inspect
Explain Procedure of torque converter testing
Demonstrate test all level of gear
Explain Updating log book
Document Page
31

CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
7.7.6
7.7.7
7.7.8
7.7.9
7.7.10
7.7.11
7.7.12
7.7.13
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Inspect planetary gear system leakage
Apply torque converter testing procedure
Test all level of gear
Update log book
gas extraction
Keep work areas clean, uncluttered and free of spills
Document Page
32

PROGRAM
COURSE NAME
CODE NAME
GMA 303
COMPETENCY
CONTENT
STANDARD
performance
8. Overhaul power
shift
transmission
Hrs
LEARNING STANDARD
8.1. Obtain Power Shift Transmission
Service Manual
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
8.1.6
8.2. Remove Power Shift

Transmission Assembly
8.2.1
8.2.2
8.2.3
8.2.4
8.2.5
8.2.6
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Identify ISources of power shift transmission service

manual
Explain Procedure of acquiring power shift
transmission service manual
Justify Power shift transmission service manual
Determine source of power shift transmission
service manual
Acquire power shift transmission service manual
Interpret power shift transmission service manual
Read precaution warnings given by manual
List Types of transmission oil accordance with
service manual
Explain Operation of power shift transmission
Demonstrate Procedure of removing power shift
accordance with service manual transmission
Demonstrate Taking out power shift transmission
unit accordance with service manual
Drain transmission oil accordance with service
manual
Document Page
33

CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
8.2.7
8.2.8
8.2.9
8.3. Dismantle Power Shift

Transmission Components
8.3.1
8.3.2
8.3.3
8.3.4
8.3.5
8.3.6
service manual
Loosen power shift mounting bolts accordance with
service manual
Take out power shift transmission unit accordance
with service manual
Apply procedure of removing power shift
transmission accordance with service manual
Explain Function of power shift transmission
Describe Operation of power shift transmission
Demonstrate Procedure of dismantling power shift
transmission component accordance with service
manual
Uninstall power shift transmission hydraulic control
valve accordance with service manual
Take out torque converter assembly accordance
with service manual
Disassemble power shift transmission component
such as
8.4. Check Power Shift Transmission

Components
8.4.1
8.4.2
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Clutch packs assembly

Planetary gear sets
Speed gear sets
Bearing and seal
List Types of power shift transmission components

defects accordance with service manual
Specify Method of checking components from crack,
broken and worn-out accordance with service
manual
Document Page
34

CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
8.4.3
Demonstrate Measuring and adjusting end-play,

pre-load and backlash accordance with service
manual
Demonstrate Changing defect parts accordance
with service manual
Determine types of power shift transmission
components defects accordance with service
manual
Inspect components from crack, broken and wornout accordance with service manual
Measure end-play, pre-load and backlash and do
necessary adjustment accordance with service
manual
Change defect parts accordance with service
manual
Explain Operation of power shift transmission
Explain Function ability of power shift transmission
accordance with service manual components
Demonstrate Procedure of reassembling power shift
transmission component accordance with service
manual
Reassemble power shift transmission component
such as
8.4.4
8.4.5
8.4.6
8.4.7
8.4.8
8.5. Assemble Power Shift
Transmission Components
8.5.1
8.5.2
8.5.3
8.5.4
8.5.5
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Clutch packs assembly

Planetary gear sets
Speed gear sets
Bearing and seal
Reinstall power shift transmission hydraulic control
valve accordance with service manual
Document Page
35

CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
8.6. Install Power Shift Transmission

Assembly
8.5.6
Fix torque converter assembly accordance with

service manual
8.6.1
List Function of transmission oil accordance with

service manual
Explain Function ability of power shift transmission
Demonstrate Procedure of Installing power shift
transmission accordance with service manual
Demonstrate Topping up transmission oil
Place power shift transmission unit to location
Tighten power shift mounting bolts accordance with
service manual
Connect external attachment accordance with
service manual
Top up transmission oil accordance with service
manual
Apply procedure of installing power shift
transmission. accordance with service manual
8.6.2
8.6.3
8.6.4
8.6.5
8.6.6
8.6.7
8.6.8
8.6.9
8.7. Test Power Shift Transmission
Performance
8.7.1
8.7.2
8.7.3
8.7.4
8.7.5
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Spicify engine starting procedure accordance with

service manual
Spicify Leakage inspect procedure accordance with
service manual
Explain procedure of power shift transmission
testing accordance with service manual
Explain Update log book accordance with service
manual
Justify to test all level of gear accordance with
service manual
Document Page
36

CONTENT
STANDARD
performance
Hrs
LEARNING STANDARD
8.7.6
8.7.7
8.7.8
8.7.9
8.7.10
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service manual
Inspect power shift transmission system leakage
Apply power shift transmission testing procedure
Test all level of gear accordance with service
manual
Document Page
37

KSKV Transmission System Repair

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KSKV Transmission System Repair

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December Edition 2013

MINISTRY OF EDUCATION, MALAYSIA

TRANSMISSION SYSTEM REPAIR

: 5.0 HOURS/WEEK (1T+4P)

NON FACE TO FACE

December Edition 2013

Overhaul manual gear box

December Edition 2013

December Edition 2013

TRANSMISSION SYSTEM REPAIR

1.2. Remove Manual Gear Box

Explain sources gear box service manual in

December Edition 2013

1.3. Dismantle Gear Box

1.1.9. State gear box main components with standard

Shifting fork assembly

1.1.14. Soak parts and components with solvent with

December Edition 2013

1.4. Check Gear Box Components

Gear crack or worn-out

December Edition 2013

1.6. Install Manual Gear Box

Determine operation of gear box assembly

December Edition 2013

1.7. Test Gear Box Operations

Inspect function ability of gear box accordance with

December Edition 2013

TRANSMISSION SYSTEM REPAIR

2.2. Remove Transfer Box Assembly

Identify Sources of transfer box accordance with

December Edition 2013

2.3. Dismantle Transfer Box

2.4. Check Transfer Box Components

Disconnect external attachment accordance with

December Edition 2013

2.6. Install Transfer Box Assembly

Gear crack or worm

Synchronizer units wear or crack

Oil seal broken

December Edition 2013

2.7. Test Transfer Box Operations

Explain technique of tighten up transfer box bolt

December Edition 2013

December Edition 2013

TRANSMISSION SYSTEM REPAIR

3.2. Remove power Take Off

Explain Source of power take off service manual

December Edition 2013

3.3. Dismantle Power Take Off

3.4. Check Power Take Off

Uunscrew bolt of power take off follow by technique

December Edition 2013

3.6. Install Power Take Off Assembly

Explain operation of power take off assembly

December Edition 2013

3.7. Test Power Take Off Operations

Top up power take off oil accordance with services

December Edition 2013

TRANSMISSION SYSTEM REPAIR

4.2. Remove Differential Assembly

Identify source of differential assembly service

December Edition 2013

4.3. Dismantle Differential Assembly

Explain pulling out wheel shaft from centre housing