DIET 2020 Syllabus

Subject Code

DIET

Course Number

2020

Course Title

Truck Drivetrains

Prerequisites

Prerequisites/Corequisites: DIET 1000, DIET 1010

Corequisites

Terms Offered

Offered Summer

Credit Hours

(2-5-4)

Course Description

This course introduces power train systems used on medium and heavy duty trucks. Topics include power trains, clutches and flywheels, power train electronic systems, auto-shift mechanical transmissions, power take-offs, truck drive lines, differentials and final drives, torque converters, and automatic transmissions.

Course Outcomes

DisassembleIntroduction to Power Trains

Demonstrate an understanding of the terms and definitions.
Describe basic components of a power train and their functions.
Demonstrate an understanding of the sequence foe the transmission of power through a power train.
Demonstrate an understanding of the working applications of the power train.
Describe types of gears found in power trains.
Demonstrate an understanding of the formula for calculating gear ratio.
Demonstrate an understanding of how to determine gear rotation.
Demonstrate an understanding of the formula for calculating gear speed.
Calculate gear ratio.
Calculate gear rotation.
Calculate gear speed.

Clutches and Flywheels

Demonstrate an understanding of the terms and definitions.
Describe components of a basic clutch assembly.
Describe parts of a flywheel.
Demonstrate an understanding of the function of a flywheel.
Describe parts of a dry type disc clutch.
Describe types of clutches and their descriptions.
Describe types of pressure plates.
Demonstrate an understanding of the difference between a disengaged and an engaged clutch.
Describe clutch linkage mechanism and their functions.
Perform inspections and adjustment of clutch linkages, cables, levers, brackets, brushings, pivot springs, and safety switches (push and pull-type assemblies).
Check clutch pedal free play.
Define conditions to look for during clutch inspection.
Describe symptoms that occur when a clutch housing bore has excessive run-out.
Describe clutch malfunctions and probable causes.
Identify noises of clutch noises, binding, slippage, pulsation, vibration, grabbing, and chatter; determine needed action.
Demonstrate an understanding of an dual clutch disc.
Perform adjust of clutch linkage free travel.
Perform adjustment of free travel on a pull type clutch.
Remove a clutch assembly.
Inspect a clutch disc.
Check a clutch housing alignment, flywheel housing face, and bore run-out.
Inspect a pressure plate and cover.
Inspect, adjust, lubricate, or replace release (throw out) bearings, sleeves, bushings, springs, housing, levers, release fork, fork pads, rollers, shafts, and seals.
Inspect, adjust, repair, or replace hydraulic clutch slave and master cylinders, lines, and hoses.
Perform bleeding procedure for hydraulic clutch systems.
Inspect a pilot bearing and pilot bushing.
Perform reinstallation of a clutch assembly.
Inspect input shaft and bearing retainer; perform needed action.
Inspect, adjust, and replace self-adjusting/continuous adjusting clutch mechanism, clutch pressure plate, and clutch disc.
Inspect flywheel mounting area on crankshaft, rear main oil seal, and measure crankshaft end play; determine needed action.
Insect flywheel, starter rear gear, and measure flywheel face and pilot bore run-out; determine needed action.

Power Train Electronic Systems

Demonstrate an understanding of diagnostic procedures.
Demonstrate an understanding on how to retrieve fault codes.
Demonstrate an understanding of how to clear fault code.
Check for proper clutch operation.
Confirm proper clutch adjustment.
Demonstrate an understanding of the clutch brake contact.
Describe electrical pretests.
Demonstrate an understanding of the power-up sequence test.
Describe fault codes.
Describe symptom driven diagnostics.
Describe front box control test.
Demonstrate an understanding on the gear display power supply test.
Describe the electric shifter test.
Describe the start enable relay test.
Describe the starting gear engagement test.
Describe the J-1939 data link test.
Describe the auxiliary box test.
Describe the up/down button test.
Describe the neutral lock input test.
Describe the splitter test.
Describe the shift complaint test.
Describe how to interpret wiring diagrams and schematics.

Auto-Shift Mechanical Transmissions

Demonstrate an understanding of the terms and definitions.
Demonstrate an understanding of the types of mechanical transmissions.
Describe parts of a sliding gear transmission.
Describe parts of a sliding clutch transmission top shaft.
Describe parts of a front section countershaft.
Describe parts of a transmission front section case with clutch housing.
Describe parts of an auxiliary section of a transmission.
Describe parts of a shift lever housing and reverse stop plunger.
Describe parts of a shift bar housing.
Describe parts of a remote shift control assembly.
Demonstrate an understanding of the air flow for range setting.
Indicate air flow in air lines for range shifting.
Check transmission fluid level and condition and add proper type of coolant.
Inspect for leakage and replace transmission cover plates, gaskets, seals, and cap bolts.
Inspect seal surfaces and vents and repair as needed.
Remove and disassemble a mechanical transmission.
Inspect input shaft, gear, spacers, bearings, retainers, and slingers; determine needed action.
Identify causes of transmission noise, shifting, lock-up, jumping out of gear, overheating, and vibration problems; determine needed action.
Inspect, test, repair, or replace air shift controls, lines, hoses, valves, regulators, filters, and cylinder assemblies.
Inspect, adjust, and replace transmission shift lever, cover, rails, forks, lever, bushings, sleeves, detents, interlocks, springs, and lock bolts/safety wires.
Inspect transmission oil filters and coolers; replace as needed.
Inspect speedometer components; determine needed action.
Inspect transmission parts.
Perform reassembly of a mechanical transmission.
Disassemble a shifting bar housing.
Inspect a shifting bar housing and parts.
Reassemble a shifting bar housing and parts.
Inspect and replace transmission mounts, insulators, and mounting bolts.
Inspect and adjust power take-off (PTO) assemblies, controls, and shafts; determine needed action.
Inspect and test the function of reverse lights, neutral start, and warning device circuits; determine needed action.
Perform inspection and testing of the transmission temperature gauge and sensor sending unit; determine needed action.
Perform installation of a mechanical transmission.
Test a mechanical transmission after rebuilding.
Perform installation of an automated mechanical transmission.
Test an automated mechanical transmission after rebuilding.
Inspect and test the operation of automated mechanical transmission and manual electronic shift controls, range and splitter solenoids, shift motors, indicators, speed am\nd range sensors, electronic transmission control units (ECU/TCU), neutral, in gear, and reverse switches, and wiring harnesses; determine needed action.
Inspect and test operation of automated mechanical transmission electronic shift selectors, air and electrical switches, displays and indicators, wiring harnesses, and air lines; determine needed action.
Use appropriate diagnostic tools and procedures to diagnose automated mechanical transmission problems.
Check and record diagnostic codes, clear codes, and interpret digital multi-meter (DMM) readings; determine needed actions.

Power Take-offs

Demonstrate an understanding of the terms and definitions.
Demonstrate safe operation of PTO's.
Identify three types of PTO guards and shifts.
Define three types of PTO systems.
Demonstrate an understanding of the SAE standards for tractor PTO drives.
Describe complaints and causes foe noise, heat, and vibration in transmission-mounted PTOs.
Describe troubleshooting PTOs for poor work rate.
Describe complaints and causes for external oil leaks in PTOs.
Describe troubleshooting PTOs for hard shifting.
Describe troubleshooting PTOs for jumping out of gear.
Describe troubleshooting power shift PTOs.
Identify parts of as two gear, one speed PTO.
Identify components of hydraulic and electric circuits in a power shift PTO.
Identify parts of a PTO air shift system.
Describe shift covers for transmission mounted PTO.
Demonstrate an understanding of the procedure for lubricating PTO systems.
Identify questions that are relevant when selecting the proper PTO.
Perform installation of a transmission mounted PTO.

Truck Drive Lines

Demonstrate an understanding of the terms and definitions in relation to vehicle suspension.
Define two characteristics of a Hotchkiss drive.
Demonstrate an understanding of the types of propeller shafts.
Identify parts of a propeller shaft with shift yoke.
Identify parts of a center bearing.
Demonstrate an understanding of the difference between constant velocity, cross, and roller u-joints.
Identify parts of a cross and roller u-joint.
Identify causes of drive shaft and universal joint noise and vibration problems; determine needed action.
Describe points on a drive train to check component angles.
Measure driveline angles; determine needed action.
Demonstrate an understanding of the acceleration and deceleration of a propeller shaft with Cardon u-joints.
Describe problems causing drive line noise or vibration.
Inspect, service, or replace drive shafts, slip joints, yokes, drive flangers, universal joints, driveshaft boots and seals, and retaining hardware.
Check phasing of all drive shafts.
Inspect drive shaft center support bearings and mounts; determine needed actions.
Perform removal and replacement of a propeller shaft.
Perform disassembly, inspection, and reassembly of a u-joint with a bolted end.
Remove and replace a cross and roller u-joint.
Install, align, and time a telescoping drive line.
Balance a propeller shafts.

Differentials and Final Drives

Demonstrate an understanding of the terms and definitions.
Describe types of differentials and final drives.
Identify parts of a gear tooth.
Describe methods used to evaluate ear tooth contact patterns.
Identify parts of a differential.
Identify parts of a planetary gear set.
Describe planetary gear set components and their characteristics.
Describe types of differential locks.
Demonstrate an understanding of the purposes of a power divider.
Demonstrate an understanding of the basic parts p\of a power divider.
Demonstrate an understanding of the shifting mechanisms and their descriptions.
Demonstrate an understanding of the difference between flared and compression fittings.
Remove a differential assembly.
Perform disassembly of a differential case and gear assembly.
Clean and inspect a differential case and gear assembly.
Identify causes of drive axle(s) drive unit noise and overheating problems; determine needed action.
Inspect and replace a differential case assembly including spider gears, cross shaft, side gears, thrust washers, case halves, and bearings.
Inspect and replace components of a locking differential case assembly.
Inspect differential carrier housing and caps, side bearing bores, and pilot (spigot, pocket) bearing bore; determine needed action.
Measure ring gear run out; determine needed action.
Inspect and replace ring and drive pinion gears, spacers, sleeves, bearing cages, and bearings.
Measure and adjust drive pinion bearing preload.
Measure and adjust drive pinion depth.
Measure and adjust side bearing preload and ring gear backlash.
Check and interpret ring gear and pinion tooth contact pattern; determine needed action.
Inspect, adjust, or replace ring gear thrust block/screw.
Reassemble a differential case and gear assembly.
Remove, repair, and reassemble a differential carrier and power divider assembly.
Inspect power divider (inter-axle differential) assembly; determine needed action.
Inspect, adjust, repair, or replace an air operated power divider (inter-axle differential) lockout assembly including diaphragms, seals, springs, yokes, pins, lines, hoses, fittings, and controls.
Inspect, repair, or replace drive axle lubrication systems including pumps, troughs, collectors, slingers, tubes, and filters.
Check and repair fuel leaks.
Inspect and replace drive axe housing cover plates, gaskets, sealants, vents, magnetic plugs, and seals.
Install a differential assembly in a differential housing.
Disassembly a planetary gear assembly outer ends.
Clean and inspect parts of a planetary axle.
Reassemble a planetary gear assembly.
Perform adjustment on a planetary gear assembly including bearing preload.
Check drive axle fluid level and condition; determine needed service.
Add the proper type of lubrication to drive axles as needed.
Inspect and replace drive axle shafts.
Perform removal and replacement of wheel assemblies.
Check rear wheel seal and axle flanage gasket; perform needed action for leaks.
Identify causes of drive axle wheel bearing noise and check for damage; perform needed action.
Clean, inspect, lubricate, and replace wheel bearings.
Replace seals and wear rings.
Inspect and replace retaining hardware.
Perform adjustment of drive axle wheel bearings.
Perform preventive maintenance on differential and final drives.
Assemble an air line with reusable fitting (flared).
Assemble an air line with compression fittings.
Inspect and test drive axle temperature gauge and sending unit/sensor; determine needed action.

Torque Converters

Demonstrate ban understanding of then terms and definitions.
Demonstrate an understanding of how a basic fluid coupling works.
Identify parts of a torque converter.
Describe torque converter parts and their functions.
Define types of fluid flow in torque converters and their characteristics.
Describe the operation of a twin-turbine torque converter.
Describe the operation of a lock-up clutch torque converter.
Perform draining and refilling procedures on a torque converter.
Check for oil leaks.
Test a torque converter.

Automatic Transmissions

Demonstrate an understanding of the terms and definitions.
Identify major parts of an automatic transmission.
Describe steps in oil pump and regulating valve operation.
Describe low range, high range, and reverse range functions in an automatic transmission.
Demonstrate an understanding of the characteristics of automatic transmission fluid.
Describe the procedure for properly checking automatic transmission fluid.
Demonstrate an understanding of in-vehicle transmission tests and their functions.
Identify parts of a planetary gear system.
Describe planetary gear system operation.
Describe speed, torque, and directional functions of an automatic transmission and ways they are accomplished.
Identify tools and equipment required for automatic transmission overhaul.
Describe parts normally replaced at each automatic transmission overhaul.
Demonstrate an understanding of the important elements of cleaning and inspection.
Describe special considerations for bearing inspection and handling.
Identify transmission components and their inspection requirements.
Describe make-ready procedures for removing or installing an automatic transmission.
Demonstrate an understanding of the general rules for determining whether to reuse or replace a part.
Remove an automatic transmission from a vehicle.
Disassembly an automatic transmission into subassemblies.
Check end play on a torque converter assembly.
Rebuild a stator assembly.
Reassembly a torque converter assembly.
Disassemble, clean, inspect, and reassembly a modulated lockup valve assembly.
Disassemble, clean, inspect, and reassemble a low shift assembly.
Disassemble, clean, inspect, and reassemble a control valve body assembly.
Disassemble, clean, inspect, and reassemble an oil pump and front support assembly.
Disassemble, clean, inspect, and reassemble a forward clutch and turbine shaft.
Disassemble, clean, inspect, and reassemble a fourth clutch.
Disassemble, clean, inspect, and reassemble a center support assembly.
Disassemble, clean, inspect, and reassembly gear unit and main shaft assembly.
Disassemble, clean, inspect, and reassemble an output shaft.
Disassemble, clean, inspect, and reassemble a rear cover assembly.
Disassemble, clean, inspect, and reassemble an adaptor housing and first clutch piston.
Disassemble, clean, inspect, and reassemble a transmission housing.
Reassemble an automatic transmission.
Perform installation of an automatic transmission.
Test an automatic transmission.
Perform shift speed adjustments on an automatic transmission.
Inspect and test operation of an automatic transmission electronic shift controls, shift solenoids, shift motors, indicators, speed and range sensors, electronic/transmission control units (ECU/TCU), neutral, gear, and reverse switches, and wiring harness.
Inspect and test the operation of automatic transmission electronic shift selectors, switches, displays, and indicators.
Use appropriate diagnostic tools and procedures to diagnose automatic transmission problems.
Check and record diagnostic codes, clear codes, and interpret digital multi-meter (DMM) readings; determine needed action.