The driven gear in a final drive assembly is the

AURLTQ001 Diagnose and repair light vehicle final drive assemblies

Assessment 1 – Questioning – Written Assessment

Student Name

Student ID Number

Unit Start Date

Unit End Date

Assessment Due Date

Date Submitted

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 that I can locate The RTO Complaints and Appeals Policy and Procedure on their website at (Insert Website Link)

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, (if applicable). e.g. Student Handbook and Access and Equity Policy (Insert Website Link)

Yes / No

I have access to all required resources?

Yes / No

Cheating & Plagiarism Declaration

Student Declaration: In accordance with The RTO Plagiarism Policy, 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

Date:

______ / ______ / 20______

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:

Assessor’s Name:

Student Signature

Date

Assessor Signature

Date

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 final drive assemblies.

The topics that will be covered in the assessment are:

1. Prepare to diagnose and repair light vehicle final drive assembly

2. Diagnose final drive assembly

3. Repair final drive assembly

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.

· Read the assessment carefully before commencing.

· Your Assessor will use the assessment criteria in this document and will provide feedback / comment.

· You MUST answer all the questions in the assessment tasks in your own words and own handwriting.

· 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 68 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

To receive a ‘satisfactory’ outcome for this assessment students MUST successfully answer all questions. If a student achieves less than 100%, they can reattempt the assessment after further study has taken place. Students who cannot achieve a minimum of 100% you will not have satisfactorily completed this assessment

Your assessor will be looking for the following in this assessment task: -

· Work health and safety (WHS) and occupational health and safety (OHS) requirements relating to diagnosing and repairing light vehicle final drive assemblies, including procedures for working with hazardous oils

· Environmental procedures for trapping, storing and disposing of oils released from final drive assemblies

· Operating principles of light vehicle final drive assemblies and associated components, including:

· Final drive gears, including:

· Gear types

· Gear ratios and torque reduction and multiplication

· Differential function

· Application, purpose and operation of the following components of light vehicle final drive assemblies and components, including:

· Removable carrier housing (banjo) type final drives

· Integral carrier housing type final drives

· Transaxle final drives

· Differentials, including limited slip differentials

· Axle shafts for rigid axles, including:

· Semi floating live axles

· Three quarter floating live axles

· Fully floating live axles

· Diagnostic testing procedures for light vehicle final drive assemblies, including:

· Road testing procedures, including:

· Final drive assembly noise diagnostic

· Wheel bearing noise diagnostic

· Pre-dismantling inspection procedures

· Repair procedures for light vehicle final drive assemblies, including procedures for:

· Dismantling final drive assemblies

· Inspecting final drive assemblies

· Reassembling and adjusting pinion depth, pinion bearing preload, crown wheel and pinion backlash, side

· Bearing preload and crown wheel and pinion tooth contact

· Repairing wheel bearings of rear wheel drive light vehicles

· Post-repair testing procedures for light vehicle final drive assemblies.

Assessment conditions

Assessors MUST satisfy NVR/AQTF assessor requirements.

Competency is to be assessed in the workplace or a 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 final drive assemblies 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 repair workplace or simulated workplace

· Workplace instructions

· Manufacturer light vehicle final drive assembly specifications

· Two different light vehicles:

· One with faults in its removable carrier housing (banjo) type final drive assembly

· One with faults in its integral carrier housing type final drive assembly

· Diagnostic equipment for light vehicle final drive assemblies

· Tools, equipment and materials appropriate for light vehicle final drive assemblies.

Resources required

Learning Resources available to students include:

· Automotive Technology (A System Approach) 6th Edition – Chapters 5, 6, 7, 38, 39, 40 & 45

· Websites

· Trainer Handouts

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.

Assessment 1 – Questioning

Written Assessment

1. Identify five (5) important items of personal safety when working on final drive assemblies in an automotive workplace?

1

2

3

4

5

2. What are the precautions that you should be aware of when handling final drive oil?

https://go.lupinsys.com/caltex/harms/public/.../Geartex_LSD_SAE_140-SDS.pdf

3. How should waste final drive assembly oils be stored and disposed?

Multiple Choice question. Selected the correct answer.

4. When changing the final drive oil, what should you use to catch the waste oil?

A. Drain pan.

B. Mop bucket.

C. Storm water drain.

D. Funnel.

5. When handling, trapping, storing and disposing of new or waste final drive oils, which document should you use to find this information?

True or False question

6. The differential pinion gears do not rotate on the pinion shaft when both driving wheels are turning at the same speed.

☐ True

or

☐ False

True or False question

7. In a hypoid gearset, the drive pinion meshes with the ring gear at gear centreline.

☐ True

or

☐ False

True or False question

8. In a differential gearset, the side gears deliver torque to the pinion gears.

☐ True

or

☐ False

9. Name the seven [7] components of a typical final drive unit below.

1

2

3

4

5

6

7

10. Why are hypoid gears and why are hypoid gears used?

Multiple Choice question. Selected the correct answer.

11. A _____-type limited slip differential uses a set of helical gears to transfer torque from the wheel that is slipping to the wheel with traction.

A. Spicer.

B. Torsen.

C. Ravigneaux.

D. DeDion.

12. Ring and pinion gearsets are normally classified as?

Multiple Choice question. Selected the correct answer.

13. When one drive pinion gear tooth contacts every ring gear tooth after several revolutions, this is called a?

A. Hunting gearset.

B. Non-hunting gearset.

C. Partial non-hunting gearset.

D. None of these answers are correct.

True or False question

14. A partial non-hunting gearset is one in which one pinion tooth contacts only six ring gear teeth.

☐ True

or

☐ False

Fill in the Gaps

15. Complete the following statement about gear ratios using the following words.

Words: Dividing, Driven, Gear, Number, Larger, Multiplication, Ratios,

Gear __________ express the mathematical relationship of one gear to another. __________ ratios can vary by changing the diameter and __________ of teeth of the gears in mesh. A gear ratio also expresses the amount of torque __________ between two gears. The ratio is obtained by __________ the diameter or number of teeth of the __________ gear by the diameter or teeth of the drive gear. If the smaller driving gear had eleven teeth and the __________ gear had forty-four teeth, the ratio is 4:1.

Multiple Choice question. Selected the correct answer.

16. 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 question. Selected the correct answer.

17. 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 question. Selected the correct answer.

18. 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.

True or False question

19. Axles with a numerically high gear ratio such as 4.11 allow the engine to run slower at any given speed, resulting in better fuel conservation.

☐ True

or

☐ False

True or False question

20. Axles with numerically low gear ratio such as 2.83 allow for fast acceleration and good pulling power.

☐ True

or

☐ False

21. Define final drive.

22. Describe the function of a differential.

Multiple Choice question. Selected the correct answer.

23. Which of the following is NOT a function of the final drive in a rear axle?

A. Changes the direction of power flow 90 degrees.

B. Transfers braking torque to the front wheels.

C. Allows the drive wheels to rotate at different speeds when negotiating a turn.

D. Reduces speed/multiplies torque.

24. Describe the action of differential side gears when the vehicle is cornering.

Multiple Choice question. Selected the correct answer.

25. When the vehicle is turning left, ______.

A. The left-side gear and axle shaft are turning slower than the housing [carrier].

B. The right-side gear and axle shaft are turning faster than the housing [carrier].

C. The differential pinion gears rotate on the pinion shaft.

D. All answers are correct.

Multiple Choice question. Selected the correct answer.

26. Which of the following is NOT a function of the final drive in a rear axle?

A. Changes the direction of power flow 90 degrees.

B. Transfers braking torque to the front wheels.

C. Allows the drive wheels to rotate at different speeds when negotiating a turn.

D. Reduces speed/multiplies torque.

True or False question

27. A removable-carrier axle housing is sometimes called a banjo type differential.

☐ True

or

☐ False

Fill in the Gaps

28. Complete the following statement about removable carrier housing (banjo) using the following words.

Words: Assembly, Axle, Banjo, Carrier, Contaminants, Heavy-duty, Housing,

The removable __________ axle housing is open on the front side. Because it resembles a __________, it is often called a banjo __________. The backside of the housing is closed to seal out dirt and __________ and keep in the lubricant. The gears are mounted in a carrier __________ that can be removed as a unit from the __________ housing. Removable carrier axle housings are most commonly used today on trucks and other __________ vehicles.

Fill in the Gaps

29. Complete the following statement about integral carrier housing using the following words.

Words: Carrier, Final, Gear, Housing, Removable, Tubes

The integral __________ is most often found on cars and light trucks. A cast-iron __________ forms the centre of the axle housing. Steel axle __________ are pressed into both sides of the carrier to form the housing. The housing and carrier have a __________ rear cover that allows access to the __________ drive assembly. Because the carrier is not removable, the __________ assemblies must be removed and serviced separately.

True or False question

30. Transaxle contain the transmission and the final drive gear assembly.

☐ True

or

☐ False

Fill in the Gaps

31. Complete the following statement about transaxle assemblies using the following words.

Words: Axles, Differential, Gear, Housing, Propelled, Ring, Side, Transaxle, Transfers, Transmission, Vehicles, Weight

Front-wheel drive (FWD) vehicles are __________ by the front wheels. For this reason, they must use a drive design different from that of an RWD vehicle. The __________ is the special power transfer unit commonly used on FWD vehicles. A transaxle combines the transmission gearing, __________, and drive axle connections into a single case __________ located in front of the vehicle. This design offers many advantages. One major advantage is the good traction on slippery roads due to the __________ of the drivetrain components being directly over the driving __________ of the vehicle. It is also more compact and lighter than the __________ of an RWD vehicle. Transverse engine and transaxle configurations also allow for lower hood lines, thereby improving the __________ aerodynamic.

The final drive __________ gear is driven by the transaxle’s output shaft. The ring gear then __________ the power to the differential case. The case holds the ring __________ with its mating pinion gear. The differential __________ gears are connected to the drive axles.

32. Name the nine [9] components of typical front-wheel-drive powertrain below.

1

2

3

4

5

6

7

8

9

True or False question

33. Limited slip differential clutch packs are designed to slip slightly when the vehicle is turning.

☐ True

or

☐ False

True or False question

34. Pressure is kept on the limited slip differential clutch packs by either an S-shaped spring or coil springs.

☐ True

or

☐ False

35. Name the eight [8] components of the limited slip differential case below.

1

2

3

4

5

6

7

8

36. Name the three (3) different types of axle shafts below.

A.

B.

C.

Multiple Choice question. Selected the correct answer.

37. Which type of drive axle supports the weight of the vehicle?

A. Semi-floating.

B. Three-quarter floa.ting.

C. Full-floating

D. Both “semi-floating” and “three-quarter floating”.

Multiple Choice question. Selected the correct answer.

38. Full floating axle shafts are found on ______.

A. Front axles of an FWD car.

B. Rear axle of an RWD car.

C. Front axle of a 4WD SUV.

D. Rear axle of a heavy-duty truck.

True or False question

39. The axles in a full-floating axle housing drive the wheel assemblies but do not support the weight of the vehicle.

☐ True

or

☐ False

True or False question

40. A three-quarter floating axle has one wheel bearing per wheel on the outside of the axle housing.

☐ True

or

☐ False

Multiple Choice question. Selected the correct answer.

41. C-shaped washers [C-locks] are used to retain the axle shaft used with _____ bearings.

A. Sealed ball.

B. Tapered roller.

C. Straight roller.

D. All answers are correct.

Multiple Choice question. Selected the correct answer.

42. Which type of bearing is NOT used on semi-floating axles?

A. Needle bearing.

B. Ball bearing.

C. Straight roller bearing.

D. Tapered roller bearing.

43. Describe the four (4) distinct modes the vehicle should be operated in during a road test when diagnosing final drive problems.

1

2

3

4

44. What two (2) conditions are usually the first symptoms to be noticed when a differential or drive axle shaft problem occurs?

1

2

True or False question

45. A bad axle or wheel bearing will not cause a tyre wear problem.

☐ True

or

☐ False

46. Consider the various noises that could originate from the rear-axle assembly, and the faults associated with such noises.

Fill in the Gaps

47. Complete the following statement about crown wheel and pinion diagnosis using the following words.

Words: Accelerating, Float, Gear, Noise, Tooth, Vehicle

Crown wheel and pinion noise originates from poor __________ contact and may be noticed on drive, overdrive or __________. It can be more pronounced on one of these than on the others.

Drive noise is most pronounced when __________, as the gear teeth are under load. The bearings are also under load so that any lack of preload will allow the __________ teeth to change their area of contact.

Noise on overdrive occurs as the __________ decelerates from medium speeds, while float __________ occurs under light cruising conditions.

True or False question

48. Rough pinion bearings will produce a continuous whine, which will persist when coasting in neutral, right down to low speed.

☐ True

or

☐ False

True or False question

49. Faulty rear-axle bearings produce a growling noise, which is hard to distinguish from a differential noise.

☐ True

or

☐ False

50. Describe how to measure ring and pinion gearset backlash.

51. Before repairing a banjo final drive assembly. What five (5) pre-dismantling checks that should be carried out?

1

2

3

4

5

Fill in the Gaps

52. Complete the following statement about dismantling a unitised final drive assembly using the following words.

Words: Bearing, Bolts, Carrier, Case, Crown, Differential, Pinion, Preloaded, Shims, Spread, Wheel

The differential side bearings are __________ and this holds the differential case firmly in the housing. When dismantling, the bearing mountings are usually __________ slightly to relieve the preload so that the differential __________ with the crown wheel can be easily removed. The sequence is:

1 Mark the left-hand and right-hand __________ caps to identify their positions for reassembly.

2 Remove the bearing cap __________ and remove the bearing caps.

3 Fit a spreader tool to the __________ housing.

4 Adjust the nut on the spreading tool to spread the housing so that the __________ wheel and differential case can be removed from the __________.

5 Remove the crown __________ and differential case and release the spreader.

6 Identify the right and left bearing cups and __________ or spacers so that they can be correctly located during reassembly.

7 Proceed to remove the __________ from the housing and continue with any further dismantling required.

53. After dismantling the final drive assembly, you should inspect it for worn or damaged components. Referring to the link or ask the trainer for handout, complete the following table. http://pdf.textfiles.com/manuals/AUTOMOBILE/NISSAN/murano/2007/2007_Murano/rfd.pdf

Component

Condition and Measures

Hypoid Gear

Bearings

Side Gear and Pinion Mate Gear

Side Gear Thrust Washer and Pinion Mate Thrust Washer

Oil Seals

Differential Case

Companion Flange

True or False question

54. Adjusting Backlash sets the depth of the mesh between the ring and pinion gear teeth.

☐ True

or

☐ False

Multiple Choice question. Selected the correct answer.

55. Pinion gear depth is adjusted by ______.

A. Threaded adjusters behind the housing bearing outer cups.

B. Shims placed between the differential housing [carrier] and housing bearings.

C. Threaded adjusters between the companion flange and front pinion bearing.

D. Shims placed between the pinion bearing and pinion gear.

True or False question

56. Whenever the ring and pinion gears or the pinion or differential case bearings are replaced, pinion gear depth, pinion bearing preload, and the ring and pinion gear tooth patterns and backlash must be checked and adjusted.

☐ True

or

☐ False

57. Explain how pinion bearing preload is set?

58. What can happen if the pinion bearing preload was set incorrectly?

True or False question

59. It is recommended that a new pinion seal be installed whenever the pinion shaft is removed from the differential.

☐ True

or

☐ False

True or False question

60. A typical procedure for measuring and adjusting backlash and preload involves rocking the ring gear and measuring its movement with a dial indicator.

☐ True

or

☐ False

61. The pattern of gear teeth determines how quietly two meshed gears run. There are terms commonly used to describe the possible patterns on a ring gear. Using the images below, name patterns on a ring gear and the necessary corrections.

Fill in the Gaps

62. Complete the following statement about measuring and adjusting backlash and side-bearing preload on a unitised final drive assembly using the following words.

Words: Backlash, Bearing, Combined, Cup, Dial, Gearset, Housing, Indicator, Position, Record, Shims, Spacers, Thickness, Tighten

1 Measure the __________ of the original side bearing preload shims.

2 Install the differential case into the __________.

3 Install service __________ that are the same thickness as the original preload shims between each bearing __________ and the housing.

4 Install the bearing caps and finger __________ the bolts.

5 Mount a dial __________ to the housing so that the button of the indicator touches the face of the ring gear. Using two screwdrivers, pry between the __________ and the housing. Pry to one side and set the dial indicator to zero, then pry to the opposite side and __________ the reading.

6 Select two shims with a __________ thickness to that of the original shims plus the indicator reading, then install them.

7 Using the proper tool, drive the shims into __________ until they are fully seated.

8 Install and tighten the __________ caps to specifications

9 Check the backlash and preload of the __________. Check the backlash by holding the input pinion, rocking the ring gear, and noting the movement on the __________ indicator. Adjust the shim pack to allow for the specified backlash. Recheck the __________ at four points equally spaced around the ring gear.

True or False question

63. An oxyacetylene torch can be used to remove the axle bearing retaining ring.

☐ True

or

☐ False

True or False question

64. A steel cold chisel and hammer can be used to remove the axle bearing retaining ring.

☐ True

or

☐ False

Multiple Choice question. Selected the correct answer.

65. Whenever a tapered roller bearing is replaced, its ______ must be replaced with it.

A. Castellated nut.

B. Thrust washer.

C. Spindle.

D. Race.

66. Consider the various post repair checks that you would make during a road test on the final drive assembly?

Multiple Choice question. Selected the correct answer.

67. Which source of information will give you the most detail about diagnosing and repairing final drive assemblies on the vehicle you are working on?

A. Workshop manual.

B. Owner’s manual.

C. Google.

D. Textbooks.

68. Why is it very important that the Job Card is completed correctly?