Course Outline for Automotive Technology 203
Automotive Manual Transmissions and Transaxles

Effective: Fall 2022
SLO Rev: 03/03/2021
Catalog Description:

ATEC 203 - Automotive Manual Transmissions and Transaxles

117.00 Hours

May be repeated 99 time(s)
Automotive Manual Transmission fundamentals including: Theory, diagnosis, repair and adjustment of automotive manual transmissions/transaxles, driveshafts, half shafts, final drives, clutches, viscous couplings, and transfer cases. Two, four and all-wheel drive assemblies, theory, service and repair. This course is free and students may repeat this course until mastery of the skills is met. This course is a noncredit course that is equivalent to the ATEC credit course of the same title. Both options cover the same content and students will be enrolled in the same class at the same time. If a student chooses to move from noncredit to credit courses, please meet with ATEC faculty to discuss assessing equivalency and credit by exam. This course is part of a Certificate of Completion. Available Certificates can be found in the Chabot College Catalog.
Prerequisite: ATEC 250 or ATEC 50 (same as APAU 9724) or equivalent (may be taken concurrently)
0948.00 - Automotive Technology*
Pass/No Pass/Satisfactory Progress
Type Hours
Lecture 27.00
Laboratory 90.00
Total 117.00
Measurable Objectives:
Upon completion of this course, the student should be able to:
  1. diagnose fluid usage, level, leakage and condition concerns, drain and fill manual transmission/transaxle and final drive unit;
  2. diagnose clutch noise, binding, slippage, pulsation, and chatter, and determine necessary action;
  3. inspect, clutch pedal linkage, cables, automatic adjuster mechanisms, brackets, bushings, pivots, and springs and perform necessary action;
  4. inspect and replace hydraulic clutch slave and master cylinders, lines, hoses, and release bearing, lever and pivot; and perform necessary action;
  5. inspect and replace pilot bearing or bushing, release bearing, clutch pressure plate assembly and clutch disc;
  6. inspect flywheel and ring gear for wear and cracks, measure runout; and determine necessary action;
  7. diagnose noise, hard shifting, jumping out of gear, and fluid leakage concerns and determine necessary action;
  8. disassemble, clean, inspect and reassemble transmission/transaxle components;
  9. measure endplay or preload (shim or spacer selection procedure) on transmission/transaxle shafts, and perform necessary action;
  10. diagnose constant velocity (CV), and universal joint noise and vibration concerns, and determine necessary action;
  11. inspect, service, and replace shafts, yokes, boots, and cv joints;
  12. diagnose final drive noise and vibration concerns, and determine necessary action;
  13. inspect and replace companion flange, pinion seal, and measure companion flange runout;
  14. inspect ring gear, measure runout, and determine necessary action;
  15. remove, inspect, reinstall and adjust drive pinion, seals, ring gear, spacers, sleeves, and bearings;
  16. measure and adjust drive pinion depth, and pinion bearing preload;
  17. check ring and pinion tooth contact patterns, gear backlash, and perform necessary action;
  18. inspect and flush differential housing, and refill with correct lubricant;
  19. inspect and replace drive axle shaft seals, bearings, and retainers;
  20. remove and replace drive axle shafts;
  21. disassemble, inspect, and reassemble transfer case and components.
Course Content:

Course content, Lecture

  1. Automotive safety and shop practice 
  2. Proper care and manipulation of basic hand tools
  3. Fundamentals, operating and servicing principles of manual transmissions/transaxles
    1. Design features
    2. Power Flows- four and five speed transmissions/transaxles
    3. Synchronizers
    4. Shift Mechanisms
    5. Lubrication
    6. Problem diagnosis
    7. Service procedures
    8. Electronically controlled transmissions
  4. Fundamentals, operating and servicing principles of drivelines and couplings
    1. Universal and constant velocity joints
    2. FWD/RWD driveshafts
    3. Service procedures
  5. Fundamentals, operating and servicing principles of clutches
    1. Components – clutch discs, pressure plate assemblies, pilot and release bearings
    2. Clutch linkage
    3. Problem diagnosis
    4. Service procedures
  6. Fundamentals, operating and servicing principles of final drives, and drive axle assemblies
    1. Components – ring and pinion gears, differential, axle shafts
    2. Lubrication
    3. Problem diagnosis
    4. Service procedures
  7. Fundamentals, operating and servicing principles of four wheel drive and all wheel drive assemblies
    1. Transfer cases
    2. Front drive axles
    3. Lubrication
    4. Problem diagnosis
    5. Service procedures
  8. Hazardous waste handling
  9. Hybrid, electric, and alternative fuel safety
  10. Hybrid, electric, and alternative fuel applicable systems awareness
  11. Soft Skills

Course content, Laboratory

  1. Demonstrate proper shop safety and working practices, including tools and equipment, and hazardous waste handling
  2. Repair/service clutch system
  3. Disassemble, inspect, repair, and reassemble manual transmission
  4. Diagnose and service a transaxle
  5. Diagnose and service a differential
  6. Diagnose and service a transfercase
Methods of Instruction:
  1. Lecture/Discussion
  2. Demonstration
  3. Guest speakers
  4. Field Trips
  5. Laboratory
  6. Distance Education
Assignments and Methods of Evaluating Student Progress:
  1. Read chapter on All Wheel Drive Systems.
  2. Complete review quiz at the end of chapter.
  3. Complete laboratory assignments using service information, lecture materials, and text.
  1. Class Participation
  2. Laboratory exercises
  3. Homework
  4. Quizzes
  5. Midterm Examination
  6. Final Examination
  7. Practical Examination
Upon the completion of this course, the student should be able to:
  1. determine gear ratios for a manual transmission/transaxle, and correctly complete worksheet;
  2. measure end play;
  3. measure differential ring and pinion back lash.
Textbooks (Typical):
  1. Halderman, James (2018). Manual Drivetrains and Axles (8th). Pearson.
  • Safety Glasses
  • Shop/Safety Clothing
Abbreviated Class Schedule Description:
Automotive Manual Transmission fundamentals including: Theory, diagnosis, repair and adjustment of automotive manual transmissions/transaxles, driveshafts, half shafts, final drives, clutches, viscous couplings, and transfer cases. Two, four and all-wheel drive assemblies, theory, service and repair. This course is a noncredit course that is equivalent to the ATEC credit course of the same title. Both options cover the same content and students will be enrolled in the same class at the same time.
Prerequisite: ATEC 250 or ATEC 50 (same as APAU 9724) or equivalent (may be taken concurrently)