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Copyright by Goodheart-Willcox Co., Inc.
Chapter 5
Sealing Materials, Fasteners, and
Lubricants. . . . . . . . . . . . . . . . . . . . . . . 85
Seals 86
Types of Seals / Seal Service
Gaskets 92
Gasket Materials / Gasket Problems / Gasket Service
Sealers 94
Types of Sealers / Form-in-Place Gaskets /
Thread-Locking Compounds and Thread Sealers
Adhesives 95
Fasteners 96
Threaded Fasteners / Threaded Fastener
Classification / Fastener Torquing and Tightening
Sequence / Removing Broken Fasteners / Snap Rings
Drive Train Lubricants 99
Lubricating Oils / Grease
Chapter 6
Clutch Construction and Operation . . 105
Construction and Operation Overview 106
Detailed Construction and Operation 108
Flywheel / Transmission Input Shaft / Clutch Disc /
Pressure Plate Assembly / Throwout Bearing / Clutch
Fork / Clutch Linkage System / Clutch Housing
Chapter 7
Clutch Problems, Troubleshooting,
and Service . . . . . . . . . . . . . . . . . . . . . 125
Clutch Problems and Troubleshooting 126
Clutch Drag / Clutch Slippage / Grabbing Clutch /
Clutch Chatter / Clutch Vibration / Clutch Explosion /
Abnormal Noise / Hard Pedal Effort
In-Car Clutch Service 132
Clutch Adjustment / Clutch Linkage Repair and
Replacement
Clutch Removal 137
Front-Engine, Rear-Wheel Drive / Front-Engine,
Front-Wheel Drive
Clutch Parts Inspection and Repair 140
Pilot Bearing Service / Flywheel Service / Clutch
Disc Service / Pressure Plate Assembly Service /
Throwout Bearing Assembly Service / Clutch Fork
Service / Clutch Housing Service
Clutch Installation 150
Front-Engine, Rear-Wheel Drive / Front-Engine,
Front-Wheel Drive
Chapter 8
Manual Transmission Construction
and Operation . . . . . . . . . . . . . . . . . . 157
Purpose of the Manual Transmission 158
Operating the Manual Transmission 158
Construction and Internal Operation 158
Manual Transmission Shafts / Transmission Gears /
Synchronizers / Shift Forks / Manual Transmission
Shift Linkage / Manual Transmission Case /
Extension Housing / Accessory Parts
Manual Transmission Gear Oil 172
Manual Transmission Power Flow 172
Neutral / Reverse Gear / First Gear / Second Gear /
Third Gear / Fourth Gear / Fifth Gear
Manual Transmission Designs 174
4-Speed Transmissions / 5-Speed Transmissions /
6-Speed Transmissions
Chapter 9
Manual Transmission Problems,
Troubleshooting, and Service . . . . . . . 179
Manual Transmission Problems and
Troubleshooting 180
Lubricant Leakage / No-Drive Condition / Hard
Shifting / Gear Disengagement / Gear Clash /
Abnormal Noise
In-Car Manual Transmission Service 185
Manual Transmission Removal 185
General Removal Procedures
Manual Transmission Disassembly 189
Removing External Components / Removing Internal
Components / Disassembling the Components
Manual Transmission Parts Inspection 193
Visual Inspection / Measurement Inspection
Manual Transmission Assembly 196
Assembling the Components / Installing Internal
Components / Installing External Components
Manual Transmission Installation 201