AURLTQ101 Diagnose and repair light vehicle final drive assemblies

AURLTQ101 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 Procedureon 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 light vehicle final drive assembly 3. Repair light vehicle 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 67 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: – Methods to locate and interpret information required to diagnose and repair light vehicle final drive assemblies, including:Information provided by customers and supervisorsManufacturer specifications and procedures or equivalent documentationWorkplace procedures required to diagnose and repair light vehicle final drive assemblies, including: Establishing serviceability of tools and equipmentDocumentation proceduresHousekeeping procedures, including:Examination of tools and equipmentStorage of equipmentIdentification, tagging and isolation of faulty equipmentDisposal of excess materialsRecycling proceduresWorkplace health and safety (WHS) requirements relating to diagnosing and repairing light vehicle final drive assemblies, including procedures for working with hazardous oilsEnvironmental requirements relating to diagnosing and repairing light vehicle final drive assemblies, including procedures for trapping, storing and disposing of oils released from final drive assembliesOperating principles of light vehicle final drive assemblies and associated components, including:Final drive gears, including:Gear typesGear ratios and torque reduction and multiplicationDifferential functionPurpose and operation of light vehicle final drive assemblies and components, including:Removable carrier housing (banjo) type final drivesIntegral carrier housing type final drivesTransaxle final drivesDifferentials, including limited slip differentialsAxle shafts for rigid axles, including:Semi floating live axlesThree quarter floating live axlesFully floating live axlesDiagnostic testing procedures for light vehicle final drive assemblies, including procedures for:Road testing procedures, including:Final drive assembly noise diagnosticWheel bearing noise diagnosticPre-dismantling inspection proceduresRepair procedures for light vehicle final drive assemblies, including procedures for:Dismantling final drive assembliesInspecting final drive assembliesReassembling and adjusting pinion depth, pinion bearing preload, crown wheel and pinion backlash, side bearing preload and crown wheel and pinion tooth contactRepairing wheel bearings of rear wheel drive light vehiclesPost-repair testing procedures for light vehicle final drive assemblies
Assessment conditions	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 workplaceWorkplace instructionsManufacturer light vehicle final drive assembly specificationsTwo [2] different light vehicles:One with faults in its removable carrier housing (banjo) type final drive assemblyOne with faults in its integral carrier housing type final drive assemblyDiagnostic equipment for light vehicle final drive assembliesTools, equipment and materials appropriate for light vehicle final drive assemblies. Assessors of this unit MUST satisfy the requirements for assessors in applicable vocational education and training legislation, frameworks and/or standards.
Resources required	Learning Resources available to students include: Automotive Technology (A System Approach) 7th Edition – Chapters 5, 6, 7, 38, 39, 40 & 45WebsitesTrainer 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 incorrectFeedback will be provided on either resultWhere 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 documentWhere 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 some important items of personal safety or PPE when diagnosing and repairing light vehicle final drive assemblies?

Multiple Choice question. Selected the correct answer.

• Which of the following statements about safety glasses is true?

1. They should offer side protection.
2. The lenses should be made of a shatterproof material.
3. Some service operations require additional eye protection to be worn with safety glasses.
4. All the answers are correct.

Multiple Choice question. Selected the correct answer.

• When working and handling hazardous oils, which glove will give you the best protection against hazardous oils released from the vehicle when diagnosing and repairing light vehicle final drive assemblies?

1. Heavy work gloves.
2. Nitrile gloves.
3. Polyurethane gloves.
4. Insulating gloves.

• Referring to the VACC Automotive Environmental Guide, explain the four [4] step procedure for trapping, storing and disposing of hazardous oils released from the vehicle when diagnosing and repairing light vehicle final drive assemblies.

Multiple Choice question. Selected the correct answer.

• When working on light vehicle final drive assemblies, which document should you use to find how to handle, trap, store and dispose of new or waste hazardous oils?

1. Safety Data Sheet (SDS).
2. Technical Service Bulletin (TSB).
3. Product Information Letter (PIL).
4. All the answers are correct.

Multiple Choice question. Selected the correct answer.

• When working on light vehicle light vehicle final drive assemblies, trapping and storing wasted hazardous oils by setting up equipment such as:

1. Drip table or screen table with a used-oil collection bucket.
2. Place drip pans underneath vehicles that are leaking fluid.
3. Do not mix other waste with waste hazardous oils.
4. All the answers are correct.

• Describe the function of a differential.

• What are hypoid gears and why are hypoid gears used?

Multiple Choice question. Selected the correct answer.

• 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.

1. Spicer.
2. Torsen.
3. Ravigneaux.
4. DeDion.

True or False question

1. 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

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

True

or

False

True or False question

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

True

or

False

1. What is the function of the ring and pinion gears in the rear axle of an RWD vehicle?

Multiple Choice question. Selected the correct answer.

1. Ring and pinion gearsets are normally classified as ________.

1. Hunting gearset.
2. Non-hunting gearset.
3. Partial non-hunting gearset.
4. All the answers are correct.

Multiple Choice question. Selected the correct answer.

1. Which of the following gear ratios generates the highest torque or power output?

1. 0.85:1.
2. 2.67:1.
3. 5.23:1.
4. 11.12:1.

Multiple Choice question. Selected the correct answer.

1. Gears can _____.

1. Transfer speed and torque.
2. Decrease speed and increase torque.
3. Increase speed and decrease torque.
4. All the answers are correct.

Multiple Choice question. Selected the correct answer.

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

1. Changes the direction of power flow 90 degrees.
2. Transfers braking torque to the front wheels.
3. Allows the drive wheels to rotate at different speeds when negotiating a turn.
4. Reduces speed/multiplies torque.

Multiple Choice question. Selected the correct answer.

1. The _____ is the final set of reduction gears the engine’s power passes through on its way to the drive wheels?

1. Final fear.
2. Final drive.
3. Drive shaft.
4. Driveline.

True or False question

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

True

or

False

Fill in the Missing Words

• Place the missing word to complete the following statement about integral carrier housing using the following words.

Missing Words: carrier, final, gear, housing, removable, tubes

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

True or False question

• Transaxles contain the transmission and the final drive gear assembly.

True

or

False

Multiple Choice question. Selected the correct answer.

• A collapsible pinion spacer is used to set the _____.

1. Pinion depth.
2. Pinion bearing preload.
3. Housing (carrier) bearing preload.
4. Backlash.

• Describe the action of differential side gears when the vehicle is cornering

• What is the purpose of a limited slip differential?

.

True or False question

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

True

or

False

True or False question

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

True

or

False

Multiple Choice question. Selected the correct answer.

• Which type of drive axle supports the weight of the vehicle?

1. Semi-floating.
2. Three-quarter floating.
3. Full-floating.
4. Both “semi-floating” and “three-quarter floating”.

Multiple Choice question. Selected the correct answer.

• Full floating axle shafts are found on ______.

1. Front axles of an FWD car.
2. Rear axle of an RWD car.
3. Front axle of a 4WD SUV.
4. Rear axle of a heavy-duty truck.

True or False question

• 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

• 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.

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

1. Sealed ball.
2. Tapered roller.
3. Straight roller.
4. All answers are correct.

• How is the bearing usually secured on the axle shaft of a semi-floating rear axle?

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

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

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

Fill in Missing Words

• Place the missing word to complete the following statement about crown wheel and pinion diagnosis using the following words.

Missing 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

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

True

or

False

AURLTQ101 Diagnose and repair light vehicle final drive assemblies

True or False question

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

True

or

False

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

True or False question

• 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.

• Pinion gear depth is adjusted by ______.

1. Threaded adjusters behind the housing bearing outer cups.
2. Shims placed between the differential housing [carrier] and housing bearings.
3. Threaded adjusters between the companion flange and front pinion bearing.
4. Shims placed between the pinion bearing and pinion gear.

• Explain how pinion bearing preload is set?

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

True or False question

• 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

• 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

• 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 of face milled ring gear, name patterns on a ring gear and the necessary corrections.

True or False question

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

True

or

False

True or False question

• 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.

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

1. Castellated nut.
2. Thrust washer.
3. Spindle.
4. Race.

• 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.

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

1. Workshop manual.
2. Owner’s manual.
3. Google.
4. Textbooks.

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

True and False

• An automotive technician must adhere to workshop safety guidelines and procedures when using all tools and equipment.

True

or

False

True and False

• An automotive technician is required to document the work that was performed on a vehicle. Writing or typing in the description of the steps performed during the diagnosis of the vehicle should be worded as if the technician is talking to the customer.

True

or

False

True and False

• Inspect your tools for cracks, broken parts, or other dangerous conditions before you use them. Never use broken or damaged tools.

True

or

False

True and False

• For best results and long tool life, each tool used must be cleaned and checked before placing it back into the toolbox.

True

or

False

Multiple Choice question. Select the correct answer.

• Lockout/tagout practices and procedures are intended to reduce the risk of automotive technicians’ inadvertently using tools, equipment or materials that have been determined to?

1. Be unsafe or potentially unsafe.
2. That are in the process of being serviced.
3. Both “Be unsafe or potentially unsafe” and “That are in the process of being serviced”.
4. Neither “Be unsafe or potentially unsafe” and “That are in the process of being serviced”.

True and False

• Disposing of excess oil, can be dispose into their correct sealed recycling drum.

True

or

False

True and False

• Second-hand final drive components, axle shafts, final drive assemblies etc that are in good condition can be reused on the other vehicles of the same make and model?

True

or

False

True and False

• An automotive technician must adhere to workshop safety guidelines and procedures and follow the manufactures procedures in the workshop manual when diagnosing faults in final drive assemblies.

True

or

False

• You are diagnosing final drive assembly fault Mitsubishi Pajero and require the drive gear backlash, runout and clearance specifications. Referring to the Mitsubishi Pajero “Rear Axle” Workshop Manual, locate and interpret the backlash, runout and clearance specification for the following:

Axle Shaft Axial Play (mm):

Clearance Between Axle Shaft Retainer and Snap Ring (mm):

Drive Gear Backlash (mm):

Drive Gear Runout (mm):

Differential Gear Backlash (mm):

Multiple Choice question. Select the correct answer.

• 62.   A work order is selected or assigned to a service technician who then performs the listed tasks. The work order should be written so that the technician knows exactly what needs to be done. However, if there is any doubt, the technician should clarify the needed task with the ________ or the person who spoke to the customer.

1. Service advisor.
2. Service technician.
3. Spare parts manager.
4. New car sales manager.

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