| Preface |
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xv | |
| Acknowledgments |
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xvii | |
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Chapter 1 Introduction to the Trucking Industry |
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1 | (14) |
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History of the Trucking Industry |
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2 | (1) |
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2 | (2) |
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2 | (1) |
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2 | (1) |
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Truck Type and Weight Class |
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3 | (1) |
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4 | (1) |
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Medium- and Heavy-Duty Truck Manufacturers |
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5 | (4) |
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Trucking Industry Careers |
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9 | (2) |
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11 | (1) |
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11 | (1) |
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11 | (1) |
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Technician Certifications |
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11 | (2) |
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11 | (2) |
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13 | (2) |
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15 | (12) |
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16 | (1) |
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16 | (1) |
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17 | (1) |
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17 | (1) |
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18 | (1) |
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19 | (1) |
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20 | (1) |
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20 | (1) |
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How to Use a Fire Extinguisher |
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21 | (1) |
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21 | (3) |
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Hazardous Materials (HAZMAT) and Safety Training |
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21 | (1) |
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Material Safety Data Sheet |
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22 | (1) |
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22 | (1) |
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Mine Safety and Health Administration |
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23 | (1) |
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24 | (3) |
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Chapter 3 Tools and Measuring Equipment |
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27 | (18) |
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28 | (1) |
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SAE and Metric Thread Bolts |
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28 | (1) |
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U.S. to Metric Conversions |
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28 | (1) |
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28 | (7) |
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28 | (2) |
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Impact versus Chrome Sockets |
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30 | (1) |
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Twelve-Point versus Six-Point Sockets |
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31 | (1) |
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Specialty Sockets and Bolts |
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31 | (1) |
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31 | (1) |
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Tightening and Torquing Procedures |
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32 | (1) |
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32 | (1) |
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Pliers and Adjustable Wrenches |
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33 | (1) |
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Hammers, Chisels, and Punches |
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34 | (1) |
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35 | (1) |
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Shop Hydraulic Lifting Tools and Support Stands |
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36 | (1) |
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37 | (1) |
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38 | (1) |
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Micrometers and Precision Measuring Tools |
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38 | (3) |
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Introduction to Micrometers |
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38 | (1) |
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38 | (1) |
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39 | (1) |
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Measuring with a Micrometer |
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40 | (1) |
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40 | (1) |
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40 | (1) |
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40 | (1) |
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41 | (1) |
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42 | (3) |
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Chapter 4 Basic Electrical |
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45 | (18) |
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Conductors, Insulators, and Semiconductors |
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46 | (1) |
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46 | (1) |
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46 | (1) |
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47 | (1) |
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47 | (1) |
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Conventional and Electron Theories |
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47 | (1) |
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47 | (1) |
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47 | (1) |
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47 | (5) |
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47 | (1) |
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48 | (1) |
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48 | (1) |
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Electrical Comparison with Water Flow |
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49 | (1) |
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49 | (1) |
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50 | (1) |
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50 | (1) |
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51 | (1) |
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52 | (4) |
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52 | (1) |
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52 | (1) |
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Digital Volt-Ohmmeter (DVOM) Settings |
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52 | (3) |
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Making Voltage Measurements |
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55 | (1) |
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Making Resistance Measurements |
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56 | (1) |
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56 | (3) |
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56 | (3) |
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59 | (2) |
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61 | (2) |
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63 | (10) |
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64 | (1) |
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64 | (3) |
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64 | (1) |
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64 | (2) |
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Electromagnetic Components |
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66 | (1) |
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Component Testing and Diagnosis |
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67 | (5) |
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67 | (1) |
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68 | (1) |
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69 | (1) |
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Clamping Diode or Resistor |
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70 | (2) |
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72 | (1) |
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73 | (14) |
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74 | (1) |
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74 | (1) |
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74 | (1) |
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74 | (1) |
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Battery Charge and Discharge |
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74 | (1) |
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74 | (2) |
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Maintenance-Type Batteries |
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74 | (1) |
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Maintenance-Free Batteries |
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75 | (1) |
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76 | (1) |
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76 | (1) |
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Battery Cables and Connections |
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76 | (3) |
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76 | (1) |
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Series Battery Connections |
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76 | (1) |
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Parallel Battery Connections |
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77 | (1) |
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77 | (1) |
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78 | (1) |
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78 | (1) |
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79 | (1) |
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Battery Testing and Diagnosis |
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79 | (7) |
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Battery Visual Inspection |
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79 | (1) |
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Battery Capacitance or Conductance Test |
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79 | (2) |
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81 | (1) |
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Static or Open-Circuit Voltage Test |
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82 | (1) |
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82 | (1) |
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Battery Surface-Discharge Test |
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83 | (1) |
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Battery Parasitic-Draw Test |
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83 | (1) |
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84 | (1) |
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84 | (2) |
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86 | (1) |
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Chapter 7 Starting System |
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87 | (12) |
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88 | (1) |
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88 | (2) |
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90 | (1) |
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Starting System Testing and Diagnosis |
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91 | (3) |
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91 | (1) |
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91 | (2) |
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Starter Amperage Draw Tests |
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93 | (1) |
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94 | (2) |
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96 | (3) |
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Chapter 8 The Charging System |
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99 | (12) |
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100 | (1) |
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100 | (4) |
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Alternator Removal and Installation |
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104 | (1) |
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104 | (1) |
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104 | (1) |
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Alternator Component Testing |
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105 | (2) |
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105 | (1) |
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Alternator Component Testing |
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105 | (1) |
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106 | (1) |
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Charging System Testing and Diagnosis |
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107 | (3) |
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107 | (1) |
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Charging-System Voltage-Drop Tests |
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107 | (1) |
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Alternator Amperage Output Tests |
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108 | (1) |
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109 | (1) |
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110 | (1) |
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Chapter 9 Lighting and Wiring |
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111 | (18) |
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112 | (1) |
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112 | (1) |
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112 | (1) |
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113 | (4) |
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113 | (2) |
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115 | (2) |
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117 | (1) |
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Connection/Resistance Problems |
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117 | (1) |
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Short and Short-to-Ground Problems |
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118 | (1) |
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118 | (5) |
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118 | (1) |
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119 | (1) |
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Headlight and Parking-Light Switch Circuit |
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119 | (2) |
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Brake Lights and Turn Signals |
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121 | (1) |
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Turn Signals, Four-Way Flashers, and Brake-Light Bulbs |
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121 | (1) |
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122 | (1) |
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123 | (1) |
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123 | (2) |
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124 | (1) |
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124 | (1) |
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Weather-Tight Connections |
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124 | (1) |
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Lighting-Circuit Voltage Drops |
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125 | (2) |
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127 | (2) |
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Chapter 10 Computer Systems |
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129 | (22) |
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130 | (1) |
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130 | (1) |
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130 | (1) |
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130 | (1) |
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Analog-to-Digital (A/D) Convertors |
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130 | (1) |
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131 | (1) |
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131 | (1) |
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Computer System Operation |
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131 | (1) |
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132 | (10) |
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132 | (1) |
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133 | (3) |
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136 | (1) |
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137 | (2) |
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Speed and Position Sensors |
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139 | (1) |
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Permanent-Magnet Generator Operation |
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139 | (1) |
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Hall-Effect Sensor Operation |
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140 | (2) |
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142 | (1) |
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Single-Pole, Single-Throw (SPST) Switches |
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142 | (1) |
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Single-Pole, Double-Throw (SPDT) Switches |
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143 | (1) |
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143 | (1) |
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143 | (1) |
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143 | (1) |
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143 | (5) |
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143 | (2) |
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145 | (1) |
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146 | (2) |
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148 | (3) |
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Chapter 11 Advanced Computer Systems |
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151 | (12) |
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Computer Systems and Their Original Equipment Manufacturers |
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152 | (1) |
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Automatic Braking System (ABS)/Automatic Traction Control (ATC) |
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152 | (1) |
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Automated Manual Transmissions |
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152 | (1) |
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Allison Automatic Transmissions |
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152 | (1) |
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152 | (1) |
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152 | (1) |
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Computer System Malfunctions |
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153 | (1) |
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Malfunction Indicator Lights (MILs) |
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153 | (1) |
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154 | (1) |
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154 | (1) |
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155 | (1) |
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OEM Laptop- or PC-Based Diagnostic Software |
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156 | (3) |
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157 | (1) |
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158 | (1) |
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158 | (1) |
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Sensor Output Voltage Test |
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158 | (1) |
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159 | (1) |
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159 | (1) |
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Accident-Prevention Technology and Collision-Mitigation Systems |
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159 | (3) |
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Roll and Stability Control |
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160 | (1) |
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Forward and Side Radar Systems |
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160 | (1) |
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Forward and Side Radar Setup |
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161 | (1) |
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162 | (1) |
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Chapter 12 Mobile Heating, Ventilation, and Air-Conditioning Systems |
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163 | (24) |
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The Basics of Air Conditioning |
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164 | (3) |
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164 | (1) |
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165 | (1) |
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165 | (1) |
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Effects of Pressure on Boiling Points |
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165 | (1) |
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165 | (1) |
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Section 609 of the Clean Air Act of 1990 |
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166 | (1) |
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166 | (1) |
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Pressure-Temperature Coefficient |
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167 | (1) |
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167 | (3) |
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Refrigeration System with an Expansion Valve |
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168 | (1) |
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Refrigeration System with a Fixed Orifice Tube |
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168 | (1) |
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Auxiliary Rear AC or Sleeper AC |
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169 | (1) |
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170 | (6) |
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170 | (1) |
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171 | (1) |
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172 | (1) |
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Binary/Trinary Switches and Pressure Sensors |
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172 | (1) |
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173 | (1) |
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174 | (1) |
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175 | (1) |
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175 | (1) |
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176 | (1) |
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176 | (4) |
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Refrigerant Recovery and Recharging Stations |
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176 | (2) |
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178 | (1) |
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179 | (1) |
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Using a Refrigerant Identifier |
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179 | (1) |
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179 | (1) |
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Using an Electronic Leak Detector |
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179 | (1) |
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Using an Ultraviolet Leak Tester |
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179 | (1) |
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Replacing AC System Components |
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180 | (2) |
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Hose and Line Connections |
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180 | (1) |
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180 | (1) |
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180 | (1) |
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Replacing a Receiver Drier |
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180 | (1) |
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181 | (1) |
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181 | (1) |
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Replacing a Fixed Orifice Tube |
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181 | (1) |
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181 | (1) |
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181 | (1) |
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181 | (1) |
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182 | (3) |
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182 | (1) |
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182 | (1) |
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183 | (2) |
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185 | (2) |
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Chapter 13 Heating and Air-Conditioning Controls |
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187 | (16) |
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Basics of the Engine Cooling System |
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188 | (5) |
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188 | (1) |
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189 | (1) |
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189 | (1) |
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Cooling System Components |
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190 | (3) |
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193 | (6) |
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194 | (1) |
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Door Controls and Actuators |
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194 | (1) |
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195 | (1) |
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Auxiliary or Sleeper AC/Heat Control |
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195 | (1) |
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196 | (1) |
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196 | (2) |
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198 | (1) |
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198 | (1) |
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199 | (1) |
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Air-Conditioning Protection and Diagnostic System (APADS) |
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199 | (2) |
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201 | (2) |
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Chapter 14 Tires, Wheels, and Wheel-End Systems |
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203 | (32) |
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204 | (3) |
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207 | (1) |
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207 | (2) |
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208 | (1) |
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209 | (4) |
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209 | (1) |
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209 | (2) |
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211 | (1) |
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SmartWay Transport Partnership (Division of the U.S. Environmental Protection Agency) |
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211 | (2) |
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213 | (7) |
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215 | (1) |
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215 | (1) |
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216 | (1) |
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217 | (1) |
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217 | (3) |
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Hubs, Wheel Bearings, and Seals |
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220 | (12) |
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220 | (1) |
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220 | (1) |
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Wheel Bearing Endplay Check |
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220 | (1) |
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221 | (7) |
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228 | (1) |
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229 | (3) |
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232 | (3) |
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Chapter 15 Frame and Suspension |
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235 | (22) |
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Frame Types and Construction |
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236 | (5) |
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236 | (1) |
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236 | (1) |
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237 | (1) |
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238 | (2) |
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240 | (1) |
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Leaf-Spring Suspension Systems |
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241 | (7) |
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Leaf-Spring System Components |
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241 | (2) |
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Off-Road Vocational versus On-Road Highway Suspension Systems |
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243 | (3) |
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246 | (2) |
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248 | (1) |
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Air-Spring Suspension Systems |
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248 | (3) |
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Parts of an Air/Leaf-Spring Suspension System |
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248 | (1) |
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249 | (1) |
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Air Suspension System Checks and Inspections |
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250 | (1) |
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Air Suspension System Component Replacement |
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251 | (1) |
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Air-Spring Diagnosis and Adjustment |
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252 | (1) |
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252 | (1) |
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Ride Height Too Low or Too High |
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253 | (1) |
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253 | (1) |
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253 | (1) |
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Air-Operated Pusher and Tag Axles |
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253 | (1) |
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254 | (1) |
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254 | (1) |
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254 | (1) |
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255 | (1) |
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255 | (1) |
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Cab Air Suspension System Diagnosis |
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255 | (1) |
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256 | (1) |
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Chapter 16 Steering Systems |
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257 | (36) |
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Components of the Steering Linkage |
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258 | (4) |
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258 | (1) |
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258 | (1) |
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258 | (1) |
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258 | (1) |
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258 | (1) |
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259 | (1) |
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259 | (2) |
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261 | (1) |
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261 | (1) |
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261 | (1) |
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261 | (1) |
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Steering-Linkage Maintenance and Checks |
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262 | (3) |
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265 | (1) |
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Replacing Kingpin Bushings |
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265 | (6) |
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265 | (3) |
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268 | (3) |
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271 | (1) |
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271 | (11) |
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271 | (1) |
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271 | (1) |
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272 | (2) |
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274 | (1) |
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274 | (1) |
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274 | (1) |
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Power Steering System Tests |
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275 | (1) |
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Steering-Gear Replacement |
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276 | (1) |
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276 | (3) |
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Power Steering Pump Repair |
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279 | (3) |
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Steering-System Maintenance |
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282 | (1) |
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282 | (8) |
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Prealignment Checks and Setup |
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282 | (1) |
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283 | (1) |
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284 | (1) |
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285 | (1) |
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286 | (1) |
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286 | (1) |
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287 | (1) |
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288 | (1) |
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288 | (1) |
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Kingpin Inclination or Steering-Axis Inclination |
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288 | (1) |
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|
288 | (1) |
|
|
|
288 | (1) |
|
Toe-Out on Turns or Ackerman Angle |
|
|
289 | (1) |
|
|
|
290 | (3) |
|
Chapter 17 Trailers and Fifth Wheels |
|
|
293 | (24) |
|
|
|
294 | (2) |
|
|
|
294 | (1) |
|
|
|
294 | (1) |
|
|
|
295 | (1) |
|
|
|
295 | (1) |
|
|
|
296 | (1) |
|
|
|
296 | (1) |
|
Trailer Suspension Systems |
|
|
296 | (2) |
|
|
|
296 | (1) |
|
Air/Leaf-Spring Suspension |
|
|
297 | (1) |
|
Sliding Tandem Suspension |
|
|
297 | (1) |
|
|
|
298 | (1) |
|
Trailer Door Operation and Service |
|
|
298 | (1) |
|
Overhead or Roll-Up Doors |
|
|
298 | (1) |
|
|
|
299 | (1) |
|
Trailer Lighting Operation and Service |
|
|
299 | (1) |
|
|
|
299 | (1) |
|
|
|
299 | (1) |
|
Reflectors or Reflective Tape |
|
|
300 | (1) |
|
SmartWay Transportation Partnership |
|
|
300 | (1) |
|
Coupling Devices and Fifth Wheel Operation |
|
|
300 | (2) |
|
|
|
300 | (1) |
|
|
|
301 | (1) |
|
Simplex/Holland A-Type Lock |
|
|
301 | (1) |
|
|
|
301 | (1) |
|
|
|
301 | (1) |
|
|
|
301 | (1) |
|
Compensating Fifth Wheel Mounts |
|
|
302 | (1) |
|
|
|
302 | (1) |
|
|
|
303 | (1) |
|
|
|
303 | (1) |
|
Fifth Wheel Diagnosis and Service |
|
|
303 | (10) |
|
|
|
303 | (1) |
|
|
|
303 | (1) |
|
Fifth Wheel Repair and Replacement |
|
|
304 | (1) |
|
|
|
304 | (9) |
|
|
|
313 | (1) |
|
Coupling and Uncoupling a Trailer |
|
|
313 | (2) |
|
|
|
315 | (2) |
|
Chapter 18 Hydraulic Brake Systems |
|
|
317 | (26) |
|
Pascal's Laws of Hydraulics |
|
|
318 | (1) |
|
Hydraulic Brake System Pressures |
|
|
318 | (1) |
|
|
|
318 | (1) |
|
|
|
318 | (1) |
|
|
|
318 | (1) |
|
Brake Fluid Recommendations |
|
|
319 | (1) |
|
Basic Hydraulic Brake System Components |
|
|
319 | (4) |
|
|
|
319 | (1) |
|
|
|
320 | (1) |
|
|
|
320 | (3) |
|
|
|
323 | (1) |
|
|
|
323 | (1) |
|
Pressure Differential Valve/Switch |
|
|
323 | (1) |
|
|
|
323 | (1) |
|
Hydraulic Brake System Diagnosis |
|
|
323 | (1) |
|
Hydraulic Brake System Services |
|
|
324 | (2) |
|
Bleeding and Flushing a Hydraulic System |
|
|
324 | (1) |
|
|
|
325 | (1) |
|
|
|
326 | (9) |
|
|
|
326 | (4) |
|
|
|
330 | (5) |
|
|
|
335 | (1) |
|
|
|
335 | (1) |
|
|
|
336 | (1) |
|
|
|
336 | (4) |
|
|
|
337 | (3) |
|
|
|
340 | (1) |
|
Power Brake Booster Removal and Reinstallation |
|
|
340 | (2) |
|
|
|
342 | (1) |
|
Chapter 19 Air-Brake Foundation Brakes |
|
|
343 | (28) |
|
S-Cam Brake Principles of Operation |
|
|
344 | (9) |
|
|
|
344 | (2) |
|
|
|
346 | (2) |
|
|
|
348 | (1) |
|
|
|
348 | (3) |
|
|
|
351 | (1) |
|
|
|
352 | (1) |
|
|
|
352 | (1) |
|
|
|
353 | (1) |
|
|
|
353 | (8) |
|
S-Cam Brake Adjustment Check |
|
|
353 | (1) |
|
Slack-Adjuster-to-Pushrod Angle |
|
|
354 | (1) |
|
DOT Inspection Limits for Brake Adjustments |
|
|
354 | (1) |
|
Replacing a Slack Adjuster |
|
|
354 | (1) |
|
|
|
354 | (1) |
|
|
|
355 | (5) |
|
|
|
360 | (1) |
|
|
|
361 | (7) |
|
|
|
362 | (1) |
|
Air Disc-Brake Inspections |
|
|
363 | (5) |
|
|
|
368 | (1) |
|
|
|
368 | (1) |
|
|
|
368 | (1) |
|
|
|
369 | (2) |
|
Chapter 20 Air-Brake Air System |
|
|
371 | (28) |
|
Air System Theory of Operation |
|
|
372 | (1) |
|
Air Supply System Components and Operation |
|
|
372 | (12) |
|
|
|
372 | (3) |
|
|
|
375 | (2) |
|
|
|
377 | (1) |
|
|
|
378 | (1) |
|
|
|
378 | (4) |
|
|
|
382 | (1) |
|
|
|
382 | (1) |
|
|
|
382 | (1) |
|
|
|
383 | (1) |
|
Primary Air-System Components and Operation |
|
|
384 | (4) |
|
|
|
384 | (1) |
|
|
|
384 | (2) |
|
Service-Brake Relay Valve |
|
|
386 | (2) |
|
Secondary Air-System Components and Operation |
|
|
388 | (1) |
|
|
|
388 | (1) |
|
|
|
388 | (1) |
|
|
|
388 | (1) |
|
Emergency/Parking and Trailer Air-System Components and Operation |
|
|
389 | (5) |
|
Parking-Brake Control Knobs |
|
|
389 | (1) |
|
|
|
390 | (1) |
|
Parking-Brake Relay Valve |
|
|
391 | (2) |
|
|
|
393 | (1) |
|
Bobtail Proportioning Valve |
|
|
394 | (1) |
|
|
|
394 | (1) |
|
|
|
394 | (4) |
|
Trailer Supply Push-Pull (PP-7) Valve |
|
|
394 | (1) |
|
|
|
395 | (1) |
|
|
|
395 | (1) |
|
|
|
396 | (1) |
|
Trailer Spring-Brake Valve |
|
|
397 | (1) |
|
Trailer Service-Brake Relay Valve |
|
|
397 | (1) |
|
Dash-Mounted Trailer Hand Valve |
|
|
397 | (1) |
|
|
|
398 | (1) |
|
Pressure-Protection Valve or Priority Valve |
|
|
398 | (1) |
|
|
|
398 | (1) |
|
DOT Air-Brake-System Inspections |
|
|
398 | (1) |
|
|
|
398 | (1) |
|
Chapter 21 Anti-lock Brake Systems |
|
|
399 | (30) |
|
Air ABS Overview and Terminology |
|
|
400 | (1) |
|
ABS Components, Operation, and Testing |
|
|
400 | (9) |
|
|
|
402 | (1) |
|
|
|
402 | (1) |
|
|
|
402 | (3) |
|
|
|
405 | (4) |
|
Automatic Traction Control (ATC) Operation |
|
|
409 | (1) |
|
|
|
409 | (1) |
|
Meritor Wabco ToolBox Software |
|
|
410 | (1) |
|
Using Meritor ToolBox Software |
|
|
410 | (1) |
|
|
|
411 | (1) |
|
|
|
412 | (3) |
|
|
|
412 | (3) |
|
|
|
415 | (5) |
|
Three- or Four-Channel HABS |
|
|
416 | (1) |
|
|
|
416 | (4) |
|
|
|
420 | (1) |
|
Meritor Wabco Hydraulic Power-Brake (HPB) System |
|
|
420 | (7) |
|
|
|
420 | (3) |
|
|
|
423 | (1) |
|
HPB Bleeding and Depressurizing Procedures |
|
|
424 | (3) |
|
|
|
427 | (2) |
|
|
|
429 | (20) |
|
Driveshaft Overview and Terminology |
|
|
430 | (1) |
|
Driveshaft Components and Operation |
|
|
430 | (11) |
|
|
|
430 | (4) |
|
|
|
434 | (6) |
|
Driveshaft Tube and Yokes |
|
|
440 | (1) |
|
|
|
440 | (1) |
|
|
|
441 | (2) |
|
|
|
442 | (1) |
|
|
|
443 | (5) |
|
Measuring Driveline Angles |
|
|
443 | (5) |
|
|
|
448 | (1) |
|
|
|
449 | (30) |
|
Clutch Overview and Terminology |
|
|
450 | (5) |
|
|
|
450 | (1) |
|
|
|
450 | (1) |
|
|
|
451 | (1) |
|
|
|
451 | (2) |
|
|
|
453 | (1) |
|
|
|
453 | (1) |
|
|
|
453 | (2) |
|
Clutch Components and Operation |
|
|
455 | (2) |
|
|
|
455 | (1) |
|
|
|
455 | (1) |
|
|
|
456 | (1) |
|
|
|
457 | (2) |
|
Push-Type Clutch Adjustment |
|
|
457 | (1) |
|
Heavy-Duty Pull-Type Clutch Adjustment |
|
|
458 | (1) |
|
Clutch Replacement and Inspection |
|
|
459 | (19) |
|
Push-Type Clutch Replacement and Inspection |
|
|
459 | (3) |
|
Pull-Type Clutch Replacement and Inspection |
|
|
462 | (1) |
|
|
|
463 | (1) |
|
|
|
464 | (1) |
|
|
|
465 | (1) |
|
|
|
466 | (2) |
|
Reinstalling the Transmission |
|
|
468 | (4) |
|
|
|
472 | (6) |
|
|
|
478 | (1) |
|
|
|
479 | (34) |
|
Drive-Axle Overview and Terminology |
|
|
480 | (9) |
|
|
|
480 | (1) |
|
|
|
481 | (1) |
|
|
|
482 | (2) |
|
|
|
484 | (1) |
|
Inter-Axle Differential or Power Divider |
|
|
484 | (3) |
|
|
|
487 | (2) |
|
Drive-Axle Carrier Service |
|
|
489 | (2) |
|
Removing a Drive-Axle Carrier |
|
|
490 | (1) |
|
Installing a Drive-Axle Carrier |
|
|
490 | (1) |
|
Drive-Axle Service and Overhaul |
|
|
491 | (14) |
|
|
|
491 | (1) |
|
|
|
492 | (1) |
|
|
|
492 | (2) |
|
Single-Drive-Axle Disassembly |
|
|
494 | (5) |
|
Single-Drive-Axle Assembly |
|
|
499 | (2) |
|
IAD or Power-Divider Axle Disassembly |
|
|
501 | (1) |
|
Inter-Axle Differential Inspection |
|
|
501 | (2) |
|
IAD or Power-Divider Axle Assembly |
|
|
503 | (1) |
|
Integral-Drive-Axle Disassembly and Reassembly |
|
|
504 | (1) |
|
Inter-Axle--Lock Service and Diagnosis |
|
|
505 | (1) |
|
Main Locking Differential (Optional) |
|
|
505 | (1) |
|
Positraction or Limited Slip Differentials |
|
|
505 | (5) |
|
|
|
510 | (2) |
|
|
|
510 | (2) |
|
|
|
512 | (1) |
|
Chapter 25 Single-Countershaft Manual Transmissions |
|
|
513 | (24) |
|
Transmission Overview and Terminology |
|
|
514 | (11) |
|
|
|
514 | (2) |
|
|
|
516 | (2) |
|
|
|
518 | (1) |
|
|
|
518 | (2) |
|
|
|
520 | (1) |
|
|
|
521 | (3) |
|
|
|
524 | (1) |
|
Five- and Six-Speed Transmission Removal and Installation |
|
|
525 | (1) |
|
|
|
525 | (1) |
|
Installing a Transmission |
|
|
525 | (1) |
|
Five- and Six-Speed Transmission Service and Overhaul |
|
|
525 | (7) |
|
Five- and Six-Speed Transmission Disassembly |
|
|
525 | (2) |
|
|
|
527 | (2) |
|
|
|
529 | (1) |
|
Six-Speed Shift-Cover Repair |
|
|
530 | (2) |
|
Five- and Six-Speed Transmission Diagnosis |
|
|
532 | (1) |
|
|
|
532 | (1) |
|
|
|
532 | (1) |
|
|
|
532 | (1) |
|
|
|
532 | (1) |
|
Transmission Pops Out of Gear |
|
|
532 | (1) |
|
|
|
533 | (2) |
|
|
|
533 | (1) |
|
|
|
533 | (1) |
|
|
|
533 | (2) |
|
|
|
535 | (2) |
|
Chapter 26 Twin-Countershaft Manual Transmissions |
|
|
537 | (44) |
|
Twin-Countershaft Transmission Overview and Terminology |
|
|
538 | (8) |
|
Main-Transmission Nonsynchronized Shifting |
|
|
539 | (1) |
|
|
|
539 | (1) |
|
|
|
540 | (2) |
|
|
|
542 | (1) |
|
|
|
542 | (1) |
|
|
|
543 | (3) |
|
Twin-Countershaft Main-Transmission Service |
|
|
546 | (10) |
|
|
|
546 | (1) |
|
Installing the Transmission |
|
|
546 | (1) |
|
Twin-Countershaft Transmission Disassembly |
|
|
546 | (3) |
|
|
|
549 | (2) |
|
|
|
551 | (1) |
|
|
|
552 | (4) |
|
|
|
556 | (1) |
|
Twin-Countershaft Auxiliary-Transmission Components and Operation |
|
|
556 | (3) |
|
Two Speed Auxiliary-Transmission Power Flow for All Transmissions |
|
|
556 | (2) |
|
Three-Speed Auxiliary-Transmission Power Flow |
|
|
558 | (1) |
|
Twin-Countershaft Auxiliary-Transmission Service |
|
|
559 | (7) |
|
Two-Speed Auxiliary-Transmission Repairs |
|
|
562 | (4) |
|
Transmission Two-Speed Auxiliary Air-System Components |
|
|
566 | (6) |
|
Pressure Regulator and Filter |
|
|
566 | (1) |
|
|
|
567 | (1) |
|
|
|
568 | (1) |
|
|
|
568 | (3) |
|
|
|
571 | (1) |
|
Transmission Three-Speed Auxiliary-Section Air-System Components |
|
|
572 | (1) |
|
|
|
572 | (1) |
|
|
|
572 | (1) |
|
Twin-Countershaft Transmission Diagnosis |
|
|
573 | (2) |
|
|
|
573 | (1) |
|
|
|
573 | (1) |
|
|
|
573 | (1) |
|
|
|
573 | (1) |
|
|
|
574 | (1) |
|
Transmission Pops Out of Gear |
|
|
574 | (1) |
|
|
|
575 | (1) |
|
Twin-Countershaft Transmission Maintenance |
|
|
575 | (4) |
|
|
|
575 | (1) |
|
|
|
575 | (1) |
|
|
|
575 | (4) |
|
|
|
579 | (2) |
|
Chapter 27 Automated Manual Transmissions |
|
|
581 | (32) |
|
Automated Transmission Overview and Terminology |
|
|
582 | (13) |
|
Transmission ID and Models |
|
|
582 | (1) |
|
Automated Transmission Overview |
|
|
582 | (2) |
|
|
|
584 | (2) |
|
|
|
586 | (1) |
|
|
|
586 | (2) |
|
|
|
588 | (1) |
|
Electronic Clutch Actuator |
|
|
589 | (1) |
|
Low-Capacity Inertia Brake |
|
|
590 | (1) |
|
High-Capacity Inertia Brake |
|
|
590 | (1) |
|
|
|
590 | (4) |
|
|
|
594 | (1) |
|
|
|
594 | (1) |
|
Eaton Medium-Duty ASW (Wet Clutch) Six-Speed Transmission Components and Operation |
|
|
595 | (1) |
|
|
|
595 | (1) |
|
|
|
595 | (1) |
|
|
|
595 | (1) |
|
AutoShift and UltraShift Transmission Testing and Diagnosis |
|
|
595 | (6) |
|
|
|
599 | (1) |
|
Vehicle Information and Setup |
|
|
600 | (1) |
|
Manually Retrieving Trouble Codes |
|
|
601 | (1) |
|
|
|
601 | (1) |
|
Retrieving Soft or Intermittent Codes |
|
|
601 | (1) |
|
|
|
602 | (1) |
|
|
|
602 | (1) |
|
Diagnosis with No Fault Codes |
|
|
602 | (1) |
|
|
|
603 | (5) |
|
|
|
605 | (1) |
|
|
|
606 | (2) |
|
|
|
608 | (1) |
|
ZF/FreedomLine Transmissions |
|
|
608 | (3) |
|
|
|
608 | (2) |
|
|
|
610 | (1) |
|
|
|
611 | (2) |
|
Chapter 28 Automatic Transmissions |
|
|
613 | (32) |
|
Automatic Transmission Components |
|
|
614 | (10) |
|
|
|
614 | (1) |
|
|
|
614 | (1) |
|
|
|
615 | (2) |
|
|
|
617 | (7) |
|
Automatic Transmission Planetary Gear Sets |
|
|
624 | (4) |
|
Planetary Gear Set Operation |
|
|
624 | (1) |
|
Gear-Set Components Being Held |
|
|
624 | (1) |
|
Gear-Set Components Being Driven |
|
|
625 | (1) |
|
Planetary Gear Set Arrangement |
|
|
625 | (1) |
|
Thrust Washers and Bearings |
|
|
625 | (3) |
|
Planetary Carrier Components |
|
|
628 | (1) |
|
|
|
628 | (1) |
|
|
|
628 | (5) |
|
|
|
633 | (2) |
|
|
|
633 | (1) |
|
|
|
633 | (1) |
|
|
|
634 | (1) |
|
Torque-Convertor Oil Flows |
|
|
634 | (1) |
|
Torque-Converter Clutch (TCC) |
|
|
635 | (1) |
|
Torque-Converter Testing and Diagnosis |
|
|
635 | (2) |
|
Torque-Converter Stall Test |
|
|
635 | (1) |
|
Torque-Converter Endplay Check |
|
|
636 | (1) |
|
Removing and Installing a Torque Converter |
|
|
636 | (1) |
|
Automatic Transmission Removal and Reinstallation |
|
|
637 | (3) |
|
|
|
638 | (1) |
|
Installing a Transmission |
|
|
638 | (2) |
|
Automatic Transmission Service and Maintenance |
|
|
640 | (2) |
|
|
|
640 | (1) |
|
|
|
640 | (2) |
|
|
|
642 | (3) |
|
Chapter 29 Allison Automatic Transmissions |
|
|
645 | (34) |
|
Allison 1000/2000/2400 Series Transmission Components and Theory of Operation |
|
|
646 | (2) |
|
|
|
646 | (1) |
|
Transmission Sensors and Switches |
|
|
646 | (1) |
|
|
|
647 | (1) |
|
|
|
647 | (1) |
|
|
|
647 | (1) |
|
|
|
648 | (1) |
|
Allison 1000/2000/2400 Series Transmission Diagnosis |
|
|
648 | (5) |
|
|
|
648 | (1) |
|
|
|
649 | (1) |
|
Torque-Converter Stall Test |
|
|
649 | (1) |
|
|
|
650 | (3) |
|
Allison 1000/2000/2400 Series Transmission Overhaul |
|
|
653 | (18) |
|
|
|
653 | (1) |
|
|
|
654 | (1) |
|
|
|
654 | (2) |
|
C1 and C2 Clutch-Housing Assembly |
|
|
656 | (9) |
|
|
|
665 | (6) |
|
Transmission Final Assembly |
|
|
671 | (6) |
|
|
|
671 | (1) |
|
|
|
671 | (4) |
|
Preparing the Transmission to Install |
|
|
675 | (2) |
|
|
|
677 | (2) |
|
Chapter 30 Preventive Maintenance Inspections |
|
|
679 | (18) |
|
|
|
680 | (6) |
|
|
|
680 | (6) |
|
Driver's Daily Inspection Report |
|
|
686 | (1) |
|
|
|
686 | (9) |
|
Commercial Vehicle Safety Alliance |
|
|
689 | (1) |
|
Performing a DOT Inspection |
|
|
690 | (1) |
|
"Minimum Periodic Inspection Standards" (Appendix G to Subchapter B of
Chapter III) |
|
|
690 | (4) |
|
|
|
694 | (1) |
|
|
|
695 | (2) |
|
Chapter 31 Auxiliary Power Units |
|
|
697 | (13) |
|
|
|
698 | (1) |
|
|
|
698 | (1) |
|
APU with Air Conditioning, Alternator, and Separate Inverter |
|
|
699 | (1) |
|
APU with Air Conditioning, Alternator, and Generator |
|
|
699 | (1) |
|
|
|
699 | (1) |
|
|
|
700 | (1) |
|
Air Conditioner and Heater |
|
|
700 | (1) |
|
|
|
701 | (1) |
|
|
|
701 | (1) |
|
|
|
701 | (1) |
|
|
|
701 | (1) |
|
Air Conditioner Operation |
|
|
701 | (1) |
|
|
|
701 | (1) |
|
|
|
702 | (1) |
|
|
|
702 | (8) |
|
APU Maintenance and Service |
|
|
702 | (2) |
|
APU Preventive Maintenance Inspections |
|
|
704 | (1) |
|
Component Service, Replacement, and Adjustment |
|
|
704 | (3) |
|
|
|
707 | (3) |
| Chapter 31 Review |
|
710 | (1) |
| Index |
|
711 | |
