Automatic gearbox repair training

Lesson 1 • Transmission Shop Hazard Identification

Catalogues chemical, mechanical, and ergonomic hazards unique to gearbox work. Connects hazard awareness to the protective measures applied throughout the course.

Lesson 2 • Personal Protective Equipment Selection

Matches PPE types to specific transmission repair tasks and fluid exposures. Reinforces correct donning, inspection, and replacement of protective gear.

Lesson 3 • Tool Care and Workshop Organisation

Establishes standards for tool storage, calibration, and cleanliness in a transmission shop. Organised workspaces reduce errors and improve rebuild quality.

Lesson 1 • Core Components and Their Functions

Identifies every major internal component and explains its mechanical role. Provides the vocabulary and component recognition needed for all subsequent diagnostic work.

Lesson 2 • Automatic Transmission History and Types

Traces the evolution from early hydraulic automatics to modern dual-clutch and CVT units. Establishes context for understanding why design differences affect repair strategies.

Lesson 3 • Power Flow and Gear Ratio Principles

Explains how gear ratios are achieved through planetary set combinations. Connects ratio theory to real-world vehicle performance and fuel economy outcomes.

Lesson 4 • Electronic Control System Overview

Covers the role of the transmission control module, sensors, and solenoids in modern shift management. Prepares learners for electronic diagnostics introduced in Chapter 3.

Lesson 1 • Electrical and Solenoid Circuit Testing

Tests solenoid resistance, duty cycle, and wiring integrity using a digital multimeter and oscilloscope. Isolates electrical faults from mechanical failures before teardown.

Lesson 2 • Scan Tool and Fault Code Interpretation

Uses OBD scan tools to retrieve, interpret, and clear transmission fault codes. Connects code data to hydraulic and mechanical root causes.

Lesson 3 • Customer Complaint and Symptom Analysis

Translates customer descriptions into technical symptom categories for structured diagnosis. Accurate symptom capture prevents misdiagnosis and unnecessary teardown.

Lesson 4 • Road Test and Shift Quality Evaluation

Evaluates shift timing, firmness, slippage, and noise under controlled driving conditions. Road test findings guide teardown depth and parts replacement decisions.

Lesson 1 • Transmission Removal Techniques by Vehicle Type

Adapts removal sequences for FWD, RWD, AWD, and transaxle configurations. Understanding layout differences prevents damage to surrounding components.

Lesson 2 • Internal Gear Train Disassembly

Guides systematic removal of clutch packs, planetary sets, and shafts from the case. Organised staging of parts enables accurate wear assessment and correct reassembly.

Lesson 3 • Torque Converter Removal and Handling

Details safe torque converter removal, fluid draining, and preliminary inspection for damage. Converter condition directly influences rebuild success and longevity.

Lesson 4 • External Component Disassembly

Removes the oil pan, filter, valve body, and external sensors as the first disassembly stage. Proper sequencing prevents damage to delicate valve body bores and solenoids.

Lesson 1 • Valve Body and Solenoid Bench Testing

Tests valve body bores for wear, checks valve free movement, and bench-tests solenoid operation. Valve body condition determines hydraulic shift quality after reassembly.

Lesson 2 • Clutch Pack and Friction Material Inspection

Evaluates friction disc thickness, steel plate flatness, and clutch pack clearance against specifications. Worn or glazed friction material is the most common cause of shift quality failure.

Lesson 3 • Pump, Bushing, and Seal Inspection

Measures pump gear clearances, bushing wear, and seal groove condition to assess hydraulic efficiency. Pump wear directly affects line pressure and overall transmission performance.

Lesson 4 • Planetary Gear Set and Shaft Inspection

Checks gear tooth condition, planet pin wear, and shaft runout to identify fatigue and overload damage. Gear train integrity is critical to ratio accuracy and noise-free operation.

Lesson 1 • Clutch Pack Assembly and Clearance Setting

Assembles friction and steel plates in correct sequence and sets pack clearance with snap rings. Precise clearance directly controls clutch apply speed and shift feel.

Lesson 2 • Seal and O-Ring Replacement Techniques

Covers removal, sizing, lubrication, and installation of lip seals, O-rings, and Teflon rings. Correct seal installation prevents fluid leaks that cause pressure loss and slippage.

Lesson 3 • Bushing Replacement and Sizing

Removes worn bushings and installs, aligns, and sizes replacements to restore shaft clearances. Proper bushing fit controls fluid leakage between hydraulic circuits.

Lesson 4 • Valve Body Reconditioning and Reassembly

Cleans, inspects, and reassembles the valve body with correct check balls, springs, and separator plates. Valve body accuracy is the foundation of correct hydraulic shift control.

Lesson 1 • Gear Train and Clutch Pack Installation

Installs planetary sets, clutch drums, and shafts in the correct sequence with proper lubrication. Sequence errors cause interference fits and immediate component failure.

Lesson 2 • Vehicle Installation and Initial Startup

Reinstalls the transmission, reconnects all systems, fills fluid, and performs the initial startup check. Correct startup procedures catch leaks and pressure faults before road testing.

Lesson 3 • Torque Converter Installation and Engagement

Installs the torque converter with correct engagement depth and verifies pump drive engagement. Incorrect converter seating destroys the pump within minutes of startup.

Lesson 4 • Case Preparation and Bearing Installation

Cleans the case, installs new bearings, and verifies end-play before internal assembly begins. Case preparation sets the dimensional foundation for all subsequent component fits.

Lesson 1 • Repair Documentation and Customer Handover

Completes repair orders, warranty records, and customer explanation of service performed. Accurate documentation protects the shop and builds customer confidence.

Lesson 2 • Adaptive Reset and TCM Initialisation

Resets adaptive shift tables and performs TCM initialisation after a rebuild to establish a clean baseline. Skipping this step causes erratic shifting during the break-in period.

Lesson 3 • Structured Post-Rebuild Road Test

Executes a defined road test sequence to verify shift timing, firmness, and converter lockup function. Structured testing ensures all operating ranges are confirmed before delivery.

Lesson 4 • Fault Code Scan and Data Review

Performs a final scan for stored or pending codes and reviews live data for out-of-range values. A clean scan confirms electronic system integrity after the rebuild.