13

LIST OF PRACTICALS

13.1 Filing

Materials 50 x 50 x 10 mm. mild steel.

Tools Bastard file & second cut file.
Procedure
• . Mark the dimensions with chalk and
scriber.··
• Mark the lines with a prick punch.
•.. Use the bastard file to remove excess
.material.
• Finish all sides by using a second cut
.. file~

13.2 Cutting

Material 50 x 60 x.l 0 mm mild steel

Tools Hacksaw

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Four- Wheeler Chassis Mechanisms

Procedure
• Mark the line for cutting.
• Hold the job in a vice.
• Start cutting using a hacksaw. .
• Use the full length of the blade during
cutting.

13.3 Drilling
Material 50 x 50 x 10 mm. mild steel
Tools Centre punch, drill machine, drill bit.
Procedure

• Mark the spot with the centre punch.

• Hold the material in the jaws of the vice.
• Drill the hole.

13.4 CuttingInternal Thread

Material 20 x 20 x 15 mm mild steel

Tools Drill machine, Tap set
Procedure
• Drill the correct size hole.
• Start cutting using the first tap.
• Use mobile oil to wash the chips
• Use the second tap.
• Use the finishing tap.

13.5 CuttingExternalThread
Material IZmm. dia. rod mild steel
Tools Die set, handle
Procedure
• Loosen the die.
• Start cutting with a forward and backwards
motion.
• Tighten the die.
• Cut to correct size.
• Lubricate with mobile oil.

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 List of practicals

13.6 Clutch

Dismantling the Clutch

• Bolts
• Pressure plate
• Clutch plate
• Release bearing
• Diaphragm spring

Servicing
Clean the pressure plate in k-oil and the clutch plate in
petrol.

Inspection
Inspect the following:
• Clutch plate rivets
• Clutch facing
• Pressure plate
• Ball bearing
• Diaphragm

Assembly
Fit the clutch plate on the pressure plate.

13.1 Gear-Box

Dismantle the following:

• Drain the oil
• . Main shaft
• Counter shaft
• Counter gear
• Top pinion
.• Synchronizer
• Fork
• Changer
• Lock washer

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Four- Wheeler Chassis Mechanisms

• Bearings (needle, ball,taper roller)

• Oil seal

Servicing
Clean the parts with k-oil
Inspection
Inspect the following items:
• Worn gear teeth
• . Bearings (needle,ball ,taper)
• Main shaft
• Counter shaft .
• Shim washers
• Synchronizer
• Changer •..

Assembly
Assemble the following as listed below:
• . . Counter gear
• Main shaft and pinion
• Top pinion
• Bearings
•. Oil seal
• Housing
• Gear oil

13.8 Universal Joint & Propeller Shaft

Dismantle the Universal joint assembly.

• ~Universal joint cross
• . Yoke
• Propeller shaft

Servicing ..
Clean with k-oil

Inspection ~
Inspect the following parts:

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 List of practicals

.• . Needle bearings
. .• Slip yoke
.• .Propeller shaft

Assembly
. Assemblethe following: .
• . . Fit the cross in the yoke

13.9 Rear Axle

.,

Dismantle the rear axle assembly: .

• Rear axle
• Axle bearing. .
.... '. "

• Oil seal
• Oil seal retainer
• Rear hub

Servicing
Clean with k-oil

Inspection.
• Rear axle splines
• Bearing
•. Oil seal' '. . .
Note: If the rear axle needs to bereplaced then. fila new bearing at the
same time.

Assembly
•• Place the bearing on the axle
• Key~.
• .Oil seaton retainer
• Rear hub
• Washer and nut. .

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, '" ,. v . neeler Chassis Mechanisms

13.10 Differential

Dismantle the differential assembly

• Drain oil
• Differential cover
• Crown housing
• Bevel gear
• Taper roller bearing
• Oil seal

Servicing
Clean in k-oil

Inspection
Inspect the following items: (,.
• Taper roller bearing
• Bevel pinions
• Star pinions
• Tail and crown pinion
• Oil seal

Assembly
• Crown assembly
• Tail oil seal
• Crown on cage
• Bevel end star pinion
• Taper roller bearing
•. Fit the crown assembly on differential
housing
• Differential cover

13.11 Front axle & Steering System

Dismantle the following parts:

• Wheels
• Axle nut from hub
• Axle
• Dust cover

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 List of practicals

• Lock from both side hubs

• Ball bearing

Servicing
Clean with k-oil

Inspection
Inspect the following parts:
• Hub
• Bearing
• Dust cover
• Lock

Assembly
• Boot ( dust cover)
• Apply grease to bearing and hub
• Hub

13.12 Master Cylinder

Dismantle
• Piston lock
• Master cylinder hydraulic kit

Servicing
Clean in petrol

Inspection
• Pistons
• Hydraulic kit

Assembly
• Bucket in master cylinder pistons
• Return spring
• Valve
• Piston lock
• Fit assembly on body
• Fill brake oil to level

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Four- Wheeler Chassis Mechanisms

13.13 Drum Brakes

Dismantle the following;

• Axle nut
• Drum
• Brake shoes
• Wheel cylinder kit
• Hand brake lever

Servicing
Clean in petrol

Inspection
• Wheel cylinder piston bore
• Buckets
• Return spring
• Brake lining
• Hand brake cable

Assembly
• Wheel cylinder piston kit
• Brake shoes
• Hand brake lever
• Brake shoe lock

13.14 Wheels,Tyres & Tubes

Dismantling
• Loosen the wheel nuts
• Lift the car by setting the jack
• Open the nuts
• Pull out the wheel

Inspection
• Rim is bent
. • Tyrewear
• Tyre inflation

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 List of practicals

Assembly
• Insert the Wheel
• Tighten the nuts
• Release the jack
• Tighten the nuts fully
• Align the wheels

13.15 Chassis
"

• Put the iron stand on the axle casing with

the help of the jack
• Open all four wheels

Servicing
Clean in K-oil

Inspection
• Chassis alignment
• Cracks on the chassis
• Cross members rivets
• WornlBroken nuts and bolts

Assembly
\
• Fit-all wheels
• Tighten all nuts

13.16 Steering Wobble

) Inspect
• Tie rod end
• Arm ball joint
• Suspension bush
• Wheel bearing

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Four-Wheeler Chassis Mechanisms

Replace any worn part

Assembly
• Assemble the above
• Do wheel alignment
• Damper kit adjustment with torque wrench
• Balance the wheels

13.17 Noisy Brakes

Inspection
• Lift the car
• Open the wheel
• Wheel bearing
• Brakes pads
• Scored disc •..
• Calliper kit

Replace any worn parts

Brake pads lock should be set correctly

13.18 Tyre Rotation

Inspection
• Thread ware
• Tyre pressure
• Rotate the tyres

13.19 Shock Absorbers

Inspection
• Shocker kit
• Thrust bearing
• Oil leakage
• Shock absorber pressure
• Shocker bush

13.20 Adjusting Brakes

Do this when:
• The brake pedal needs to be pushed far
down
• The car pulls to one side while braking

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(
List of practicals
\

Procedure

• Jack and support the car

• Remove the wheels
• Remove the brake drums
• Adjust the brakes
• Change the brake shoe if necessary

13.21 Rear Wheel Bearing

Do this when:
• There is a rumbling noise from the rear
wheel
Procedure
• Check the source of the noise
• Remove the halfaxle and bearing ••.
• Change the.defective bearing
• Assemble the rear axle

13.22 Checking the Differential Oil

Do this when:
• Every 5000 km.
• Change every 20,000 km. or after 2 years
Procedure

• Top up with fresh oil

• -Drain the oil
• Remove the differential side cover and
clean with k-oil
• Assemble the side cover
• Fill up with fresh oil

13.23 Gear Oil

Do this when:
• Shifting gears is not smooth
• Gears do not mesh properly
Procedure
• Replace gear lever kit
• Repair gear shifter shaft if necessary
• Adjust the gear changer

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Four- Wheeler Chassis Mechanisms

--.••....
13.24 Clutch Plate
Do this when:
• The clutch slips
• Excessive noise while depressing
the clutch pedal
Procedure
• Replace the clutch
..
13.25 Wiper Arm
Do this when:
• The wiper leaves streaks
Procedure
• Squeaky sound is heard

• Replace the wiper blade

13.26 Leaf Spring

Do this when:
• Insufficient tension
• Jerky bounce
• Broken leaf spring
Procedure
• Remove and send to the blacksmith
to re-tension
• Replace broken space

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