Transmission Rebuild Course

Lesson 1 • Fluid Systems and Lubrication

Covers transmission fluid types, hydraulic circuits, and cooling requirements. Students understand how fluid condition directly affects shift quality and component life.

Lesson 2 • Power Flow and Torque Concepts

Explains torque multiplication, gear ratios, and mechanical advantage in transmissions. Provides the physics foundation needed for all diagnostic and rebuild work.

Lesson 3 • Transmission Types and Applications

Covers manual, automatic, CVT, and dual-clutch designs and their vehicle applications. Establishes the classification framework used throughout the course.

Lesson 4 • Major Component Identification

Identifies housings, shafts, gears, clutch packs, and valve bodies by name and function. Prepares students to read exploded diagrams and parts lists accurately.

Lesson 1 • Cleaning and Inspection Equipment

Introduces parts washers, ultrasonic cleaners, and inspection lighting for thorough component evaluation. Clean parts are essential for accurate wear assessment and leak-free assembly.

Lesson 2 • Hydraulic and Pneumatic Equipment

Covers transmission jacks, fluid evacuators, and air-pressure testing tools. Students learn safe operation and weight-capacity limits for each piece of equipment.

Lesson 3 • Workspace and Bench Organization

Establishes parts-tray systems, labeling protocols, and rebuild stand use for organized disassembly. Proper organization prevents lost parts and assembly errors.

Lesson 4 • Hand Tools for Transmission Work

Covers snap-ring pliers, spanner wrenches, clutch spring compressors, and seal drivers. Correct tool selection prevents component damage during disassembly and assembly.

Lesson 1 • Drivetrain Disconnection Procedures

Teaches driveshaft, axle, and linkage removal sequences for front- and rear-wheel-drive vehicles. Correct disconnection order prevents joint and seal damage.

Lesson 2 • External Component Disassembly

Removes bell housing, extension housing, oil pan, and valve body in the correct sequence. Each step is linked to inspection points that reveal failure causes.

Lesson 3 • Pre-Removal Inspection and Documentation

Covers fluid sampling, external leak mapping, and shift complaint documentation before removal. Thorough pre-removal data guides diagnosis and prevents repeat failures.

Lesson 4 • Transmission Removal Techniques

Covers crossmember removal, jack positioning, and torque converter retention during extraction. Students practice safe lowering and transport to the rebuild bench.

Lesson 1 • Hydraulic Component Evaluation

Inspects valve body bores, check balls, solenoids, and pump gears for wear and damage. Hydraulic faults are the leading cause of shift complaints and must be identified precisely.

Lesson 2 • Cleaning and Preparation for Inspection

Establishes cleaning sequences for metal, rubber, and electronic components before measurement. Contamination-free surfaces are required for accurate wear readings.

Lesson 3 • Gear and Shaft Wear Assessment

Measures gear tooth wear, shaft runout, and bearing journal diameters against specifications. Students distinguish serviceable wear from replacement-required conditions.

Lesson 4 • Clutch Pack and Band Inspection

Evaluates friction disc thickness, steel plate flatness, and band lining condition. Clutch pack clearance measurements determine correct shim and snap-ring selection.

Lesson 1 • Seal Bore and Housing Preparation

Teaches bore cleaning, polishing, and chamfering techniques before seal installation. Proper bore preparation is the single greatest factor in seal longevity.

Lesson 2 • O-Ring and Lathe-Cut Seal Service

Addresses O-ring groove inspection, sizing, and installation without twisting or cutting. Lathe-cut seals on pistons require specific stretch and seating procedures.

Lesson 3 • Seal and Gasket Material Selection

Covers lip seal, O-ring, and formed-in-place gasket materials and their fluid compatibility. Incorrect material selection causes premature seal failure and fluid contamination.

Lesson 4 • Gasket Application and Torque Sequences

Covers gasket alignment, sealant application, and torque-to-yield bolt sequences for all mating surfaces. Correct torque patterns prevent warping and uneven sealing.

Lesson 1 • Planetary Gear Set Assembly

Assembles sun gears, planet carriers, and ring gears with correct thrust washer placement. Thrust washer thickness selection controls end play and prevents gear contact.

Lesson 2 • Band Adjustment and Servo Assembly

Installs servo pistons, adjusts band struts, and sets band clearance to specification. Band adjustment affects shift quality and must be verified before final assembly.

Lesson 3 • Piston and Return Spring Assembly

Installs clutch pistons, check balls, and return springs or Belleville washers with correct orientation. Piston seating and spring preload directly affect clutch apply pressure.

Lesson 4 • Clutch Pack Rebuilding Procedures

Covers friction disc soaking, alternating plate stacking, and snap-ring selection for correct pack clearance. Proper pack clearance is critical for shift timing and clutch life.

Lesson 1 • Valve Body Reassembly

Reinstalls valves, springs, and check balls in correct sequence with separator plate and gaskets. Torque sequence and bolt length management prevent warping and cross-threading.

Lesson 2 • Transmission Pump Rebuild

Covers pump gear clearance measurement, bushing replacement, and pressure regulator valve service. The pump is the hydraulic system's power source and must meet all clearance specs.

Lesson 3 • Valve Body Disassembly and Cleaning

Covers separator plate removal, check ball mapping, and ultrasonic cleaning of valve body castings. Precise documentation of check ball locations prevents shift malfunctions after assembly.

Lesson 4 • Hydraulic Pressure Testing

Uses a pressure gauge set to verify line pressure, clutch apply pressure, and governor output. Pressure readings confirm hydraulic integrity before the unit is installed in the vehicle.

Lesson 1 • Transmission Installation in Vehicle

Guides jack positioning, alignment to engine, and reconnection of all drivetrain components. Correct alignment prevents bell housing stress and input shaft seal damage.

Lesson 2 • Road Test and Performance Verification

Executes a structured road test protocol to verify shift points, engagement quality, and noise levels. Road test results confirm rebuild success and identify any remaining issues.

Lesson 3 • Torque Converter Service and Installation

Covers torque converter flush, stall speed verification, and correct engagement onto pump drive. Improper converter installation is a leading cause of immediate post-rebuild failure.

Lesson 4 • Final Internal Assembly Sequence

Establishes the correct order for installing the gear train, pump, and valve body into the case. Assembly sequence errors cause interference fits and internal damage.