Removing and refitting transmissions on motorsport vehicles
Overview
This standard identifies the competences you need to carry out the removal and refitting of transmissions to motorsport vehicles and ancillary components such as pumps, oil coolers, heat exchangers, suspension mountings, oil tanks, flexible and rigid pipework, gear rods, gear and belt drives, control cables and `lifed' components, in accordance with approved procedures.
It covers a range of motorsport vehicles such as single seater, rallying, sports cars, karts, historic vehicles and other specific approved competition vehicles. The removal and refitting methods and techniques will include dismantling the equipment to sub-assembly and component level, protecting exposed components, checking components for serviceability, making mechanical and electrical connections, setting, aligning and adjusting refitted components, tightening fasteners to the required torque, and replenishing oils, greases and fluids.
On completion of the removal and refitting activities you will be required to carry out a range of final checks, tests and adjustments, such as checking gear change, oil and hydraulic fluid leaks, starting and running the engine to ensure that the transmission meets the required specification.
Your responsibilities will require you to comply with organisational policy and procedures for the removal and refitting activities undertaken, and to report any problems with these activities that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You must ensure that all tools, equipment and materials used are correctly accounted for on completion of the activities, and that all necessary job/task documentation is completed accurately and legibly.
You will be expected to work as a member of a team, with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out. Where team working is involved, you must demonstrate a significant personal contribution during the team activities in order to satisfy the requirements of the standard, and competence in all the areas required by the standard must be demonstrated.
Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying the appropriate removal and refitting techniques and procedures to motorsport vehicle transmissions and ancillary components. You will understand the removal and refitting methods and procedures, and their application. You will know how the equipment functions, the common problems that can occur, the purpose of the individual components and associated defects, in adequate depth to provide a sound basis for carrying out the removal and refitting activities, correcting faults and ensuring that the equipment is replaced to the required standard. You will also have sufficient knowledge of these components to ensure that they are fit for purpose and meet the specifications, thus providing a sound basis for carrying out the refitting activities.
You will understand the safety precautions required when working on motorsport vehicles, especially those for isolating the equipment. You will be required to demonstrate safe working practices throughout, and will understand your responsibility for taking the necessary safeguards to protect yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant instructions, vehicle manuals and publications to carry out the required work
- remove and refit the components in their correct positions using appropriate methods and techniques
- take suitable precautions to prevent damage to components and surrounding structure
- ensure that the removed components are clean and free from dirt, oil and debris, and that they are in a usable condition, prior to being refitted and tested
- replace and secure the components, using the specified connectors and securing devices
- check that all operations have been completed, and that the finished assembly meets the required specification
- label and store, components that require repair or overhaul
- deal promptly and effectively with problems within your control and report those that cannot be solved
ensure that work records are completed, stored securely and available to others as per organisational requirements
leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you
- the hazards associated with the activities, and how to minimise them and reduce risks
- the personal protective equipment and clothing (PPE) to be worn during the activities
- the procedures for obtaining the various types of manuals/drawings, job instructions and specifications that are used during the removal and refitting of motorsport transmissions, and how to interpret them correctly
- how to identify different transmissions, the components to be used and component identification systems (life numbers and component orientation indicators)
- the removal and refitting methods and procedures to be used, and the importance of adhering to these procedures
- how the ancillaries are to be aligned and positioned, prior to securing and the tools and equipment that are used (including jigs and fixtures)
- the various mechanical fasteners that will be used, and their method of removal and installation (threaded fasteners, pipe/hose fittings, quick release fasteners and circlips)
- the application of sealants and adhesives within the removal and refitting activities, and the precautions to be taken when working with them
- the company `lifing' procedure for components, to meet the team's requirements
- the operational function of the various motorsport transmission components
- the use of torque wrenches and the importance of ensuring that fasteners are adjusted to the required settings
- how to apply correct lubricant/fluids to motorsport transmissions and the importance of ensuring that the lubricant/fluid is to the correct specification
- the consumables, tools and equipment to be used for the removal and refitting of motorsport transmissions
- the importance of using the specified fasteners for the removal and refitting, and why you must not use substitutes
- hot to deal with components or fastening devices that are incorrectly installed, damaged or have other faults
- the quality control procedures to be followed during the removal and refitting operations
- how to conduct checks to ensure the accuracy and quality of the motorsport transmission removal and installation
- how to recognise defects (incorrect refitting, ineffective fasteners, component damage)
- the importance of ensuring that the completed removal and installation is free from leaked fluids and lubricants
- the methods and equipment used to transport, handle and lift motorsport transmissions into position, and how to check that the lifting equipment is within its current certification dates
- the preparations to be undertaken on the components and mounting points, prior to fitting the ancillaries to the motorsport transmission
- how to check that the tools and equipment to be used are correctly calibrated, and are in a safe, tested and serviceable condition
- the importance of ensuring that all tools are used correctly, checked and stored after use
- the problems with the removal and refitting operations, and the importance of informing appropriate people of non-conformances
- the recording documentation to be completed for the activities undertaken
- the procedure for the safe disposal of waste materials, scrap components, oils and fluids
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
- how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
Carry out all of the following during the removal and refitting of the motorsport transmission equipment:
- plan the removal and refitting activities prior to beginning the work
- obtain and use the appropriate documentation (such as job instructions, assembly drawings, manuals, quality control documentation)
- adhere to procedures or systems in place for risk assessment, hazardous substances personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- provide safe access and working arrangements for the working area, and ensure that any appropriate environmental conditions can be met
- ensure that the work area is suitably prepared for the removal and refitting activities to take place
- obtain approval to carry out the removal and refitting activities
- position and secure the vehicle, using the correct equipment
- ensure that any required consumables are available
- leave the vehicle and work area in a safe condition, free from spillages and foreign object debris
- return all tools and equipment to the correct location on completion of the activities
Remove and refit transmission equipment for one of the following types of motorsport vehicle:
- single seater
- sports car
- historic vehicle
- rallying
- kart
- other specific approved competition vehicle
Use appropriate methods and techniques to remove and refit motorsport transmissions, using sixteen of the following:
- removing covers, cowlings and bodywork
- replacing damaged/defective components
- making an initial judgment of the condition of the transmission system (such as damage, missing components)
- replacing all 'lifed' items (such as components, seals, gaskets)
- re-assembling components to the appropriate level (such as sub-assembly)
- draining, removing oils, greases or fluids
- disconnecting hoses and hard lines
- setting up, aligning and adjusting replaced components
- disconnecting electrical connections (where appropriate)
- making mechanical connections, and tightening fastenings to the required torque
- supporting items of equipment to be removed
- dismantling the system to an appropriate level
- making electrical connections (where appropriate)
- protecting exposed components, vents, looms and pipework
- replenishing oils, greases or fluids
- bleeding systems (such as hydraulic, pneumatic)
- marking and labelling components to aid reassembly
- returning transmission and ancillary components to working order on completion of the activities
- checking components for serviceability
Use six of the following during the removal and refitting activities:
- jigs
- specialist tools
- alignment devices
- fixtures
- torque wrenches
- fluid filling devices
- hand tools
- lifting trolleys
- bleeding devices
- support stands
- special purpose tools
- measuring equipment
Remove and refit six of the following motorsport transmission ancillary components:
- oil coolers
- gear change systems
- gear clusters
- looms and plugs
- pumps
- sensing devices
- seals/gaskets and 'O' rings
- heat exchangers
- pipes and connections
- clutch slave cylinders
- oil tanks
- catch tanks
- suspension components
- drive/propeller shafts
- aerodynamic devices
- bodywork mountings
Carry out final checks and adjustments on the refitted transmission equipment, to include seven of the following:
- checking that transmission and ancillary components are free from foreign objects, dirt or other contamination
- checking that the transmission assembly is complete and complies to specification
- checking that all mechanical fixings are secure and have been `torqued' to specification and where appropriate, that bolt locking devices are fitted
- ensuring that correct alignment, seating, and clearance of components is achieved
- checking for system leaks (such as oil, hydraulic, pneumatic)
- ensuring that pipes and cables are correctly secured and free from potential chafing
- ensuring that the equipment is run and checked for correct gear change sequence
- placing temperature tabs onto heat sensitive areas
- checking that electrical equipment is functioning correctly
- carrying out other specific tests
Check removal and refit of motorsport transmissions complies with one of the following:
- race associations vehicle manufacturer's specification
- team/company standards and procedures
- specific vehicle requirements