Product Overview

Summary: This Torque Converter Repair Safe Operating Procedure sets out a safe, consistent method for inspecting, disassembling, repairing and testing torque converters used in vehicles and plant. It helps Australian workshops control mechanical, chemical and ergonomic risks while lifting quality, reliability and compliance with WHS obligations.

Torque converters operate under high loads, pressures and temperatures, and poor repair practices can quickly lead to serious mechanical failures, oil leaks, and safety incidents in the workshop and out in the field. This Safe Operating Procedure provides a structured, step‑by‑step method for safely handling, disassembling, cleaning, inspecting, repairing, reassembling and testing torque converters used in passenger vehicles, heavy vehicles, earthmoving plant and industrial equipment. It embeds WHS risk controls into every stage of the job, from isolating equipment and managing hot components to handling oils and using lifting equipment correctly.

Developed specifically for Australian conditions, this SOP helps workshops meet their duty of care under WHS legislation while improving consistency and workmanship. It clarifies roles and responsibilities, defines required tools and PPE, and sets clear quality checkpoints so that every repair is carried out to a documented standard. The result is fewer reworks, reduced downtime for clients, safer work practices for mechanics and apprentices, and a defendable process you can show to regulators, customers and auditors.

Key Benefits

• Ensure torque converter repairs are completed safely, consistently and in line with Australian WHS requirements.
• Reduce the risk of crush, pinch and manual handling injuries when lifting, moving and mounting torque converters.
• Minimise oil spills, fire hazards and exposure to hazardous substances through controlled handling and disposal practices.
• Improve repair quality and reliability with defined inspection criteria, tolerances and test procedures.
• Streamline training and onboarding by giving mechanics and apprentices a clear, step‑by‑step repair method.

Who is this for?

• Automotive Workshop Managers
• Heavy Vehicle Mechanics
• Plant and Equipment Technicians
• Transmission Specialists
• Mining and Civil Maintenance Supervisors
• Fleet Maintenance Managers
• WHS Advisors in Automotive and Heavy Industry
• Apprentice Mechanics and Trainees

Hazards Addressed

• Manual handling injuries from lifting and manoeuvring heavy torque converters and transmission components
• Crush and pinch injuries when mounting, clamping or aligning units in jigs or on workbenches
• Exposure to hot surfaces and hot fluids during removal from recently operated vehicles or plant
• Contact with and inhalation of hazardous substances such as transmission fluid, cleaning solvents and degreasers
• Eye and skin injuries from pressurised fluid release during disassembly and testing
• Fire and explosion risks associated with flammable cleaning agents and oil residues
• Slips, trips and falls caused by spilled oils, parts and tools around the work area
• Noise exposure from testing equipment and associated workshop machinery
• Hand and finger injuries from use of hand tools, rattle guns, presses and cutting equipment
• Environmental contamination from incorrect storage or disposal of waste oils, filters and oily rags

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology
• 3.0 Roles and Responsibilities
• 4.0 Applicable Legislation, Standards and References
• 5.0 Required Competencies, Training and Authorisation
• 6.0 Tools, Equipment and Materials
• 7.0 Personal Protective Equipment (PPE) Requirements
• 8.0 Pre‑Job Planning and Risk Assessment (JSA/SWMS)
• 9.0 Isolation, Lock‑Out and Tag‑Out (LOTO) Requirements
• 10.0 Safe Handling and Lifting of Torque Converters
• 11.0 Removal of Torque Converter from Vehicle or Plant
• 12.0 Draining, Cleaning and Controlling Spills
• 13.0 Disassembly Procedure and Component Identification
• 14.0 Inspection Criteria, Measurements and Wear Limits
• 15.0 Repair, Replacement and Machining Requirements
• 16.0 Reassembly, Torque Settings and Use of Sealants
• 17.0 Pressure Testing, Balancing and Functional Testing
• 18.0 Reinstallation into Vehicle or Plant
• 19.0 Quality Control, Sign‑off and Documentation
• 20.0 Hazard Identification and Control Measures
• 21.0 Emergency Procedures (Spills, Injuries, Fire)
• 22.0 Environmental Management and Waste Disposal
• 23.0 Housekeeping and Post‑Job Review
• 24.0 Recordkeeping, Maintenance History and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory WHS Regulations
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Code of Practice: How to Manage Work Health and Safety Risks
• AS/NZS 4024 series: Safety of machinery
• AS/NZS 4801: Occupational health and safety management systems (superseded but still widely referenced)
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 2161 series: Occupational protective gloves
• AS 1940: The storage and handling of flammable and combustible liquids