Woldia University (WU)

Course Name: Motor Vehicle Engineering (Meng 5412)

Target group: 5th year Motor vehicle stream students
ECTS: 4
A.Y: 2016 E.C
 PART-2 TRANSMISION (GEARBOX)

Introduction
• Definition
• Transmission or Gearbox or Transaxle is an assembly of gears and shafts to transmit the rotation and
torque of the engine to the driveline or final drive
• Functions of Transmission
• To provide a means to vary the torque ratio between the engine and the road wheels as required
• To provide a neutral position so that the engine and road wheel are disconnected even with the clutch is
in engaged position
• To provide a means of reverse the car by reversing the direction of rotation of the drive.
 Necessity of Transmission
• To vary the torque to overcome the various resistance acting against
the vehicle motion at various speeds
• To vary the tractive effort of the vehicle available at various speeds
in order to overcome the various resistance
• To start the vehicle from rest, with the engine running continuously
• To stop the vehicle by disconnecting the drive when appropriate
 Necessity of Transmission
• Total resistance consists of
• Wind resistance IV- level
• Gradient Resistance
• Rolling Resistance 1 Gear

Tractive Effort and Total Resistance

• Internal parts Resistance
• Inertial Resistance 2nd Gear III- level

II- level
I- level

3rd Gear

o A B C
Speed
 Necessity of Transmission
• Let the vehicle is traveling on a top gear and the total resistance is taken curve-I
• OB is the stabilizing speed
• The speed below OB, (OA) give acceleration
• The speed beyond OB, (OC) gives deceleration
• If the vehicle negotiate the curve-III obstacle
• The top gear curve does not cross curve-III, i.e the vehicle can not go at this gear to
overcome the given resistance
• If the gear shifted to the 2nd gear
• OA is the stabilizing speed
• Similarly with the 2nd gear not possible to negotiate the curve-IV resistance, for which the 1st
gear has to be selected
 Types of Transmission
• Manual Transmission
• Sliding Mesh Gearbox
• Constant Mesh Gearbox
• With Dog Clutch
• With Synchromesh
• Automatic Transmission (AT)
• Continuously variable Transmission (CVT)
• Infinitely Variable Transmission (IVT)
Manual Transmission
 Manual Transmission
• Major components of a manual transmission
• Transmission Case (20)
• Extension Housing (21)
• Transmission Shafts
• the input shaft or clutch shaft (1)
• the countershaft, or cluster gear shaft (12)
• the reverse idler shaft (14)
• the main shaft or the output shaft (5)
• Transmission Gears
• input gear, countershaft gears(11), main shaft gears(4,6,7,8), and the
reverse idler gear(13)
• Shift Linkage and Levers
• TRANSMISSION OIL
 Sliding Mesh Gearbox
• The simplest type of Gearbox
• has two or more shafts mounted in parallel or in line, with sliding spur gears arranged to
mesh with each other and provide a change in speed or direction

Main Shaft

A F D

Lay Shaft
B C
E G
Sliding Mesh Gearbox

2nd Gear
1st Gear A F D
A F D

B E C G
B E C G

A F D A F D

B B E C G
E C G

Reverse Gear
Top Gear
Sliding Mesh Gearbox
• The limitations
• Low mechanical efficiency
• The noise level is high
• The driver required considerable skill in changing the gear
 Constant Mesh- Dog Clutch
• also known as the collar shift transmission
• In this types, all the gears are in constant mesh
with the corresponding gears on the lay shaft

Neutral Position
1st Gear Position
 Constant Mesh- Dog Clutch
• Five-speed manual transmission
 Constant Mesh- Dog Clutch
• Advantages
• The length of the Gearbox reduced hence less deflection of sliding fork
• It permit the use of helical gear, hence smooth & silent operation
• No clashing of gear tooth hence no chance of teeth failure
• Load per tooth is less (the load shared by all the teeth)
 Synchromesh Gearbox
• Manual transmissions in modern passenger cars use synchronizers
to eliminate the need for double-clutching
• A synchro's purpose is
• to allow the collar and the gear to make frictional contact before
the dog teeth make contact.
• lets the collar and the gear synchronize their speeds before the
teeth need to engage
• Lock the main shaft gear to the main shaft
Synchromesh clutch
 Synchromesh Gearbox
• The cone on the blue gear fits into the
cone-shaped area in the collar, (bronze
cone)and
• friction between the cone and the collar
synchronize the collar and the gear.
• The outer portion of the collar then slides
so that the dog teeth can engage the gear
Synchromesh Gearbox
 Synchromesh Gearbox
• Inner Striking Surface
 Synchromesh Gearbox
• Outer striking Surface
Synchromesh Gearbox
• Outer synchromesh (GM)
 Synchromesh Gearbox
• Advantages
• Simplifies the operation of changing gears without the occurrence of clashes b/n the
gear tooth & consequent damages
• Avoid double clutching

TRANSAXLES
• A transaxle is a transmission and differential combination in a single assembly.
• Transaxles are used in front-wheel (FF)or (RR) drive vehicles.
• A transaxle allows the wheels next to the engine to propel the vehicle.
 TRANSAXLES
• Vehicle manufacturers claim that a transaxle and front-wheel drive has several
advantages over a vehicle with rear-wheel drive
• Improved efficiency and reduced drive train weight
• Improved traction on slippery surfaces because of increased weight on the drive
wheels
• Increased passenger compartment space (no hump in floorboard for rear drive
shaft)
• Less un-sprung weight (weight that must move with suspension action), thereby
providing a smoother ride
• Quieter operation since engine and drive train noise is centrally located in the
engine compartment
• Improved safety because of the increased mass in front of the passengers
Automatic Transmission
 Introduction
• What is An Automatic Transmission
• Like the manual transmission is designed to Mach the load requirements of
the vehicle to the power & speed range of the engine.
• The conventional clutch and Manual Synchromesh gearbox by a torque
converter and a compound epicyclical gear train

Conventional Clutch Torque Converter

Automatic
MANUAL
Transmission
Transmission

Manual Synchromesh Compound Epicyclical

G. Box G. Train
Introduction

Manual synchromesh
Gear Train
Planetary Gears

Clutch
Torque Converter
 Introduction
• Gear shifting of Automatic transmission depending on
• Throttle Position
• Vehicle Speed
• Position of the Shift Lever
• Automatic Transmissions can be divided in two groups
• Fully Hydraulic Controlled Transmission (HCT)
• Electronically Controlled Transmission (ECT)
 Introduction
• Advantages of AT compared with Manual Transmission
• free acceleration with out Interruption
• Reduces driver fatigue by eliminating Clutch operation & Constant
Shifting Gears
• Automatically & Smoothly shift gears at speed s appropriate to the driving
conditions
• Prevents the engine & drive line from becoming overloaded, because it
connect them Hydraulically via torque converter rather than mechanically
 Major Components of AT
• Torque Converter
• Planetary Gear Unit
• Hydraulic Control Unit
• Manual Linkage
• Automatic Transmission Fluid
 Major Components of AT
• Planetary Gear Unit
• It changes the transmission output rpm and/or the direction of the output
rotation and transmits it to the final drive unit
• Consists of
• the planetary gears (which changes the output rpm)
• Clutches & Brakes (which are operated by hydraulic pressure to control
the operation of the PGs
• Shafts (for transmitting the engine power
• Bearings (for facilitating the smooth rotation of each shaft
 Planetary Gear Units
• The rolls of Planetary Gear Unit
• Providing several gear ratios to obtain proper torque & rotational
speed in accordance with the driving conditions & drivers desires
• Providing the reverse gears for reverse traveling
• Providing a neutral gear potion to allow the engine to idle which
the vehicle is stopped.
Planetary Gear Units
• Planetary Gear Set
• Is a serious of interconnecting
gears consisting of a
• Sun Gear
• Several Planetary pinion
Gear
• A Ring Gear
• The Carrier Connecting the
pinion gears to the ring gear
Carrier, Rack and Pinion of Planetary Gear Set
Planetary Gear Units

COMPOUND PLANETARY GEAR SET

 Brakes
• BRAKES
• The brakes hold one of the planetary gear components (sun gear, ring gear, or carrier)
immovable in order to obtain the necessary gear ratio
• It is operated by Hydraulic pressure.
• There are two types of brake
• wet multiple-disc brake
• In this type of brake, the plates, which are fitted to the transmission case, and
the discs, which rotate integrally with each planetary gear set
• Band type brake.
• In this type of brake, a brake band encircles the brake drum, which is
integrated with one of the planetary gear components
Brakes

Wet Multiple-disc AND Band Brake

 Clutches
• CLUTCHES AND ONE-WAY CLUTCHES
• The clutches connect the torque converter to the planetary gears
to transmit engine torque to the intermediate shaft, and they
disconnect the converter from the planetary gears to stop the
transmission of torque
• Wet multiple-disc clutches consisting of several alternately
arranged discs and plates
• Hydraulic pressure is used to connect and disconnect the clutches.
 One Way Clutch
• one-way clutch
• consists of an inner
race and an outer race,
with sprags or rollers
placed in between

• It transmits torque
only in one direction
Clutches

clutch
 Brake & Clutches
• Difference between Clutches & Brakes
• Clutches are integrated with two different planetary gear components
• for example, input shaft and sun gears, overdrive sun gear and overdrive
planetary carrier, etc
• are therefore always revolving with them
• Their function is to bring the rotational speeds of the two components up or
down to the same speed, and to cause them to rotate in the same direction
• Brakes do not move - they are fixed to the transmission case and serve only to halt
the rotation of the planetary gear unit components
 Hydraulic Control System
• Hydraulic Control System
• The hydraulic control system consists of
• Oil pan, which acts as the fluid reservoir;
• Oil pump, which generates the hydraulic pressure
• various valves having various functions
• fluid passages and tubes, which deliver the transmission fluid to the
clutches, brakes,
• Most valves in the hydraulic control system are housed in the valve body
assembly under the planetary gears
Hydraulic Control System
 Hydraulic Control System
• Roles of hydraulic control system
• Supplying transmission fluid to the torque converter.
• Regulating the hydraulic pressure generated by the oil pump.
• Converting the engine load and vehicle speed into hydraulic "signals".
• Applying hydraulic pressure to the clutches and brakes to control planetary
gear operation.
• Lubricating rotating parts with fluid.
• Cooling the torque converter and transmission with fluid.
Manual Linkage
• The automatic transmission up-shifts and down-shifts automatically.
However, two linkages allowing manual operation by the driver are
connected to the automatic transmission.
• These linkages are
• the selector lever and cable,
• the accelerator pedal and throttle cable
 Manual Linkage
• SHIFT SELECTOR LEVER (SHIFT LEVER)
• The shift selector lever corresponds to the gearshift lever of the manual
transmission
• It is connected to the transmission via a cable or linkage
• The driver can select the driving mode –
• Forward,
• Reverse,
• Neutral,
• Parking
 Manual Linkage
• In almost all automatic transmissions, the forward mode consists
of three ranges:
• "D" (Drive),
• "2" (second)
• "L" (low)
• For safety, the engine can be started only when the shift selector
lever is at the "N" (neutral) or "P" (park) position; that is, when
the transmission cannot transmit power from the engine to the
drive train.
Manual Linkage
 Manual Linkage
• ACCELERATOR PEDAL
• The accelerator pedal is connected to the throttle valve of the carburetor (to
the throttle body in an EFI engine) by the accelerator cable.
• The degree of accelerator pedal depression that is, the throttle valve
opening is correctly transmitted to the transmission by this cable.
• The automatic transmission up-shift and down-shift speeds depend on the
engine load (the throttle valve opening), and the driver can vary these by
controlling the amount of accelerator pedal depression.
 Manual Linkage
• When the accelerator pedal is depressed a little, transmission up- and
downshifting occur at relatively low vehicle speeds.
• When the accelerator pedal is depressed further, shifting occurs at relatively
high speeds.
• The accelerator and throttle cables must be adjusted correctly to the
specified lengths because correctly-timed transmission shifting requires
conversion of the amount of accelerator pedal depression into the correct
engine throttle valve opening angle, and correct transmission of that valve
opening angle to the transmission.
Manual Linkage

Amount of Acceleration Engine throttle valve Correct Up or down

Pedal Depressed Opening Shifting of Gears

Transmission valve Correctly trimmed

opening angle Shifting
 Transmission fluid
• AUTOMATIC TRANSMISSION FLUID (ATF)
• A special high-grade petroleum-based mineral oil mixed with several
special additives is used to lubricate the automatic transmission
• Roles of ATF
• Transmission of torque in the torque converter.
• Control of the hydraulic control system, as well as of clutch and brake
operation in the transmission section.
• Lubrication of the planetary gears and other moving parts.
• Cooling of moving parts.
Gear Selection & Function
• Gear selection position
• N - Neutral
• P- Parking
• R- Reverse
• D - Drive
• D 2- Manual 2
• Manual Low L
 Gear Selection & Function
• Neutral
• allows the engine to start and operate without driving the vehicles.
• All the clutches and brakes are disengaged
• The torque converter drive is separated from the planetary gear train output
• Park P
• A safety feature in that it locks the output shaft to the transmission housing.
• This effect , locks the drive wheels, preventing the vehicle from rolling forward or
backward.
• This position should not be selected unless the vehicle is at a complete stop
• The engine can be started & performance tested in the park Position
 Gear Selection & Function
• Reverse (R)
• Allows the vehicle to back up. Can test for maximum oil pump
• The engine should not start in this position
• Drive (D)
• Is the only position in which the transmission is automatic
• The transmission has three gear ratios forward. 1st & 2nd gear reduction
ratio which provide for greater torque. The 3rd is direct drive & if the
transmission has overdrives the 4th forward gear.
• There is no engine braking or the vehicle coasts during deceleration
 Gear Selection & Function
• Manual Low (L)
• This gear can be selected at any vehicle speed
• It will not downshift directly in to first gear until approximately
29 – 39 mph depending on the model.
• This gear range provides for maximum engine braking & inhibits
an up shifting to third and second gear while in manual low.
• The engine should not start in this gear position
 Gear Selection & Function
• Manual Second (2)
• This gear can be selected at any vehicle speed & will down shift
to second gear
• This gear range provides for strong engine braking & inhibits an
up shift to overdrive & 3rd gear while in manual second
• The engine should not start in this gear position