Professional Documents
Culture Documents
Automotive
Servicing NC II
Quarter 2 – Module 1 and 2:
Diagnose Manual Transmission
Failure
TLE/TVL Automotive Servicing NCII – Grade 12
Self-Directed Learning Material
Quarter 2 – Module 1 and 2: Diagnose Manual Transmission Failure
First Edition, 2020
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We hope that through this material, you will experience meaningful learning and
gain a deep understanding of the relevant competencies. You can do it!
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What I Need to Know
This module was designed to help you know the principles of manual transmission
and master the skill of diagnosing manual transmission failure. Familiarization with
the different components and parts of a manual transmission is a prerequisite
knowledge before you can proceed with diagnosing possible manual transmission
problems.
What I Know
Choose the letter of the best answer. Write the chosen letter on a separate sheet of
paper.
3. Which type of gear develops the problem of gear whine at higher speeds?
a. spur gear c. bevel gear
b. helical gear d. both a and b
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4. When an idler gear is placed between the driving and driven gear, the driven
gear _______.
a. rotates in the same direction as the driving gear
b. rotates in the opposite direction of the driving gear
c. remains stationary
d. causes the driven gear to rotate faster
5. The component used to ensure that the main shaft (output shaft) and main
(speed) gear to be locked to it are rotating at the same speed is known as a
___________.
a. synchronizer c. shift fork
b. shift linkage d. transfer case
Lesson
Diagnose Manual
1 Transmission Failure
There are two basic types of transmission and transaxle; manual and automatic,
manual transmission and transaxle are shifted manually, or by hand. Automatic
transmission and transaxle shift automatically, with no help from the driver.
The Manual Transmission is an assembly of gears, shaft, and related parts. These
are contained in a metal case or housing filled with lubricant. A manual transmission
is used in some front-wheel-drive vehicles and front-engine rear-wheel-drive vehicles.
It is positioned between the clutch and the driveshaft that carries engine power to
the drive wheels. The engine, clutch transmission, and driveshaft are all in a single
line.
Front-wheel-drive vehicles are propelled by the front wheels. For this reason, they
must use a drive design different from that of an RWD vehicle. The transaxle is the
special power transfer unit commonly used on FWD vehicles. A manual transaxle
combines the transmission gearing, differential, and drive axle connections into a
single case aluminum housing located in front of the vehicle. This design offers many
advantages. One major advantage is the good tractions on slippery roads due to the
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weight of the drivetrain components being directly over the driving axles of the
vehicle. It is also more compact and lighter than the transmission of an RWD vehicle.
Transverse engine and transaxles configuration also allows for lower hood lines,
thereby improving the vehicle’s aerodynamics.
Most manual transmissions and transaxles are constant mesh, fully synchronized
units. Constant-mesh means that whether or not the gear is locked to the output
shaft, is it in mesh with its counter gear. All gears rotate in the transmission as long
as the clutch is engaged. Fully synchronized means the unit uses a mechanism of
brass rings and clutches to bring rotating shafts and gears to the same speed before
shifts occur. These promote smooth shifting. In a vehicle equipped with a four-speed
manual shift transmission or transaxle, all four forward gears are synchronized.
Reverse gearing may or may not be synchronized, depending on the type of
transmission/transaxle.
Manual transmission problems can be developed due to high mileage, abuse, or lack
of proper maintenance. But they are rather rare. Most manual transmission issues
originate not with the transmission itself, but from related components like the
clutch assembly, linkage, or driveline: the components that transmit turning power
from the transmission to the wheels. Also, as we discuss below, symptoms that seem
to be coming from the transmission can come from unrelated parts of the car.
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What’s In
This lesson tackles the principles of Manual transmission and Transaxle. The Vehicle
produces power from its power plant called an Engine and it passes throughout the
power train where Manual Transmission and Transaxle play a very important role
for the vehicle in transmitting power from the engine to the wheels. It may deteriorate
even in normal use. The lesson also covers some diagnostics, inspection, and
servicing.
What’s New
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What is It
Transmission Designs
past, the commonly used transmission was a three-speed; four-speeds were only
found in truck and high –performance cars. The growing concern for improved gas
mileage led to smaller engines with four-speed transmissions. The additional gear
allowed the smaller engines to perform better by matching the engine torque curve
with vehicle speeds and loads.
Five-speed transmissions and transaxles are now commonly used units. Some of the
early five-speed units were four-speeds with an add-on fifth or overdrive gear.
Overdrive reduces engine speed at a given vehicle speed, which increases top speed,
improves fuel economy, and lower engine noise. Most late-model five-speed units
incorporate a fifth gear in their main assemblies. This is also true of six-speed
transmissions and transaxles. The fifth and sixth gears are included in the main
assembly and typically provide two overdrive gears. The addition of the two overdrive
gear allows the manufacturers to use lower final drive gears for acceleration. The fifth
and sixth gear reduces the overall gear ratio and allows for slower engine speeds
during highway operation.
Gears
Gear pitch is a very important factor in gear design and operation. Gear pitch refers
to the number of teeth per given unit of pitch diameter. A simple way of determining
gear pitch is to divide the number of teeth by the pitch diameter of the gear. For
example, if a gear has thirty-six teeth and a 6-inch pitch diameter, it has a gear pitch
of six. The important fact to remember is that gears must have the same pitch to
operate together. A five-pitch gear meshes only with another five-pitch gear, a six-
pitch only with a six-pitch, and so on.
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Source: Google stock photos
Spurs Gears
The spur gear is the simplest gear design used in manual transmissions and
transaxles. Spur gear teeth are cuts straight across the edge parallel to the gear’s
shaft. During operation, meshed spur gears have the only tooth in full contact at a
time. Its straight tooth design is the spur gear’s main advantage. It minimizes the
chances of popping out of gear, an important consideration during
acceleration/deceleration, and reverse operation. For this reason, spur gears are
often used for the reverse gear.
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The spur gear’s major drawback is the clicking noise that occurs as teeth contact
one another. At higher speeds, this clicking becomes a constant whine. Quieter gears,
such as the helical design, are often used to eliminate this gear whine problem.
Helical Gears
A helical gear has teeth that are cut at an angle or are spiral to the gear’s axis of
rotation. This configuration allows two or more teeth to mesh at the same time, which
distributes tooth load and produces a very strong gear. Helical gears also run more
quietly than spur gears because they create a wiping action as they engage and
disengage the teeth on another gear. One disadvantage is those helical teeth on a
gear cause the gear to move fore or aft (axial thrust) on a shaft, depending on the
direction of the angle of the gear teeth. This axial thrust must be absorbed by thrust
washers and other transmission gears, shafts, or the transmission case.
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Idler Gears
An idler gear is a gear that is placed between a drive gear and a driven gear. Its
purpose is to transfer motion from the drive gear to the driven gear without changing
the direction of rotation. It can do this because all three gears have external teeth.
Idler gears are used in reverse gear trains to change the directional rotation of the
output shaft. In all forward gears, the input shaft and the output shaft turn in the
same direction. In reverse, the output shaft turns in the opposite direction as the
input shaft. This allows the vehicle drive wheel to turn backward.
Source: Google stock photos
Gears apply torque to other rotating parts of the drive train and are used to multiply
torque. As gears with different numbers of teeth mesh, each rotates at a different
speed and torque. Torque is calculated by multiplying the force by the distance from
the center of the shaft to the point where the force is exerted.
A manual transmission is an assembly of gears and shafts that transmits power from
the engine to the drive axle. The driver controls the changes in gear ratios. By moving
the shift lever, various gear and speed ratios can be selected. The gears in a
transmission are selected to give the driver a choice of both speed and torque. Lower
gears allow for lower vehicle speeds but more torque. Higher gears provide less torque
but higher vehicle speeds. Gear ratios state the ratio of the number of teeth on the
driven gear to the number of teeth on the drive gear.
Different gear ratios are necessary because an engine develops relatively little power
at low engine speeds. The engine must be turning at a fairly high speed before it can
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deliver enough power to get the car moving. Through a selection of the proper gear
ratio, the torque applied to the drive wheels can be multiplied.
Power is moved through the transmission via four gears (two sets of two gears). Speed
and torque are altered in steps. To explain how this works, let us assign numbers to
each of the gears. The small gear on the input shaft has twenty teeth. The gear it
meshes with has forty. This provides a gear ratio of 2:1. The output of this gear set
moves along the shaft of the forty-tooth gear and rotates other gears. The gear
involved with the first gear has fifteen teeth. This gear rotates at the same speed and
with the same torque as the forty-tooth gear. However, the fifteen-tooth gear meshes
with a larger gear with fifty-five teeth. The gear ratio of the fifteen-tooth and thirty-
five-tooth gear set is 2.33:1. However, the ratio of the entire gear set (both sets of two
gears) is 4.67:1.
To calculate this gear ratio, divide the driven (output) gear of the first set by the drive
(input) gear of the first set. Do the same for the second set of gears, and then multiply
the answer from the first by the second. The result is equal to the gear ratio of the
entire gear set. The mathematical formula follows:
Most of today’s transmissions have at least one overdrive gear. Overdrive gears have
ratios than 1:1. These ratios are achieved by using a small driving gear meshed with
a smaller driven gear. Output speed is increased and torque is reduced. The purpose
of overdrive is to promote fuel economy and reduce operating noise while maintaining
highway cruising speed.
The driveline’s gear ratios further increased by the gear ratio of the ring and pinion
gears in the drive axle assembly. Typical axle ratios are between 2.5 and 4.5:1. The
final (overall) drive gear is calculated by multiplying the transmission gear ratio by
the final drive ratio. If a transmission is in first gear with a ratio of 3.63:1 and has a
final drive ratio of 3.52:1, the overall gear ratio is 12.87:1. If the fourth gear has a
ratio of 1:1, using the same final drive ratio, the overall gear ratio is 3.52:1. The
overall gear ratio is calculated by multiplying the ratio of the first set of gears by the
ratio of the second (3.63 times 3.52 equal to 12.78).
Reverse gear ratios involve two driving (driver) gears and two driven gears:
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If the input gear has twenty teeth, the idled gear has twenty-eight teeth and the
output gear has forty-eight teeth. However, since a single idler gear is used, the teeth
of it are not used in the calculation of gear ratio. The idler gear merely transfers
motion from one gear to another. The calculation for determining reverse gear ratio
with a single idler gear follows.
If the gear set uses two idler gears (one with twenty-eight teeth and the other
with forty teeth), the gear ratio involves three driving gears and three driven
gears:
= 28 × 40 × 48
20 × 28 × 40
= 53, 760
22, 400
= 2.40
Transmission/Transaxle Design
The internal components of transmission or transaxle consist of a parallel set of
metal shafts on which meshing gear sets of different ratios are mounted. By moving
the shift lever, gear ratios can be selected to generate different amounts of output
torque and speed.
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The gears are mounted or fixed to the shafts in a number of ways. They can be
internally splined or keyed to a shaft. Gears can also be manufactured as an integral
part of the shaft. Gears that must be able to freewheel around the shaft during
certain speed ranges are mounted to the shaft using bushings or bearings.
The shafts and gears are contained in a transmission or transaxle case or housing.
The components of this housing include the main case body, side or top cover plates,
extension housings, and bearing retainers. The metal components are bolted together
with gaskets providing a leak-proof seal at all joints. The case is filled with
transmission fluid to provide constant lubrication and cooling for the spinning gears
and shafts.
Transmission Features
Although they operate similarly, the layout, components, and terminology used in
transmissions and transaxles are not the same.
A transmission has three specific shafts: the input shaft, the countershaft, and the
main shaft or output shaft. The clutch gear is an integral part of the transmission’s
input shaft and always rotates with the input shaft.
The countershaft is several gears machined out of a single piece of steel. The
countershaft may also be called the counter gear or cluster gear. The counter gear
mounts on roller bearings on the countershaft. The countershaft is pinned in place
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and does not turn. Thrust washers control the amount of end play of the unit in the
transmission case.
The main gears on the main shaft or output shaft transfer rotation from the counter
gears to the output shaft. The main gears are also called speed gears. They are
mounted on the output shaft using roller bearings. Speed gears freewheel around
the output shaft until they are locked to it by the engagement of their shift
synchronizer unit.
Power flows from the transmission input shaft to the clutch gear. The clutch gears
mesh with the large counter gear of the counter gear cluster. This cluster gear is now
rotating. Since the cluster gear meshes with the speed gears on the main shaft, the
speed gears are also turning.
There can be no power output until one of the speed gears is locked to the main
shaft. This is done by activating a shift fork, which moves its synchronizer to engage
the selected speed gear to the main shaft. Power travels along with the counter gear
until reaches this selected speed gear. It then passes through this gear back to the
main shaft and out of the transmission to the driveline
Transaxle Features
Transaxles use many of the design and operating principles found in transmissions.
But because the transaxle also contains the differential gearing and drive axle
connections, there are major differences in some areas of operation.
A transaxle typically has two separate shafts—an input shaft and an output shaft.
The input shaft is the driving shaft. The output shaft is the driven shaft. The
transaxle’s main (speed) gears freewheel around the output shaft unless they are
locked to the shaft by their synchronizer assembly. The main speed gears are in
constant mesh with the input shaft drive gears. The drive gears turn whenever the
input shaft turns.
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The names used to describe transaxle shafts vary between manufacturers. The
service manuals of some vehicles refer to the input shaft as the main shaft and the
output as the driven pinion or drive shaft. Others call the input shaft and its gears
the input gear cluster and refer to the output shaft as the main shaft. For clarity,
this text uses the terms input gear cluster for the input shaft and its drive gears and
pinion shaft for the output shaft.
A pinion gear is machined onto the end of the transaxle’s pinion shaft. This pinion
gear is in constant mesh with the differential ring gear located in the lower portion
of the transaxle housing. Because the pinion gear is part of the pinion shaft, it must
rotate whenever the pinion shaft turns. With the pinion rotating, engine torque flows
through the ring gear and differential gearing to the drive shafts and driving wheels.
Some transaxles have a third shaft designed to offset the power flow on the output
shaft. Power is transferred from the output shaft. Power is transferred from the
output shaft to the third shaft using helical gears and by placing the third shaft in
parallel with the output and input shafts. Other transaxles with a third shaft use an
offset input shaft that receives the engine’s power and transmits it to a main shaft,
which serves as an input shaft. The third shaft is only added to transaxles when an
extremely compact transaxle is required.
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Source: Google stock photos
Synchronizers
Synchronizer Design
The most commonly used synchronizer—a block or cone synchronizer. The
synchronizer sleeve surrounds the synchronizer assembly and meshes with the
external splines of the clutch hub. The clutch hub is splined to the transmission
pinion shaft and is held in position by a snap ring. A few transmissions use pin-type
synchronizers.
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Source: Google stock photos
The synchronizer sleeve has a small internal groove and a large external groove in
which the shift fork rests. Three slots are equally spaced around the outside of the
clutch hub. Inserts fit into these slots and can slide freely back and forth. These
inserts sometimes referred to as shifter plates or keys, are designed with a
ridge in their outer surface. Insert springs hold the ridge in contact with the
synchronizer sleeve internal groove.
The synchronizer sleeve is precisely machined to slide onto the clutch hub
smoothly. The sleeve and hub sometimes have alignment marks to ensure proper
indexing of their splines when assembling to maintain smooth operation.
Brass or bronze synchronizing blocking rings are positioned at the front and
rear of each synchronizer assembly. Some synchronizer assemblies use frictional
material on the blocking rings to reduce slippage. Each blocking ring has three
notches equally spaced to correspond with the three insert keys of the hub. Around
the outside of each blocking ring is a set of beveled clutching teeth, which is used for
alignment during the shift sequence. The inside of the blocking ring is shaped like a
cone. This coned surface is lined with many sharp grooves. The cone of the blocking
ring makes up only one-half of the total cone clutch. The second or matching half of
the cone clutch is part of the speed gear to be synchronized. The shoulder of the
speed gear is cone-shaped to match the blocking ring. The shoulder also contains a
ring of beveled clutching teeth designed to align with the clutching teeth on the
blocking ring.
Operation
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To shift the transmission into first gear, the clutch is disengaged and the gearshift
lever is placed in first gear position. This forces the shift fork on the synchronizer
sleeve toward the first speed gear on the pinion shaft. As the sleeve moves, the inserts
also move because the insert ridges lock the inserts to the internal groove of the
sleeve.
The movements of the inserts force the blocking ring’s coned friction surface against
the coned surface of the first-speed gear shoulder. When the blocking ring and gear
shoulder come into contact, the grooves on the blocking ring cone cut through the
lubricant film on the first-speed gear shoulder and metal-to-metal contact is made.
Contact generates substantial friction and heat. This is one reason bronze or brass
blocking rings are used. A nonferrous metal such as bronze or brass minimizes wear
on the hardened steel gear shoulder. This frictional coupling is not strong enough to
transmit loads for long periods. As the components reach the same speed, the
synchronizer sleeve can now slide over the external clutching teeth on the first-speed
gear shoulder. This completes the engagement. Power flow is now from the first speed
gear to the synchronizer sleeve, to the synchronizer clutch hub, to the main output
shaft, and out to the driveline.
To disengage the first speed gear from the pinion shaft and shift into second speed
gear, the clutch must be disengaged as the shift fork is moved to pull the
synchronizer sleeve and disengage it from the first gear. As the transmission is
shifted into second gear, the inserts again lock into the internal groove of the sleeve.
As the sleeve moves forward, the forward blocking ring is forced by the inserts against
the coned friction surface on the second-speed gear shoulder. Once again, the
grooves on the blocking ring cut through the lubrication on the gear shoulder to
generate a frictional coupling that synchronizes the speed gear and shaft speeds. The
shift fork can then continue to move the sleeve forward until it slides over the
blocking ring and speed gear shoulder clutching teeth, locking them together. Power
flow is now from the second gear to the synchronizer sleeve, to the clutch hub, and
out through the pinion shaft.
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Source: Google stock photos
The shift forks and rails are assembled in the cover of this transmission with
a direct shift linkage. The gearshift lever is connected to the shift forks through a
gearshift linkage. Linkage design varies between manufacturers but can generally be
classified as being direct or remote.
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Gearshift Linkages
There are two basic designs of gearshift linkages: internal and external.
Internal linkages are located at the side or top of the transmission. The control end
of the shifter is mounted inside the transmission, as are all of the shift controls.
Movement of the shifter moves a shift rail and shift fork toward the desired gear.
This moves the synchronizer sleeve to lock the selected speed gear to the shaft. This
type of linkage is often called a direct linkage because the shifter is in direct contact
with the internal gear shifting mechanisms.
Shift rails are machined with interlock and detent notches. The interlock
notches prevent the selection of more than one gear during shifting. When a shift rail
is moved by the shifter, interlock pins hold the other shift rails in their neutral
position. The detent notches and matching spring-loaded pins or balls give the driver
feedback as to when the shift collar is adequately moved.
As the shift rail moves, a detent ball moves out of its detent notch and drops
into the notch for selected gear. At the same time, an interlock pin moves out of its
interlock notch and into the other shift rails.
External linkages function in much the same way, except that rods, external to the
transmission, are connected to levers that move the internal shift rails of the
transmission. Some transaxles are shifted by a rod or by cable.
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An external shifter assembly mounted to the transmission
A remote gearshift showing linkage, selector rod, and stabilizer (stay bars).
Neutral
The neutral power flow is illustrated below. The input shaft rotates at engine
speed whenever the clutch is engaged. The clutch gear is mounted on the input shaft
and rotates with it. The clutch gear meshes with the counter gear, which rotates
around the countershaft. The counter gear transfers power to the speed gears on the
main shaft. However, since speed gears one, two, three, and four are not locked to
the main shaft when the transmission is in neutral, they cannot transfer power to
the main shaft. The main shaft does not turn, and there is no power output to the
driveline.
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Source: Google stock photos
All gear changes pass through the neutral gear position. When changing gears,
one-speed gear is disengaged, resulting in neutral, before the chosen gear is engaged.
This is important to remember when diagnosing hard-to-shift problems.
First Gear
The first gear power flow is illustrated below. Power or torque flows through
the input shaft and clutch gear to the counter gear. The counter gear rotates. The
first gear on the cluster drives the first speed gear on the main shaft. When the driver
selects first gear, the first/second synchronizer moves to the rear to engage the first
speed gear and lock it to the main shaft. The first speed gear drives the main (output)
shaft, which transfers power to the driveline. A typical first-speed gear ratio 3:1 (three
full turns of the input shaft to one full turn of the output shaft). So, if the engine
torque entering the transmission is 220 ft-lb (298 Nm) it is multiplied three times to
660 ft-lb (895 Nm) by the time it is transferred to the driveline.
Second Gear
When the shift from first to second gear is made, the shift fork disengages the
first/second synchronizer from the first speed gear and moves it until it locks the
second speed gear to the main shaft. Power flow is still through the input shaft and
clutch gear to the counter gear. However, now the second counter gear on the cluster
transfers power to the second speed gear locked on the main shaft. Power flows from
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the second speed gear locked on the main shaft. Power flows from the second speed
gear through the synchronizer to the main shaft (output shaft) and driveline.
In second gear, the need for vehicle speed and acceleration is greater than the
need for maximum torque multiplication. To meet these needs, the second speed gear
on the main shaft is designed slightly smaller than the first speed gear. This result
in a typical gear ratio of 2.2:1, which reflects a drop in torque and an increase, is
speed.
Third Gear
When the shift from second to third gear is made, the shift fork returns the
first/second synchronizer to its neutral position. A second shift fork slides the
third/fourth synchronizer until it locks the third speed gear to the
main shaft. Power flow now goes through the third gear of the counter gear to the
third speed gear, through the synchronizer to the main shaft.
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Fourth Gear
In the fourth gear, the third/fourth synchronizer is moved to lock the clutch gear on
the input shaft to the main shaft. This means power flow is directed from the input
shaft to the main shaft (output shaft) at a greater ratio of 1:1. This ratio results in
maximum speed output and no torque multiplication. The fourth gear has no torque
multiplication because it is used at cruising speeds to promote maximum fuel
economy. The vehicle is normally downshifted to lower gears to take advantage of
torque multiplication and acceleration when passing lower vehicles or climbing
grades.
Fifth Gear
When the fifth gear is selected, the fifth gear synchronizer engages the fifth
gear to the main shaft. This causes a large gear on the countershaft to drive a smaller
gear on the main shaft, which results in an overdrive condition. Overdrive permits
an engine speed reduction at higher vehicle speeds
Reverse Gear
In reverse gear, it is necessary to reverse the direction of the main shaft (output
shaft). This is done by introducing a reverse idler gear into the power flow path. The
idler gear is located between the countershaft reverse gear and the reverse speed gear
on the main shaft. The idler assembly is made of a short drive shaft independently
mounted in the transmission case parallel to the countershaft. The idler gear may be
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mounted near the midpoint of the shaft. The reverse speed gear is the external tooth
sleeve of the first/second synchronizer.
When reverse gear is selected, both synchronizers are disengaged and in a neutral
position. The shifting linkage moves the reverse idler gear into mesh first/second
synchronizer sleeve. Power flows through the input shaft and clutch gear to the
countershaft. Form the countershaft; it passes to the reverse idler gear, where it
changes rotational direction. It then passes to the first/second synchronizer sleeve.
Rotational direction is again reversed. From the sleeve, power passes to the main
shaft and driveline.
Neutral
When the transaxle is placed in neutral, the engaged clutch drives the input
shaft and gear cluster assembly in a clockwise direction. The first/second and
third/fourth synchronizers on the main shaft are not engaged, so the pinion shaft
gears are not locked to the pinion shaft. The pinion shaft and the pinion gear do not
turn, so there is no output to the transaxle differential ring gear.
First Gear
In first gear, the first/second synchronizer engages the first speed gear to
the main shaft, locking it to the pinion shaft. The cluster’s first gear, rotating
clockwise, drives the first speed gear and the pinion shaft in a counterclockwise
direction. The counterclockwise turning pinion on the end of the pinion shaft
drives the differential ring gear, differential gearing, driveshafts, and wheels in a
clockwise direction.
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Source: Google stock photos
Second Gear
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Third Gear
Fourth Gear
The action of the shift lever moves the third/fourth synchronizer sleeve away from
the pinion shaft third speed gear and toward the fourth speed gear, locking it to the
pinion shaft.
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Source: Google stock photos
Reverse Gear
When the shift lever is placed in reverse, the reverse, idler gear shifts into mesh with
the input cluster reverse gear and the reverse speed gear. The reverse speed gear is
the sleeve of the first/second synchronizer. To act as the reverse speed gear, the
synchronizer sleeve is designed with spur teeth machined around its outside edge.
The reverse idler gear changes the direction of rotation of the pinion shaft reverse
speed gear so that the vehicle back up. Like transmissions, some transaxles have
five forward speeds. Normally, fourth and fifth gears for smaller cars have overdrive
ratios. These high gear ratios compensate for very low final drive gear ratios. Low
final drive ratios provide great torque multiplication, which is needed to safely
accelerate with a small engine.
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Final Drive Gears and Overall Ratios
Electrical Systems
Backup lights illuminate the area behind the vehicle and warn other drivers
and pedestrians that the vehicle is moving in reverse. Most manual transmissions
are equipped with a separate switch located on the transmission but can be mounted
to the shift linkage away from the transmission. If the switch is mounted in the
transmission, the shifting fork closes the switch and completes the electrical circuit
whenever the transmission is shifted into reverse gear. If the switch is mounted on
the linkage, the switch is closed directly by the linkage.
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Diagnosing Problems
Service manuals list the most common problems associated with manual
transmissions and transaxles. Proper diagnosis involves locating the exact source of
the problem. Many problems that seen transmission/transaxle related may be
caused by problems in the clutch driveline or differential. Check these areas along
with the transmission/transaxle, particularly if you are considering removing the
transmission/transaxle for service.
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Visual Inspection
1. Check for lubricant leaks at all gaskets and seals. The transmission rear seal at
the driveline is particularly prone to leakage.
2. Check the case body for signs of porosity that show up as leakage or seepage of
lubricant.
3. Push up and down on the unit. Watch the transmission mounts to see if the rubber
separates from the metal plate. If the case moves up, but not down, the mounts
require replacement.
4. Move the clutch and shift linkages around and check for loose or missing
components. Cable linkages should have no kinks or sharp bends, and all
movements should be smooth.
5. Transaxle drive axle boots should be checked for cracked, deformation, or damage.
The constant velocity joints on transaxle drive axles should be thoroughly inspected.
Transmission Noise
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synchronizers. A noise that changes or disappears in different gears can indicate a
specific problem area in the transmission.
When the vehicle is moving, both the input and main shaft (output shaft) are
turning in the transaxle. If the noise occurs in forward and reverse gears, but not in
neutral, the output of main shaft bearings is the likely failed component.
Replacement is the solution.
In transmissions, the problem is also bearing related. If the rough growling
noise occurs when the engine is running, the clutch engaged, and the transmission
in neutral, the front input shaft bearing is likely at fault. Rough growling when the
vehicle is moving in all gears indicates faulty counter gear bearings or countershaft
–to-cluster assembly needle bearings. If the problem occurs in all gears except direct
drive, the bearing at the rear of the transmission input shaft may be at fault. This
bearing supports the pilot journal at the front of the transmission output shaft. In
all forward gears except direct drive, the input shaft and output shaft turn at two
different speeds. In reverse, the two shafts turn in opposite directions. In direct drive,
the two shafts are locked together and this bearing does not turn. If the growling
noises stop during direct drive operation, the rear input shaft bearing may be at fault.
Disassembly, inspection, and replacement of damaged parts are needed.
Chipped or broken teeth are dangerous because the loose parts can cause
severe damage in other areas of the transmission/transaxle. Broken parts are
usually indicated by a rhythmical knocking sound, even at low speeds. Complete
disassembly, inspection, and replacement of damaged parts are the solution to this
problem.
Gear clash is indicated by a grinding noise during shifting. The noise is the
result of one gearset remaining partly engaged while another gearset attempts to turn
the main shaft. Gear clash can be caused by the incorrect clutch adjustment of
binding of clutch or gearshift linkage. Damaged, worn, or defective synchronizer
blocking rings can cause gear clash, as can use of an improper gear lubricant.
Hard Shifting If the shift lever is difficult to move from one gear to another,
check the clutch linkage adjustment. Hard shifting may also be caused by damage
inside the transmission/transaxle, or by a lubricant that is too thick. Common hard
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shifting includes badly worn bearings and damaged clutch gears, control rods, shift
rails, shift forks, and synchronizers.
Jumping out of Gear If the car jumps out of gear into neutral, particularly
when decelerating or going hills, first check the shift lever and internal gearshift.
Excessive clearance between gears and the input shaft or badly worn bearings can
cause jumping out of gear. Another internal transmission/transaxle parts to inspect
are the clutch pilot bearing, gear teeth, shift forks, shift rails, and springs or detents.
If these checks do not resolve the problem, the transmission or transaxle must
be removed from the vehicle and disassembled. After disassembly, inspect the
internal counter gear, clutch shaft, reverse idler, shift rails, shift forks, and spring
or detents for damage. Also, check for worn support bearings.
If the problem seems to be in the clutch assembly, make sure the
transmission/transaxle is out of gear, set the parking brake, and start the engine.
Increase the engine speed to about 1,500—2,000 rpm and gradually apply the clutch
until the engine torque causes tension at the drive train mounts. Watch the torque
reaction of the engine. If the engine’s reaction to the torque appears to be excessive,
broken or worn drive train mounts may be the cause and not the clutch.
What’s More
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What I Have Learned
Direction: Share your learning by answering the question below. Write your
answer in a separate answer sheet.
What I Can Do
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3. Clean the area around the filler plug to keep
dirt out of the engine.
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8. If fluid runs out freely, let it drain into the drain
pan until it seeks its level,
12. Pull the wire out and note the lubricant level. If
the level is down you will need to add fluid of the
correct lubricant type and grade to bring it up to the
recommended level.
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13. Check the plug for damage to the thread, and sealing the gasket if it exists.
14. Install a new gasket. Replace the filler plug and tighten it with the correct
wrench to the manufacturer’s recommended tension.
Procedures for the replacement of the rear oil seal and bushing on a transmission
vary little with each car model. Typically, to replace the rear bushing and seal follow
these steps:
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4. Pull the bushing from the housing
Assessment
Multiple Choice. Choose the letter of the best answer. Write the chosen letter on a
separate sheet of paper.
1. What power train component that provides the torque needed to move the
vehicle under a variety of road and load condition. This is done by changing
the gear ratio between the engine crankshaft and vehicle drive wheels?
a. Differential c. Clutch
b. Manual Transmission d. U- joint
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a. Differential c. Manual Transaxle
b. Manual Transmission d. Gear
4. What power train component can be shifted into neutral for starting the engine
and running without turning the drive wheels?
a. Differential c. Clutch
b. Gear d. Manual Transmission
5. Which gear is the simplest gear design used in manual transmissions and
transaxles?
a. Spur gear c. Spiral gear
b. Helical gear d. Idler
6. What power train component can be shifted into reverse so the vehicle can
move backward?
a. Differential c. Clutch
b. Manual Transaxle d. U- joint
7. Which gear that allows two or more teeth to mesh at the same time, which
distributes tooth load and produces a very strong gear?
a. Spur gear c. Spiral gear
b. Helical gear d. Spline
9. What Manual Transmission part where the main job is to bring components
that are rotating at different speeds to one synchronized speed?
a. Counter gear c. Bearing
b. Synchronizer d. Speed gear
10. Which device that illuminates the area behind the vehicle and warn other
drivers and pedestrians that the vehicle is moving in reverse.
a. Stop light c. Brake Light
b. Signal Light d. Backup lights
Additional Activities
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Identification: Identify each illustration of Manual Transmission and Manual
Transaxle speed gearing. Write your answer on a separate sheet of
paper.
1. ________
2. _________
3. ________
4. _______
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5. _______
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Additional Activities
1. 3RD gear
2. Neutral
3. 1st gear
4. 3rd gear
5. 5th gear
What’s More Assessment What I Know
1. The teacher will rate the 1. B 1. A
learners’ answers. 2. C 2. C
3. D 3. A
2. The teacher will rate the 4. D 4. A
learners’ answers. 5. A 5. A
6. B
3. Reverse gear ratio = 7. B
driven #1 × 8. D
9. B
driven #2 × driven #3 10. D
driven #1 × driven #2 ×
driven
#3
= 28 × 40 × 48
20 × 28 × 40
Answer Key
References
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