TRANSMISSION

CCAS 3381
AUTOMOTIVE SKILL I
IO N
IS S
AN SM
T R
OBJECTIVES
 To understand the operational
principles and basic mechanisms
of transmission system
Lecture – 1 hour
Workshop – 1 hour
TRANSMISSION SYSTEM (1)
Manual
Manual
Manual transmission system gear box
gear knob
Manual
gear box 5-speed manual gearbox
 Green shaft (input shaft) & gear turn at
the same rpm as the engine
 Red shaft (layshaft) & gears are directly
connected to the input so it spins when
input shaft spins
 Yellow shaft (output shaft) is splined
shaft connected directly to drive shaft
through differential to drive wheels (If
wheels are spinning output shaft spins)
 If engine is off with car coasting output
shaft turns inside blue gears (blue
gears & layshaft are motionless)
 Collar connects one of two blue gears
to output shaft via dog teeth
 Moving knob forward & backward
moves collar to engage the gears
 Reverse gear is handled by a small
idler gear (purple)
 Importance of transmission:
– Engine redline (max. rpm above
which engine explodes)
– Engines have narrow rpm ranges
(horsepower & torque are at their
maximum)
 Synchronizers allow collar & gear to
make frictional contact before dog
teeth make contact (collar & gear
synchronize their speeds before
teeth need to engage
 A car engine spins all
the time & car wheels
don't (to stop without
killing the engine
r i ng wheels, engine needs
Sp
to be disconnected
Pressure plate
from the engine)
Sp  Flywheel connected to
rin
g engine
 Clutch plate connected
to the transmission
Clutch plate
 Springs force on pressure plate
 Clutch plate springs - isolate
transmission from shock of clutch
engaging
 Friction material on the clutch disc wears
out (similar to the friction material on the
pads of a disc brake pads/shoes of a
drum brake; clutch slips & lost of power)
 Driver who slips the clutch a lot will wear
out clutch a lot faster
 Worn throw-out bearing (rumbling noise
whenever the clutch engages)
 Other clutches:
– Automatic transmission with several
clutches used to engage and disengage
various sets of planetary gears
– Car air conditioning compressor with
magnetic clutch
– Engine-driven cooling fan with
thermostatically controlled viscous clutch
 Ideally, transmission should be
flexible in its ratios that engine runs
at its single, best rpm value
(continuously variable transmission -
CVT) – Honda City
 Manual transmission checklist:
– Check for oil leaks (RM5000 new Kancil
gearbox)
 Manual transmission test drive
– With transmission lever in neutral,
parking brake applied & engine idling,
listen to any loud noises when clutch
pedal pressed or released
– Try to drive the car at all speeds one by
one - every speed should shift smooth &
easily without any noises or jerks
 Manual transmission test drive
– While driving at 2nd or 3rd gear, try to
press down sharply on the
accelerator pedal for an instance
(clutch should not slip, any slipping
i.e., engine rpm increases but speed
remains the same clutch most likely
has to be replaced)
– Try to drive with acceleration &
deceleration (there should be no
whining or humming noise under any
condition with all gears should shift
easily & noiselessly)
 Automatic transmissions:
– no clutch pedal
– no gear shift
 Automatic transmission (gearbox plus
torque converter) – like manual gearbox
& its clutch
Torque Auto Auto transmission system

converter gearbox
 In automatic transmission, same set of gears
produces all of the different gear ratios
(planetary gearset)
 Planetary gearset
– A set of bands to lock parts of gearset
– Three wet-plate clutches to lock other parts of gearset
– Hydraulic system controlling clutches & bands
– Large gear pump to move transmission fluid around
 Planetary gearset has 3 main parts:
– Sun gear
– Planet gears & planet gears' carrier
– Ring gear
 Each of these 3 parts can be input, output
or stationary (determines gear ratio)
 First Gear - 2.4:1
 Second Gear - 0.67:1
 3rd gear - 1:1 ratio in 3rd gear
 Overdrive has a faster output speed than
input speed (output of engine goes
straight to transmission)
 Ratio = 1 / (1 + S/R) = 1 / ( 1 + 36/72) =
0.67:1 (an engine turning at 2000 rev/min
output speed is 3000 RPM allowing cars to
drive at freeway speed while the engine
speed stays nice and slow
 Differentials (where engine power, in most cars,
makes its last stop before spinning the wheels)
– Aim engine power at the wheels
– Act as final gear reduction in the car (reduce
rotational speed of transmission one final time
before it hits the wheels)
– Transmit power to the wheels while allowing
them to rotate at different speeds during turning
 Device that splits engine torque two ways, allowing
each output to spin at a different speed
 Differential is found on all modern cars & trucks,
and also in many all-wheel-drive (full-time 4WD
vehicles)
Differential
 Final drive ratio (gear ratio in the
differential)
 Open differential always applies the
same amount of torque to each wheel
 Two factors determining how much
torque can be applied to the wheels:
– equipment
– traction
 Dry conditions - torque
applied to wheels
limited by engine &
gearing
 In low traction - amount of torque limited to greatest
amount that will not cause a wheel to slip under those
conditions (if you give the car more gas after the
wheels start to slip, the wheels will just spin faster –
problem with open differentials
 Limited slip differential (LSD) – positraction - allows
more torque to be transferred to the non-slipping wheel
 Automatic transmission checklist
– Place your car at a level surface, start
engine, set transmission lever to "P“
& let engine idle
– Pull transmission dipstick
– Wipe it off with a lint free clean
rag/tissue
– Insert it back carefully all the way
down into its place
– Pull again & check fluid level
 Automatic transmission
checklist
– Pull again & check fluid level
 Engine cold fluid within
"COLD" marks
 Engine hot fluid level at
upper end of "HOT" mark
(top it up if it is lower)
 Check fluid condition also:
too black & a burnt smell
-transmission may not last
 Automatic transmission
checklist
– Pull again & check fluid
level
 Thereshould not be any
metal filings or black flakes
 Topping up transmission fluid
– Use only specified
transmission fluid (check
your manual)
 Topping up transmission
fluid
– Add a small amount of
fluid through dipstick
pipe as shown in the
image & do not overfill it
– Wait for a few minutes to
let fluid to flow down
– Start engine & check
level again
 Transmission maintenance
– Most of transmission troubles start after
overheating
 Under heavy load
 Continuous stop & go traffic in hot weather
 Racing
 Accelerating too hard to free the car
 At higher temperatures transmission fluid
burns loosing its lubricating qualities &
becomes oxidized leaving deposits all over
inside
 Exposed to heat rubber seals & gaskets
inside transmission become hardened
causing leaks
 Transmission maintenance
– Most of transmission troubles start
after overheating
 Metal parts warp & loose their strength
– Poor design
– After being rebuilt by inexperienced
technician
– Harsh driving
– Too low or too high transmission
fluid level
– Wrong transmission fluid type
 How to prevent the transmission from
damage
– Always check your parking space for
leaks (get it fixed before it caused
something serious)
– Once in a while check transmission
fluid level & condition
– Use only same type of the
transmission fluid as specified in
owner's manual
– Never shift to “R” or “P” until car
comes to a complete stop
 How to prevent the transmission from
damage
– Never shift from “P” mode when
engine rpm is higher than normal idle
– Always hold a brake down when
shifting from “P”
– Do not tow with drive wheels on the
road
– Go to transmission shop when you
experience any problems with your
transmission such as leaks, noises,
problems with shifting, etc.
 ATF (owner’s manual)
 Fluid change (40,000 km or so)
 Good conditions – clean & odorless
 Transmission screen/filter
THE END
IQ + EQ + SQ = TQ*

TRANSMISSION

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TRANSMISSION

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CCAS 3381

Torque Auto Auto transmission system

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