A Presentation on

Automotive Gearboxes

By
U-03
U-18
U-46
U-48
U-52
 Contents
• Introduction
• Need of Gearboxes in Automobiles
• Classification of Gearboxes
• Sliding Mesh Gearbox
• Differential Gearbox
• Constant Mesh Gearbox
• Synchromesh Gearbox
• Epicyclic Gearbox
• Transfer Case and Overdrive
• Steering Gearbox
 Introduction
• Part of transmission system in engine
• Uses gears, splined shafts, bearings and various types of
clutches
• Types of gears used are spur, helical, bevel and spiral gears
Need of Gearboxes
• Torque must be high and constant at the
beginning, and power must be constant
at high speeds

• The required torque speed characteristics

are met by using gearbox as shown in
figure
 Classification of gearboxes
• According to application, gearboxes have the
following types
o Transmission Gearboxes

o Differential Gearbox
o Special Function Gearboxes

o Steering Gearboxes
 Sliding Mesh Gearbox
• Manual Transmission
• Simplest type
• Splined Lay Shaft and Main Shaft
• Spur Gears Slide to engage
• Wear and tear
• Noise
• Simple to manufacture and maintain
• Less no. of bearings required
• Gear Ratio of every gear makes
difference in the torque and speed
output of the vehicle
 Constant Mesh Gearbox
• Gears Continuously in mesh
• Dog clutches provided
• Double declutching required for smooth
engagement
• Speed of gears and clutch shaft needs to
be increased
• Helical gears can be used
• Quieter running
• Bearings required
• Wear and tear on gears is reduced and is
uniform
 Synchromesh Gearbox
• Similar to constant mesh
• Synchromesh Device
• No double declutching required
• Cone clutch-type device
• First equalizes speed of gears
• Then engages them smoothly
• Selector Mechanism is required
• Most expensive to manufacture
 Epicyclic Gearbox
• Used in automatic transmission, hybrid
vehicles, tractors, special purpose
vehicles like excavators
• One or more planetary gear sets
• Different torque ratios re obtained by
making one of the parts stationary
• Wilson Gearbox is used
• Driver can pre select gears for faster
selection
• Clutch packs are employed to select
various combinations
• Hydraulic actuators are used in
automatic and hybrid vehicle gearboxes
 Transfer Box
• Also called transfer case, used in four-
wheel drive vehicles
• Allows the driver to switch between
two-wheel drive and four-wheel drive
• Uses the principle of dog clutch
• Two output shafts, one for front and one
for rear respectively
• Power comes through transmission to
input shaft, then idler gear, and then to
rear wheel output shaft
• Front wheel output can be selected by
engaging the dog clutch to the gear
mounted on the rear wheel output shaft
 Overdrive
• Step up the gear ratio in the car
• Between the transmission and propeller shaft
• High cruising sped at low engine speed
• Epicyclic Gear Train
• Overdrive is engaged by locking the sun gear
to the casing
• Normal drive is obtained by locking the sun
gear with the planet carrier
• Free wheel is used to avoid output shaft
override
 Differential Gearbox
• The final drive of the vehicle
• Power is required to be split
into 2 directions at 90 degrees
• While turning, inside and
outside wheels are required to
turn at different speeds
• Uses Bevel Gears and
Compound Epicyclic Gear
Train
 Steering Gearboxes
• Converts rotary motion of steering wheel into linear
motion of steering linkages
• Provides necessary leverage
• Types
o Worm and Worm Wheel
o Worm and Nut
o Recirculating Ball Type
o Rack and Pinion
 Worm and Worm Wheel
• Worm and Wheel or Sector of wheel arrangement is
used
• Gives very high steering ratio easily
• Easy to manoeuvre
• More accurate steering
• Wear and tear is less, worm takes the for of gear
profile on sector
• In Worm and Worm Wheel back lash can be adjusted
 Worm and Nut
• Steering wheel rotation rotates the worm
• Nut moves along its length
• Drop arm end moves linearly
 Recirculating Ball Type
• Worm on steering rod, nut on worm with balls in
between
• Balls reduce friction
• Nut has external teeth which engage with teeth of
sector
• Sector is connected to drop arm
 Rack and Pinion Gearbox
• Used on light vehicles like cars and in power
steering
• Simple, light and responsive
• Steering column connected to a pinion
• Pinion is in mesh with rack which moves linearly
• Rack is directly connected to stub axles via ball
joints and tie rods
• Ideal for low steering ratios
• Helical gearing is employed, pinion is tilted
• Larger gear ratio can be used
• Friction is increased but damping is provided