INTRODUCTION TO “GEARBOX

550”

Presented by,
Nabin Chaudhary
Service Engineer Trainee
26-Sept, 2019.
 INTRODUCTION

1. A gearbox is a mechanism of transferring

power from one component to another. It is a
torque multiplier.
2. It also controls the rpm, speed and torque
produced from engine.
 OBJECTIVE OF GEARBOX

 To provide variation in speed and torque.

 To provide neutral condition to the vehicle.
 To provide reverse movement of vehicle without
changing the direction of rotation of crankshaft.
 COMPONENT USED

 Counter shaft
 Main shaft
 Sleeve
 Selector Shaft
 Synchronizer ring
 Synchronizer cone
 POWER FLOW

Power

flows from clutch disc to input
shaft
Each forward gear has a synchronizer

Keeps two meshing gears from

clashing
Shift linkage acts on shift forks within

transmission to select gear range

Power flows from input shaft to

counter gear
Then to main shaft or output shaft
 Parts are housed in transmission

case
Has drain and fill plugs for adding and

draining oil.
 Gear Ratio

 Driving gear smaller than driven gear

 Output speed decreases
 Output torque increases

 Gear ratio

 Number of teeth on driven gear divided by number of

teeth on driving gear

 Calculation of Gear Ratio:

 N1/N2=T2/T1=D1/D2 Where N is number of

revolution.T is number of teeth and D is diameter.

 GEAR PAIRING

 GEAR PAIR NO.OF REDUCTION RATIO OVERALL REVOLUTION

TEETH
 CONSTANT 37/19 1.947 --------
MESH
FIRST 39/11 3.545 6.904
2nd 36/16 2.063 4.016
3nd 27/22 1.227 2.39
4th 21/28 0.75 1.461
5th 27/19 1.947 1
6th 25/58 0.431 0.84
REVERSE 24/4 x 36/24 2.18x1.5 6.373
TRANSMISSION LUBRICATION
AND BEARING

 Transmission parts
 Separated by oil at all times
 Splash lubrication
 Oil moved throughout case by rotating gears
 Bearings support ends of almost all rotating parts.
 Allow parts to rotate with very little friction
 Reverse idler shafts and gears
 Supported by bushings.
OIL FILLING CAPACITY
• For fully assembled- 5.8liter
• Drain and Refill – 5.7liter
FAILURE OF GEARBOX

 Noise from gear box

 Breakage of Gear Teeth.
 Gear Engagement Hard
 Cylinder seal damage
 Gear slippage
 Shifter fork tip damage.
 Vehicle not moving condition after engagement.
 Main shaft or Drive shaft broken.
 REMEDIES OF GEARBOX

 Replace affected bearings.

 Replace master or slave cylinder.
 Replace fork or shift tip.
 Replace the affected parts.
THANK YOU