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TRANSMISSION
Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

TRANSMISSION
 Transmission, in automobiles,
system of parts connecting the
engine to the wheels. Suitable
torque, or turning force, is
generated by the engine only within
a narrow range of engine speeds,
i.e., rates at which the crankshaft is
turning.

Functions of Transmission
 To increase the engine torque
 To enable a free-wheel or neutral
position
 To be able to reverse.
 Help the engine drive the car.
 Connect the engine to the
transmission system

Working Principle
 A gearbox is a method of
transmitting energy from one
mechanical device to another. It
works by increasing the torque
while at the same time reducing
the speed. Torque generates
power by twisting and bending
solid material.
continued…
Location
continued…
Operation
A manual gearbox works when the clutch is pressed down. This

allows the gearshift to be put into any desired gear. Most manual
transmissions have five or six gears in their gear box.
When the gears in the gearbox are shifted into a higher gear, the
gearbox gives the vehicle more power while using less fuel. This
works because the gearbox rotates the drive shaft, alternating the
torque and power.
When the gears are shifted into a lower gear, your vehicle will run
at a lower speed. Gears engage the drive shaft at different points
along the way. When the gear is lower, it will engage the drive
shaft closer to the gearbox
Requirement
A transmission or gearbox provides speed and
torque conversions from a rotating power source
to another device using gear ratios. The most
common use is in motor vehicles, where the
transmission adapts the output of the internal
combustion engine to the drive wheels. Such
engines need to operate at a relatively high
rotational speed, which is inappropriate for
starting, stopping, and slower travel. The
transmission reduces the higher engine speed to
the slower wheel speed, increasing torque in the
process. Transmissions are also used on pedal
bicycles, fixed machines, and anywhere else
rotational speed and torque needs to be adapted
Parts of Transmission
 Transmission Case
 Extension Housing
 Front Bearing Hub
 Transmission Shafts
 Transmission Gears
 Synchronizers
 Shift Forks
 Shift Linkage and Levers

Transmission Case
 The transmission case provides support for

the bearings and shafts, as well as an
enclosure for lubricating oil. A manual
transmission case is cast from either iron or
aluminum. Because they are lighter in
weight, aluminum cases are preferred.
 A drain plug and fill plug are provided for
servicing. The drain plug is located on the
bottom of the case, whereas the fill plug is
located on the side.
Extension Housing
 Also known as the tail shaft, the extension
housing bolts to the rear of the transmission
case. It encloses and holds the transmission
output shaft and rear oil seal. A gasket is
used to seal the mating surfaces between
the transmission case and the extension
housing. On the bottom of the extension
housing is a flange that provides a base for
the transmission mount.

Front Bearing Hub
 Sometimes called the front bearing
cap, the bearing hub covers the front
transmission bearing and acts as a
sleeve for the clutch release bearing.
It bolts to the transmission case and a
gasket fits between the front hub and
the case to prevent oil leakage

Transmission Shafts
A manual transmission has four steel
shafts mounted inside the transmission
case. These shafts are the input shaft,
the countershaft, the reverse idler
shaft, and the main shaft.
 INPUT SHAFT
 COUNTERSHAFT
 REVERSE IDLER SHAFT
 MAIN SHAFT

 INPUT SHAFT.- The input shaft, also known as the clutch
shaft, transfers rotation from the clutch disc to the
countershaft gears (fig. 4-13). The outer end of the shaft
is splined except the hub of the clutch disc. The inner end
has a machined gear that meshes with the countershaft.
A bearing in the transmission case supports the input
shaft in the case. Anytime the clutch disc turns, the input
shaft gear and gears on the countershaft turn.
 COUNTERSHAFT.- The countershaft, also known as the
cluster gear shaft, holds the countershaft gear into mesh
with the input shaft gear and other gears in the
transmission (fig. 4-14). It is located slightly below and to
one side of the clutch shaft. The countershaft does not
turn in the case. It is locked in place by either a steel pin,
force fit, or locknuts.
Transmission input shaft and
bearing.

Transmission countershaft assembly- exploded view.
 REVERSE IDLER SHAFT.- The reverse idler shaft is
a short shaft that supports the reverse idle gear (fig.
4-15). It mounts stationary in the transmission case
about halfway between the countershaft and output
shaft, allowing the reverse idle gear to mesh with both
shafts.
 MAIN SHAFT.- The main shaft, also called the output
shaft, holds the output gears and synchronizers (fig.
4-16). The rear of the shaft extends to the rear of the
extension housing where it connects to the drive shaft
to turn the wheel of the vehicle. Gears on the shaft
are free to rotate, but the synchronizers are locked on
the shaft by splines. The synchronizers will only turn
when the shaft itself turns.

Reverse idler shaft and gear assembly-exploded view.
Transmission main shaft assembly-exploded view.
Transmission Gears
 Transmission gears can be classified into four
groups- input gear, countershaft gears, main shaft
gears, and the reverse idler gear. The input gear
turns the countershaft gears, the countershaft
gears turns the main shaft gears, and, when
engaged, the reverse idler gear.
 In low gear, a small gear on the countershaft drives
a larger gear on the main shaft, providing for a high
gear ratio for accelerating. Then, in high gear, a
larger countershaft gear turns a small main shaft
gear or a gear of equal size, resulting in a low gear
ratio, allowing the vehicle to move faster. When
reverse is engaged, power flows from the
countershaft gear, to the reverse idler gear, and to
the engaged main shaft gear. This action reverses
main shaft rotation .
Synchronizers
 The synchronizer is a drum or sleeve
that slides back and forth on the splined
main shaft by means of the shifting fork.
Generally, it has a bronze cone on each
side that engages with a tapered mating
cone on the second-and high-speed
gears.

A transmission synchronizer has two
functions, which are as follows:
 1. Lock the main shaft gear to the
main shaft.
 2. Prevent the gear from clashing or
grinding during shifting.

Synchronizers.
Shift Forks
 Shift forks fit around the synchronizer
sleeves to transfer movement to the
sleeves from the shift linkage. The
shift fork sets in a groove cut into the
synchronizer sleeve. The linkage rod
or shifting rail connects the shift fork to
the operator's shift lever. As the lever
moves, the linkage or rail moves the
shift fork and synchronizer sleeve to
engage the correct transmission gear.
Shift Forks
Shift Linkage and Levers
 There are two types of shift linkages
used on manual transmissions. They
are the EXTERNAL ROD and the
INTERNAL SHIFT RAIL. They both
perform the same function. They
connect the shift lever with the shift
fork mechanism.

Types of Transmission
Manual
Automatic
Tiptronic

Manual Transmission
 A manual transmission uses a mechanical
clutch which is operated by the driver. This
connects the drive train to the engine. When
the driver wants the car to start moving, they
can select the appropriate gear according to
the speed of the car. When braking is
required, a manual gearbox makes engine
braking possible. By changing down gears,
the driver slows the engine. Lower gears are
used for speeding up or slowing down, higher
gears are used when cruising at speed;
engine revs drop and less fuel is consumed

Automatic Transmission
 An automatic transmission is a gearbox that
can change gears without use of a driver
operated clutch. Instead, the vehicle relies on
a torque converter which is placed between
the engine and transmission.
 Automatics are easier to use than manuals,
and are fast gaining popularity. Initially
automatics had many drawbacks to them, but
advancements in technology have enabled a
more sophisticated automatic transmission to
emerge, bringing them closer to a manual in
fuel efficiency and performance.
An automatic transmission with a manual mode allows the driver to shift gears
without a clutch pedal.
Tiptronic
 A tiptronic is a type of automatic transmission

that allows driver flexibility and control by
adopting some of the advantages of a manual
transmission. A tiptronic gearbox allows the
driver to override the automatic mode for better
control of performance. This system allows the
car to operate as a sports car when on the open
road, or to be driven as an automatic in
congested traffic or built up urban areas.

The shift circuit
The shift circuit

Types of Manual Transmission or
gear boxes
 CRASH MESH OR SLIDING MESH

GEAR BOX
 CONSTANT MESH GEAR BOX
 SYNCHRO MESH GEAR BOX

SLIDING-MESH GEARBOX
 The sliding gearbox was popular on cars
up to about 1930, but it is rarely used. The
basic layout of a 4-speed and reverse
gearbox is shown in the figure. The
various spur-type gears are mounted on
three shafts.
 Primary shaft (alternative names – clutch
or first motion shaft)
 Lay shaft (countershaft)
 Main shaft (third motion shaft).

 Primary shaft
This shaft transmits the drive from the clutch to the
gearbox. At the end, the shaft is supported by a
spigot bearing positioned close to the splines on to
which the clutch driven plate is connected. The
main load on this shaft is taken by a bearing;
normally a sealed radial ball type, positioned close
to an input gear called a constant mesh pinion.
The gear is so named because it is always in
mesh with a larger gear, a c constant mesh wheel,
that I part of the lay shaft gear cluster. Note that a
small driving gear is called a pinion and a large
gear a wheel.

 Lay shaft
This shaft, which is normally fixed to the gearbox
casing, supports the various-sized driving pinions of
the lay shaft gear cluster.
 Main shaft
This splined output shaft carries spur gearwheels
that slide along the shaft to engage with the
appropriate lay shaft gears. At the ‘front’ end, the
main shaft is supported by a spigot bearing situated
in the centre of the constant mesh pinion. A heavy
duty radial ball bearing is fitted at the other end to
take the force of the gears as the attempt to move
apart.

SLIDING MESH GEAR BOX
1. main drive gear

2. counter shaft
3. main shaft
4. I gear
5. II gear
6. III gear
7. top speed
engaging dogs

CONSTANT MESH GEAR BOX
1. I speed gear
2. II speed gear
3. main shaft
4. III speed gear
5. top and III
speed
engaging dogs
6. top gear
7. primary shaft
or main drive
gear
8. counter
shaft/cluster
gear
Constant mesh transmission

SYNCHROMESH GEAR BOX
1. I speed gear
2. II speed gear
3. main shaft
4. outer engaging
unit
5. inner engaging
unit
6. top gear
engaging teeth
7. main drive
gear
8. top gear
synchronizing
cones
9. counter shaft
SYNCHROMESH GEAR BOX

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TRANSMISSION

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

A manual gearbox works when the clutch is pressed down. This

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

 The transmission case provides support for

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

 A tiptronic is a type of automatic transmission

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

The shift circuit

 CRASH MESH OR SLIDING MESH

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

1. main drive gear

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

Copyright © 2007 by Nelson, a division of Thomson Canada Limited.

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