DEFINITION

Transmission System
A transmission is a machine that consists of a power source and a power
transmission system, which provides controlled application of the power. Often the term
transmission refers simply to the gearbox that uses gears and gear trains to provide
speed and torque conversions from a rotating power source to another device.
Often, a transmission has multiple gear ratios (or simply "gears") with the ability to
switch between them as speed varies. This switching may be done manually (by the
operator) or automatically. Directional (forward and reverse) control may also be
provided. Single-ratio transmissions also exist, which simply change the speed and
torque (and sometimes direction) of motor output.
PARTS WITH FUNCTIONS:
Planetary Gear Sets - are the mechanical systems that provide the various forward gear
ratios as well as reverse.
Hydraulic System - a special transmission fluid sent under pressure by an Oil
Pump through the Valve Body to control theClutches and the Bands in order to control
the planetary gear sets.
Seals and Gaskets - used to keep the oil where it is supposed to be and prevent it from
leaking out.
Torque Converter - acts like a clutch to allow the vehicle to come to a stop in gear while
the engine is still running.
The Governor, Modulator or Throttle Cable - monitor speed and throttle position in
order to determine when to shift.
Computer - directs electrical solenoids to shift oil flow to the appropriate component at
the right instant.
TYPES:
Manual Transmission
A manual transmission is a gearbox that requires the auto's operator to shift from
gear to gear depending on the speed or relative position of the car. Generally, the car will
begin in the first gear position and move progressively to higher gears until the vehicle
reaches the desired speed. As the vehicle decelerates, the position of the gearshift lever
is moved regressively lower on the gears as the vehicle slows down. A manual
transmission also has a reverse and neutral position. Essentially it is called a manual
because it must be operated manually.

Automatic Transmission

An automatic transmission operates independently of the operator most of the time.

It automatically shifts to higher or lower gears depending on the speed and torque of the
engine. The operator has the choice of moving the gear shift lever. Automatic
transmissions in cars have a tendency to use more fuel than a manual transmission
because of a relative inefficiency. However, they are very convenient, and driving them
in stop-and-go traffic is much easier.
Semi-Automatic
A hybrid form of transmission where an integrated control system handles
manipulation of the clutch automatically, but the driver can stilland may be required
totake manual control of gear selection. This is sometimes called a "clutchless
manual", or "automated manual" transmission. Many of these transmissions allow the
driver to fully delegate gear shifting choice to the control system, which then effectively
acts as if it was a regular automatic transmission. They are generally designed using
manual transmission "internals", and when used in passenger cars, have synchromesh
operated helical constant mesh gear sets.

DEFINITION:

Steering System
Steering system is to convert the rotary movement of the steering wheel in drivers hand
into the angular turn of the front wheels on road. Additionally, the steering system should provide
mechanical advantage over front wheel steering knuckles, offering driver an easy turning of front
wheels with minimum effort in any desired direction.

Steering wheel, gears, linkages, and other components used to control the direction of
a vehicle's motion. Because of friction between the front tires and the road, especially
in parking, effort is required to turn the steering wheel. To lessen the effort required,
the wheel is connected through a system of gears to components that position the
front tires.
PARTS AND FUNCTIONS:

Steering Wheel used by the driver to rotate a steering shaft that passes through the
steering column.
Steering Shaft transfers turning motion from the steering wheel to the steering
gearbox
Steering Column supports the steering column and steering shaft.
Steering Gearbox changes turning motion into a straight-line motion to the left or
right.
Steering linkage connects the steering gearbox to the steering knuckles and wheels.
Pitman Arm - transfers gearbox motion to the steering linkage.Pitman arm is splined to

the gearbox.
Track Rod - Steel bar connects the right and left side of the steering linkage. Connects to
Pitman arm, Tie rod ends, and Idler arm.
Idler Arm supports the end of the center link on the passenger side of the vehicle. Bolts
to the vehicles frame.
Tie-Rod - Two tie-rod assemblies are used to fasten the center link to steering knuckles.

TYPES:

1.Rack and Pinion Steering

The system consists of a pinion attached to the steering shaft, which meshes with the
flat rack on the drag line. Pinion imparts left or right motion to the rack, which causes
the tie rods to move the road wheels consequently.
2. Worm and Sector steering gear
In this type of steering mechanism, worm is connected at the end of steering shaft and
sector is mounted on a sector shaft. The sector looks like a ball and worm looks like a
gear. The teeth of the worm mesh with the teeth of the sector. To provide free play,
worm is mounted on a bearing. It is also known as Pitman arm shaft

3.Worm and Roller steering gear

Worm and roller is similar to the worm and sector type of steering mechanism. A
toothed roller is mounted on a roller shaft and worm gear is mounted on a steering
shaft. Gear tooth of worm gear meshes with that of the roller and motion is
transmitted. The roller is mounted on a ball bearing. This mechanism has low friction
compared to Worm and Sector mechanism and is widely used on American passenger
cars.

4.Cam and Lever steering gear

Cam and lever is similar to the worm and sector gear mechanism. The worm is
replaced with cam and sector is replaced with a lever. Cam is engaged by a bearing
and lever, carries two studs that are mounted on bearing. As the driver turns the
steering wheel, studs move up and down on the cam so lever and pitman arm shaft
rotates.

5.Worm and Nut steering gear

A nut is meshed with the worm and screws up and down relative to the movement of
the worm. This is also known as re-circulating ball type mechanism. Nut is used
with ball that reduces the friction and power loss.

DIAGRAM:

DEFINITION:
Suspension System

The job of a car suspension is to maximize the friction between the tires and
the road surface, to provide steering stability with good handling and to ensure
the comfort of the passengers.

PARTS and FUNCTIONS:

Chassis
The suspension of a car is actually part of the chassis, which comprises all of
the important systems located beneath the car's body.
These systems include:

The frame - structural, load-carrying component that supports the car's engine and
body, which are in turn supported by the suspension
The suspension system - setup that supports weight, absorbs and dampens shock
and helps maintain tire contact
The steering system - mechanism that enables the driver to guide and direct the
vehicle
The tires and wheels - components that make vehicle motion possible by way of
grip and/or friction with the road

Springs
Springs are energy storing device. They store energy by deflection. Most
springs are constant rate springs, i.e., amount of the force that is stored is
proportional to the deflection of the spring.
Today's springing systems are based on one of four basic designs:

Coil springs - This is the most common type of spring and is, in essence, a heavyduty torsion bar coiled around an axis. Coil springs compress and expand to absorb
the motion of the wheels.
Leaf springs - This type of spring consists of several layers of metal (called
"leaves") bound together to act as a single unit.

Torsion bars - Torsion bars use the twisting properties of a steel bar to provide
coil-spring-like performance. This is how they work: One end of a bar is anchored
to the vehicle frame. The other end is attached to a wishbone, which acts like a
lever that moves perpendicular to the torsion bar. When the wheel hits a bump,
vertical motion is transferred to the wishbone and then, through the levering action,
to the torsion bar. The torsion bar then twists along its axis to provide the spring
force.
Air springs - Air springs, which consist of a cylindrical chamber of air positioned
between the wheel and the car's body, use the compressive qualities of air to absorb
wheel vibrations.

Tires
Tires are black rubber things that provides the only contact with the road surface. Friction between
tires and the road surface creates acceleration, braking (deceleration), and cornering.

Shocks
Shock absorbers dampen the motion of suspension. Shock absorbers do not absorb impacts;
springs do. Shock absorbers are dampers.
Shock absorbers also control the transient motion of the vehicle. Shock absorbers control HOW
the car nose dive when brake is applied. Springs control HOW MUCH car nose dives. Shock
absorber controls HOW the car goes into roll when the steering is applied. Springs and anti-roll
bar control HOW MUCH car rolls.

Anti-Roll Bars
Anti-roll bars are also known as roll bars, sway bars, anti-sway bars, etc. Anti-roll bars connect
right and left wheel. They resist roll by twisting themselves, acting as torsion springs.

TYPES
Suspension Types: Front
Dependent Front Suspensions
Dependent front suspensions have a rigid front axle that connects the front
wheels. Basically, this looks like a solid bar under the front of the car, kept in
place by leaf springs and shock absorbers. Common on trucks, dependent front
suspensions haven't been used in mainstream cars for years.

Independent Front Suspensions

In this setup, the front wheels are allowed to move independently.

Suspension Types: Rear

Dependent Rear Suspensions
If a solid axle connects the rear wheels of a car, then the suspension is usually
quite simple -- based either on aleaf spring or a coil spring. In the former design,
the leaf springs clamp directly to the drive axle. The ends of theleaf springs attach
directly to the frame, and the shock absorber is attached at the clamp that holds
the spring to the axle. For many years, American car manufacturers preferred this
design because of its simplicity.
The same basic design can be achieved with coil springs replacing the leaves. In
this case, the spring and shock absorber can be mounted as a single unit or as separate
components. When they're separate, the springs can be much smaller, which
reduces the amount of space the suspension takes up.
Independent Rear Suspensions
If both the front and back suspensions are independent, then all of the wheels are
mounted and sprung individually, resulting in what car advertisements tout as
"four-wheel independent suspension." Any suspension that can be used on the
front of the car can be used on the rear, and versions of the front independent
systems described in the previous section can be found on the rear axles. Of
course, in the rear of the car, the steering rack -- the assembly that includes the
pinion gear wheel and enables the wheels to turn from side to side -- is absent.
This means that rear independent suspensions can be simplified versions of front
ones, although the basic principles remain the same.

DIAGRAM:

DEFINITION:
Differential System
where the power, in most cars, makes its last stop before spinning the wheels.
The differential has three jobs:
To aim the engine power at the wheels
To act as the final gear reduction in the vehicle, slowing the rotational speed of the

transmission one final time before it hits the wheels

To transmit the power to the wheels while allowing them to rotate at different speeds

(This is the one that earned the differential its name.)

The differential is a device that splits the engine torque two ways, allowing each
output to spin at a different speed.
PARTS and FUNCTIONS:
The Carriers - connected into the two sun gears.
Sun Gears - gears which are connected to the shaft to the tires of the vehicles.
Ring Gears - The gear in which the input torque is applied.
Planetary Gear - The planet gears revolves around the axis of the carrier, driving the sun
gears.

TYPES

Limited Slip Differential

Use various mechanisms to allow normal differential action when going around turns.
When a wheel slips, they allow more torque to be transferred to the non-slipping wheel.

Clutch-type Limited Slip Differential

The clutch-type LSD is probably the most common version of the limited slip
differential.
This type of LSD has all of the same components as an open differential, but
it adds a spring packand a set of clutches. Some of these have a cone clutch that
is just like the synchronizers in a manual transmission.

Viscous Coupling
The viscous coupling is often found in all-wheel-drive vehicles. It is
commonly used to link the back wheels to the front wheels so that when one set
of wheels starts to slip, torque will be transferred to the other set.

The viscous coupling has two sets of plates

inside a sealed housing that is filled with a
thick fluid, as shown in below. One set of
plates is connected to each output shaft.
Under normal conditions, both sets of plates
and the viscous fluid spin at the same speed.
When one set of wheels tries to spin faster,
perhaps because it is slipping, the set of
plates corresponding to those wheels spins
faster than the other. The viscous fluid,
stuck between the plates, tries to catch up

with the faster disks, dragging the slower

disks along.
Locking and Torsen
locking differential is useful for serious off-road vehicles. This type of
differential has the same parts as an open differential, but adds an electric,
pneumatic or hydraulic mechanism to lock the two output pinions together.
This mechanism is usually activated manually by switch, and when activated,
both wheels will spin at the same speed. If one wheel ends up off the ground, the
other wheel won't know or care. Both wheels will continue to spin at the same
speed as if nothing had changed.
Torsen differential is a purely mechanical device; it has no electronics,
clutches or viscous fluids.
The Torsen (from Torque Sensing) works as an open differential when the
amount of torque going to each wheel is equal. Like the viscous coupling, they
are often used to transfer power between the front and rear wheels. In this
application, the Torsen is superior to the viscous coupling because it transfers
torque to the stable wheels before the actual slipping occurs.
However, if one set of wheels loses traction completely, the Torsen
differential will be unable to supply any torque to the other set of wheels. The
bias ratio determines how much torque can be transferred, and five times zero is
zero.

DIAGRAM:

BRAKE SYSTEM
A brake is a mechanical device which inhibits motion, slowing or stopping a
moving object or preventing its motion.
Most brakes commonly use friction between two surfaces pressed together to
convert the kinetic energy of the moving object into heat, though other methods
of energy conversion may be employed. For example, regenerative braking
converts much of the energy to electrical energy, which may be stored for later
use. Other methods convert kinetic energy into potential energy in such stored
forms as pressurized air or pressurized oil.
PARTS WITH FUNCTIONS:

Master cylinder: System component that pumps brake fluid from the reservoir through
the brake lines activating the piston.

Brake reservoir: Contains the system's hydraulic brake fluid

Brake Lines: Metal tubing that carries the brake fluid from the master cylinder to other
brake system components.

Brake caliper: A steel housing that mounts in a fixed position on the brake rotor that
contains the piston and brake pads.

Brake piston: A round rod that extends to push the brake pad against the rotor as
hydraulic fluid is fed from the master cylinder

Brake pads: A metal plate with a semi-metallic overlay that grips the steel rotor.

Brake rotors: A steel disc mounted to the wheel hub that the pads grip to stop the wheels
from rotating.

Parking Brake:a system that applies the brakes mechanically through a series of linkages
and cables. Depending on the vehicle, the parking brake system will either be actuated
using a foot pedal or a hand-operated lever.

Power Booster:a device that uses a diaphragm, engine vacuum and atmospheric pressure
to assist the driver with brake application. Also known as a vacuum booster.
Brake Hoses: flexible hoses that connect the brake lines on the chassis with the calipers
or wheel cylinders, or the junction block on a solid axle.

Brake Drums:a round cast iron housing attached to an axle shaft or spindle, on which the
brake shoes press to stop its rotation.

Brake Shoes: the brake lining in a drum brake system, when the brakes are applied the
brake shoes press against the brake drum causing the friction to stop or slow the vehicle
down.

Brake Fluid: the hydraulic fluid used to transmit hydraulic pressure through the brake
lines in a brake system.

Anti-lock Brake System [ABS]: a computer controlled system that allows the vehicle to
be controlled under heavy braking by releasing hydraulic pressure to wheels that are
about to lock up and skid. Sensors located at the wheels, monitor rotating wheel speed in
relation to other wheels and send the information to a control module that in turn controls
a hydraulic modulator, which regulates hydraulic fluid pressure to each brake assembly.
Wheel Bearings: an anti-friction bearing that uses a series of steel balls that rotate
between inner and outer bearing races.
Wheel Cylinder: a component in a drum brakes, the wheel cylinder exerts force onto the
brake shoes so they make contact with the brake drum causing friction which then stops
the vehicle.

TYPES:

Disc Brakes
Disc brakes consist of a disc brake rotor - which is attached to the wheel and a caliper, which holds the disc brake pads. Hydraulic pressure from the
master cylinder causes the caliper piston to clamp the disc brake rotor between
the disc brake pads. This creates friction between the pads and rotor, causing your
car to slow down or stop.
Drum Brakes
Drum brakes consist of a brake drum attached to the wheel, a wheel cylinder,
brake shoes, and brake return springs. Hydraulic pressure from the master

cylinder causes the wheel cylinder to press the brake shoes against the brake
drum. This creates friction between the shoes and drum to slow or stop your car.
Emergency Brakes
Vehicles also come equipped with a secondary braking system, known as
emergency, or parking brakes. Emergency brakes are independent of the service
brakes, and are not powered by hydraulics. Parking brakes use cables to
mechanically apply the brakes (usually the rear brake). There are a few different
types of emergency brakes, which include: a stick lever located between the
driver and passenger seats; a pedal located to the left of the floor pedals; or a push
button or handle located somewhere near the steering column.
Anti-Lock Brakes
Computer-controlled anti-lock braking systems (ABS) is an important safety
feature which is equipped on most newer vehicles. When brakes are applied
suddenly, ABS prevents the wheels from locking up and the tires from skidding.
The system monitors the speed of each wheel and automatically pulses the brake
pressure on and off rapidly on any wheels where skidding is detected. This is
beneficial for driving on wet and slippery roads. ABS works with the service
brakes to decrease stopping distance and increase control and stability of the
vehicle during hard braking.

DIAGRAM: