Manual Transmission Components and Operation Explained

3.
Manual Transmission Components and Operation
Manual Transmission Components

and Operation
Automotive Transmission Systems
This presentation will explore:

Gears and Gear Ratios
Manual Transmission Construction
Manual Transmission Operation
ClassAct SRS enabled.
3. Manual Transmission Components and Operation
Gear Types
Three main types of gearing are used

in a manual transmission system.
Spur
Spur gearing has teeth that are (straight cut)
cut parallel to the rotating axis.
These are noisy when operating
at high speeds.
Helical gearing has teeth cut at an

angle to the rotating axis. This Helical
provides more tooth surface area,
allowing the gearing to run quieter.
Double helical gearing incorporates

two sets of helical teeth on one gear. Double
Very quiet operation, although helical
expensive to manufacture.
Next >
Question 1
Which type of gear would NOT normally be found in a manual

transmission system?
A) Helical
B) Spur
C) Bevel
D) Double helical
Gear Ratios
If the driver gear is smaller than

the driven gear, this is known as Driven
an underdrive gear arrangement. gear
Underdrive gears are the lower

transmission range on a vehicle
and are used for low speed and
Driver
high torque. (1st , 2nd or 3rd.) gear
If the driver gear is larger than the

driven gear, this is known as an
overdrive gear arrangement.
Driven
An overdrive gear is normally the gear
high gear (5th or 6th). It is used for
high vehicle speeds and improved Driver
fuel economy. gear
Next >
Question 2
Which of the following statements about an overdrive gear is true?
A) It is normally used for the lowest gear
B) The driver gear will be the same size as the driven gear
C) The driven gear will be smaller than the driver gear
D) The driver gear will be smaller than the driven gear

Manual Transmission Layout

Transmission
case
Input
shaft
Differential
Output shaft
Axle shaft (Output to wheels)
The picture shows a typical manual gearbox that incorporates the
differential. This is known as a transaxle gearbox. It can be found on front
wheel drive, rear wheel drive or four wheel drive vehicles. Next >
Manual Transmission Casing

Manufactured from either cast iron or aluminium, the casing must be

strong to withstand the lateral forces generated, as power flows between
gear clusters.
The transmission housing must be able to support and secure the various
shafts and components in the transmission system. Precision bores, faces
and grooves are used to house the bearings, washers, gaskets and mounts.
Next >
Question 3
Which of the following would be an ideal characteristic of the

manual transmission casing?
A) Strong
B) Flexible
C) Conductor of heat
D) Porous
Manual Transmission Casing

Filler plug
Typical oil level
Drain plug
Because manual transmissions operate at high speeds, gears can easily
overheat. Lubrication is needed to ensure smooth and durable operation.
The transmission casing, used in conjunction with seals, contains the
lubrication required for the gearing. A filler plug in the side and a drain
plug underneath, enable the oil to be topped up and changed.
Next >
Input Shaft Construction

The input shaft, also known as the

clutch shaft, has a splined end that
is directly connected to the clutch Synchronizer
plate. Clutch rotation is directly teeth
Bearing
transferred to the input shaft. shoulder
Splines
The input shaft is supported by a
bearing fitted to a shoulder and
pressed into the transmission
casing. There may also be a pilot
bearing in the crankshaft.
Helical gear
A single gear is used to drive the counter
shaft. Cone and synchronizer teeth may
Cone
be incorporated for engaging the output
shaft to the input shaft, producing a ratio
of 1:1 (direct drive).
Next >
Counter (Lay) Shaft Construction

Input
shaft Output
shaft
Thrust washer
Thrust
washer
Counter shaft
The counter shaft consists of a cluster of various gears, all rotating at the
same speed, and continuously meshed with the gears on the input and
output shafts.
The counter shaft always turns in the opposite direction from the input shaft.
It often runs the length of the transmission case and uses thrust washers to
limit any sideways motion of the gear.
Next >
Reverse Shaft Construction

When selecting reverse, the

direction of drive is changed. This
is achieved by using an idler gear. Input shaft Output
shaft
The idler gear is
meshed between a
counter shaft gear and
an output shaft gear.
Construction is
Reverse Reverse
generally a gear on a
idler gear Counter shaft (fixed)
fixed shaft, which is Reverse
supported by bushes or shaft
idler gear
roller/needle bearings.
Next >
Question 4
Which shaft has a splined end?
A) Counter shaft
B) Reverse shaft
C) Input shaft
Question 5
Which shaft supports an idler gear?
A) Input shaft
B) Reverse shaft
C) Counter shaft
D) Output shaft
Question 6
Which shaft always rotates in the opposite direction from the

input shaft?
A) Counter shaft
B) Reversing shaft
C) Output shaft
Output Shaft Construction

The output shaft, also called the main shaft, is connected to the drive shaft.
Casing supports, used in conjunction with bearings, hold the shaft in place.
Different sized gears are mounted on
the output shaft. 2nd & 1st
synchronizer
These gears rotate freely on the 2nd gear
output shaft, and are meshed with blocking ring
the gears of the counter shaft.
1st
Bush gear
4th and 3rd gear
synchronizer
2nd gear
4th gear Output
blocking ring Bush shaft
3rd gear
Next >
Output Shaft Construction

Smooth and precise gear selection is carried out using synchronizers.

These prevent the clashing or crunching of gears.
Each synchronizer will normally be used
to select one of two different gears.
2nd & 1st
The synchronizers are held in synchronizer
2nd gear
place by splines on the output blocking ring
shaft, so they rotate with
the shaft. 1st
Bush gear
4th and 3rd gear
synchronizer
2nd gear
4th gear Output
blocking ring Bush shaft
3rd gear
Next >
Synchronizer Components
Close-up view of synchronizer and Shift fork

blocking rings: groove
Insert Spring for
inserts
Spring for
Blocking inserts
ring
Blocking
ring
Outer sleeve
(Teeth lock hub, blocking
Hub ring and gear together)
Insert Next >
Synchronizers
As the driver selects a gear, the Shift fork Gear cone

outer sleeve of a synchronizer Gear
groove
slides over its hub and toward the
required gear on the output shaft.
In doing so, it pushes a blocking Blocking ring

ring against the gears cone,
producing friction between the two.
When the synchronizer, blocking

ring and gear are all rotating at the Outer
same speed, the gear is said to sleeve
be synchronized. Synchronizer Hub
Next >
Synchronizers
The synchronizer sleeve now Shift fork Gear cone

slides over the gear, the inner Gear
groove
teeth of the sleeve engaging
with teeth on the gear.
This locks the gear to the Blocking ring

synchronizer hub, and
therefore to the output shaft.
Power is now transferred from the

counter shaft to the output shaft. Outer
sleeve
Synchronizer Hub
Next >
Question 7
The purpose of the synchronizers is to ensure that both gear units

rotate at the same speed. Is this true or false?
Answer True or False.

Selector Forks
Selector forks are used to move Selector fork

the synchronizer sleeves into
the required positions. The
number of forks varies with the
number of gears.
Selector
fork Selector
rods
The selector forks are moved
by selector rods (rails). The
drivers gear lever controls the
selector rods. When the driver
selects a lever position, this
transfers the movement to the
selector forks, which in turn
move the synchronizer sleeves.
Next >
Gear Lever
The gear lever is what the driver

uses to manually change gear.
Gear levers are typically located

on the steering wheel column or
between the two front seats.
Modern variations of gear levers

include finger tip buttons on the
steering wheel, short shift and
Tiptronic levers on the dashboard.
Next >
Gear Linkages
There are two main types of linkages: external and internal. These connect
the drivers gear lever to the selector rods and forks.
Various configurations of linkage are used depending on the position of the
transmission in relation to the lever (for example, rear wheel drive or front
wheel drive vehicles).
Selector Detents
Pivot pins Selector
rod
Fork
Selector forks
The diagram above shows a single rail selector that uses one selector rod.
The rod has fixed pins to move the selector forks. The gate is formed by
extensions of the selector forks. To select a gear, the rail is rotated until the
selector pin aligns with the required selector fork and then moved
backwards or forwards. Next >
Multi-Rail Selector
Multi-rail selection uses selector

Shift lever
rods sliding in the gearbox housing.
Sliding with these rods are the
selector forks, which fit onto the
synchronizer sleeves. Selector
gates
Pushing a selector fork will
move the outer sleeve of
the synchronizer hub to
engage the selected gear.
The lower end of the gear

lever moves between the
three selector gates to align
with one rod. When the gear
lever is moved forward or
backward, the selector rod Selector Selector
and fork move laterally. rods forks Next >
Question 8
How many selector rods would you expect to find in a

multi-rail linkage?
Enter your answer and press SEND.

Retainers
Spring
Selector loaded ball
rod
Neutral Position Gear Engaged
Retainers are spring-loaded balls or plungers, which locate in grooves in the

selector rods to hold the rods in their selected position.
When a rod is shifted it must be retained in the gear position, or neutral, to

give a positive feel and help prevent it jumping in or out of gear.
Next >
Interlock
Plunger Ball
If two selector rods were moved at the same time by the gear lever, two
gears would be engaged and cause the gearbox to lock up. To prevent
this, an interlocking device may be used.
A Ball and Plunger interlock (as shown in the diagrams) uses a pin sliding in
a hole drilled through the central rod. The rods on each side have single
grooves facing the middle. Holes in the casing hold the two balls.
When an outer rod is moved, the ball is forced out of the groove and pushes
the plunger across to hold the other two rods. When the centre rod is
moved, both balls will drop into the grooves of the outer rods to lock them.
Next >
Question 9
What would be the maximum number of positions for a retainer

on a selector rod?
Enter your answer and press SEND.

Question 10
The purpose of the interlock is to allow any one of the selector rods to
move but stop the other two from moving. Is this true or false?
Answer True or False.

Transmission Power Flow - Neutral

Neutral
Input Output
When the shift lever is in the neutral position, the gears on the input shaft,
the countershaft and the output shaft spin at engine speed, however, none
of the gears are engaged to the output shaft, so there is no drive. Next >
Transmission Power Flow - First Gear

1st Gear
Input Output
The diagram shows the power flow from input to output

when 1st gear is selected. Next >
Transmission Power Flow - Second Gear

2nd Gear
Input Output

when 2nd gear is selected. Next >
Transmission Power Flow - Third Gear

3rd Gear
Input Output

when 3rd gear is selected. Next >
Transmission Power Flow - Fourth Gear

4th Gear
Input Output
The diagram shows the power flow from input to output when 4th gear is
selected. Connects the input shaft to the main shaft, giving direct drive (1:1).
Next >
Transmission Power Flow - Fifth Gear

5th Gear
Input Output

when 5th gear is selected, giving overdrive. Next >
Transmission Power Flow - Reverse Gear

Reverse Gear
Input Output
The diagram shows the power flow from input to output when reverse idler
gear is selected, changing the direction of rotation of the output shaft. Next >
Summary
You should now be aware of:
Gears and Gear Ratios
Manual Transmission Construction
Manual Transmission Operation
End >

Manual Transmission Components and Operation Explained

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Manual Transmission Components and Operation Explained

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3.

Manual Transmission Components and Operation

Manual Transmission Components

This presentation will explore:

Three main types of gearing are used

Helical gearing has teeth cut at an

Double helical gearing incorporates

Which type of gear would NOT normally be found in a manual

If the driver gear is smaller than

Underdrive gears are the lower

If the driver gear is larger than the

Which of the following statements about an overdrive gear is true?

A) It is normally used for the lowest gear

C) The driven gear will be smaller than the driver gear

D) The driver gear will be smaller than the driven gear

Manual Transmission Layout

Manual Transmission Casing

Manufactured from either cast iron or aluminium, the casing must be

Which of the following would be an ideal characteristic of the

Manual Transmission Casing

Input Shaft Construction

The input shaft, also known as the

Counter (Lay) Shaft Construction

Reverse Shaft Construction

When selecting reverse, the

Which shaft has a splined end?

Which shaft supports an idler gear?

Which shaft always rotates in the opposite direction from the

Output Shaft Construction

Output Shaft Construction

Smooth and precise gear selection is carried out using synchronizers.

Close-up view of synchronizer and Shift fork

As the driver selects a gear, the Shift fork Gear cone

In doing so, it pushes a blocking Blocking ring

When the synchronizer, blocking

The synchronizer sleeve now Shift fork Gear cone

This locks the gear to the Blocking ring

Power is now transferred from the

The purpose of the synchronizers is to ensure that both gear units

Answer True or False.

Selector forks are used to move Selector fork

The gear lever is what the driver

Gear levers are typically located

Modern variations of gear levers

Multi-rail selection uses selector

The lower end of the gear

How many selector rods would you expect to find in a

Enter your answer and press SEND.

Neutral Position Gear Engaged

Retainers are spring-loaded balls or plungers, which locate in grooves in the

When a rod is shifted it must be retained in the gear position, or neutral, to

What would be the maximum number of positions for a retainer

Enter your answer and press SEND.

Answer True or False.

Transmission Power Flow - Neutral

Transmission Power Flow - First Gear

The diagram shows the power flow from input to output

Transmission Power Flow - Second Gear

The diagram shows the power flow from input to output

Transmission Power Flow - Third Gear

The diagram shows the power flow from input to output

Transmission Power Flow - Fourth Gear