Manual Transmission

A manual transmission is a
combination of gears and shafts that
designed and assembled to change
the vehicle’s drive wheel speed and
torque in relation to engine speed and
torque
Basic Transmission Parts
 Transmission Features
• A manual transmission
should:
– be able to increase torque to the drive
wheels for quick acceleration
– supply different gear ratios to match
load conditions
– provide a reverse gear
– provide an easy means of shifting gears
– operate quietly with minimal power loss
 Gear Drive

-A small gear driving a larger gear increases

torque and decreases speed
-A large gear driving a smaller gear decreases
torque and increases speed
 Transmission Gear Ratios

• First gear approximately

3:1
• Second gear approximately
2:1
• Third (high) gear approximately
1:1
• Reverse gear approximately
3:1
 Gear Types
 Spur Gears
• Somewhat noisy
• The teeth are cut parallel to the centerline of
the gear shaft
• Used for sliding gears such as reverse gear
and synchronizers
 Helical Gears
• The teeth are machined at an angle
to the centerline
• Quieter and stronger than spur
gears
• Used for main drive gears that are in
constant mesh
 Gear Backlash
• Distance between the meshing
gear teeth
• Allows lubricating oil to enter
the high-friction area between
the gear teeth
• Allows the gears to expand
during operation
 Manual Transmission
Lubrication
• Bearings, shafts, and gears are
lubricated by oil splash
lubrication
• As the gears rotate, they sling
oil around inside the
transmission
• Typically, 80 or 90SAE gear oil is
used
 Transmission Shafts
• At least four shafts are commonly
used:
– input shaft (clutch shaft)
– countershaft (cluster gear shaft)
– reverse idler shaft
– output shaft (main shaft)
 Synchronizers
• Synchronizers have two functions:
– prevent the gears from clashing
(grinding) during engagement
– lock the output gear to the output shaft
 Synchronizer Action
• When the synchronizer is away
from an output gear, the gear
freewheels (spins freely) on the
output shaft
• When the synchronizer slides
against the output gear, it locks
the output gear to the output shaft
• Power flows through the output
shaft to the drive wheels
Synchronizer Construction

The hub is splined to the output

shaft
 Synchronizer Operation
• When the driver shifts
gears, the synchronizer
sleeve slides on its
splined hub toward the
output gear
• The blocking ring cone
rubs on the side of the
drive gear cone,
causing friction
between the two
• The output gear,
synchronizer, and
output shaft begin to
spin at the same speed
 Shift Forks

Transfer movement from the gear shift

linkage to the sleeves
 Transmission Types
• There are several types:
– three-speed
– four-speed
– five-speed

• Some transmissions have an

overdrive in high gear
• Extra gear ratios are needed for
the small, low-horsepower engines
Transmission
Power Flow
First Gear
Second Gear
Third Gear
Reverse
Neutral
 Overdrive

• In many transmissions, high gear is

an overdrive
• An overdrive gear ratio is less than
1:1
– e.g. 0.87:1

• Overdrive increases fuel economy

Five-Speed, Overdrive
Transmission
Five-Speed, Overdrive
Transmission
Five-Speed, Overdrive
Transmission
Five-Speed, Overdrive
Transmission
Five-Speed, Overdrive
Transmission
Five-Speed, Overdrive
Transmission
Five-Speed, Overdrive
Transmission
 Back-up Light Switch

• Closed by the action of the reverse

gear shift linkage
• When shifted into reverse, the
linkage closes the switch
• The switch carries current to the
back-up lamps