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REFERENCE:
A A Spring force A Turn-over Type Clutch Pedal
Turn-over type clutch pedals are clutch
Spring force
Force to depress
the pedal
pedals that utilize spring force to reduce
C Force to C
furthermore the operating force.
release When the pedal is depressed and goes
the pedal
B C beyond a certain position, the spring
B force operating direction changes and is
B added with the force to be depressed.
The spring is installed between the
Pedal support
clutch pedal and pedal support and force
works on the spring to keep it constantly
extended.
There are various types of turn-over type
Start depressing Depress slightly Depress furthermore
clutch pedals with different construc-
tions.
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
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Chamber
A (to release cylinder) Conical
spring
Piston
Connecting rod
Spring retainer
Compression spring
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
SERVICE HINT:
If air is mixed into the fluid line, air is pressurized and
sufficient amount of oil pressure is not generated.
Then, it causes poor clutching or the gears unable to
shift.
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
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Release fork
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
Clutch Cover
Diaphragm spring
The primary purpose of the clutch cover
is to connect and disconnect engine
power. It must be well balanced while it
is rotating, and radiate heat efficiently at
the time of clutch engagement. The
Retracting Diaphragm spring clutch cover has a spring to push the
spring
pressure plate against the clutch disc.
These springs may be either coil springs
or a diaphragm spring. The latter is used
Clutch cover
Pivot rings in most clutches today.
Pressure plate
1. Diaphragm spring type clutch
Conventional type Pressure plate
The diaphragm spring is made of
spring steel. It is riveted or bolted to
Strap Clutch cover the clutch cover. A pivot ring is
DST (Diaphragm Spring Turnover) type
located at each side of the dia-
phragm spring and functions as a
pivot while the diaphragm spring is
operating.
The retracting springs are used to
connect the diaphragm springs to the
pressure plate.
Recent models have adopted a DST
(Diaphragm Spring Turn-over) type
clutch cover. In this type of clutch
cover, the tips of the clutch cover are
turned over to hold the diaphragm
spring at proper position directly.
The straps are connected in a
chordal (tangential) direction to
transmit the torque.
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
Clutch Disc
Facing The clutch disc contacts the friction sur-
face of the pressure plate and the fly-
Rivet wheel uniformly to transmit motive
Torsion rubber power smoothly. It also consists to
soften the impact of clutch engagement.
Clutch hub
1. Torsion rubber
The torsion rubber is incorporated in
the clutch hub and softens the rota-
tional impact of clutch engagement
by moving slightly in the circumferen-
tial direction.
Cushion plate 2. Cushion plate
The cushion plate is riveted sand-
wiched between the clutch facings.
When the clutch is engaged sud-
denly, the impact is absorbed by this
curved section to soften the shock of
gear changing and allow power to be
Torsion rubber Absorbing the shock transmitted smoothly.
Facing
SERVICE HINT:
Wear of the torsion rubber and
breakage of the cushion plate causes
a large amount of impact shock and
noise when the clutch is engaged.
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
Manual transmission
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
2nd
A 1. Driving performance curves
3rd Ideally speaking, the curved line of the engine driving
4th force should be changed continuously as A in the dia-
5th
6th
gram. However, the driving force of actual manual
transaxle changes discontinuously, as 1st though 6th
gear.
Vehicle speed
Therefore, the engine driving force is transmitted
effectively when narrowing the shaped area in the
graph to keep close to the ideal curved line.
It can be guessed to be close to the ideal curved line
A of driving force as the number of shift gear
increases. However, the design of the transaxle
becomes complicated or it causes the driver to be
complicated for shift operation.
For these reasons, the number of the shift gear con-
sists of 4th to 6th gear.
5th gear is used largely.
(1) Starting off
When the vehicle starts off, a large amount of power is
required, so the 1st gear, which has the largest driving
force, is used.
(2) Driving
After starting off, the 2nd and 3rd gears are used to
increase the vehicle speed.
These gears are used because there is an upper limit
to the vehicle speed in 1st gear and that not as much
driving force is required.
(3) High-speed driving
For high-speed driving, the 4th, 5th, and 6th gears are
used to further increase the vehicle speed. Using
gears with small driving force and lowering the engine
speed improves fuel consumption.
(4) Backing up
When the reverse gear is used, the reverse idler gear
is added, the reverse gear turns in reverse, and the
vehicle backs up.
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
Reduction Ratio
1st gear
(drive : 45 teeth) 1. Reduction ratio
Input shaft The reduction ratio is expressed as:
Operating Mechanisms
Shift lever
1. Remote control type
This type connects between the shift lever and the
Push-pull cable transaxle with a cable or links, etc.
This is used in FF vehicles, and there are characteris-
tics such vibration and noise are difficult to be gener-
ated and the shift lever position can be designed
freely.
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
• 1st gear
The gear of the output shaft rotating
meshed with the 1st gear of the input
shaft transmits power to the differen-
tial through the drive pinion.
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
• 3rd gear
The gear of the output shaft rotating
meshed with the 3rd gear of the input
shaft transmits power to the differen-
tial through the drive pinion.
• Reverse
The reverse idler gear is meshed
with the input shaft reverse gear.
The output shaft gear meshed with
the reverse idler gear transmits
power for reverse rotation to the dif-
ferential through the drive pinion.
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
REFERENCE:
Manual Transmission
For manual transmissions, the input
4th gear 2nd gear Reverse gear shaft and the output shaft are located on
3rd gear 1st gear 5th gear the same axis and the counter gear inte-
Input shaft Output shaft
grates the input shaft and the output
shaft to transmit power.
Counter gear
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
(2) Operation
<1> Neutral
Hub sleeve
Shifting key
Each speed gear is meshed with
the corresponding driven gear and
run idle on the shaft.
<2> Start of synchronization
Synchronizer ring As the shift lever is moved, the
Clutch hub Speed gear shift fork, which is fitted in a groove
in the hub sleeve, moves in the
direction indicated by the arrow.
Since the protrusion at the center
of the shifting key is fitted to the
hub sleeve groove, the shifting key
also moves to the arrow direction
at the same time, and pushes the
synchronizer ring to the speed
gear cone portion, resulting in the
synchronization start.
<3> Midway through synchroniza-
tion
When the shift lever is moved fur-
ther, the force which is applied to
the hub sleeve overcomes that of
the shifting key spring and the hub
sleeve rides up into the protrusion
of the key.
<4> End of synchronization
The force being applied to the syn-
chronizer ring becomes even
stronger and pushes the speed
gear cone portion.
This causes the speed of the
speed gear to be synchronized
with that of the hub sleeve.
When the speeds of the hub sleeve
and the speed gear become equal
to each other, the synchronizer ring
begins rotating slightly in the rota-
tion direction.
As a result, the hub sleeve splines
mesh with the synchronizer ring
splines.
<5> End of shift change
After the hub sleeve spline meshes
with synchronizer ring spline, the
hub sleeve moves further and
meshes with the speed gear
spline. Then, the shift change
ends.
SERVICE HINT:
If the inner circumference of the syn-
chronizer ring and the speed gear
cone portion become worn, both
speeds cannot be in sync. Abnormal
noise occurs or it becomes difficult to
shift gears.
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
Pin
"2nd gear"
direction
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
Fork shafts
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
3RD
5TH
5TH
1ST
1ST
Shift inner 3rd/4th and 5th/reverse shift fork
lever No.1
heads from moving so that only the
1st/2nd shift fork head can move.
REV
REV
2ND
2ND
4TH
4TH
Shift fork
head
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
FR
Spring
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SERVICE HINT:
If the hub sleeve spline chamfer por-
tion is worn, the transaxle jumps out
of gear.
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
Exercise
Use the Exercises to check your level of understanding for the material in this Chapter. After answering each
Exercise, you can use the reference button to check the pages related to the current question. When you get
a incorrect answer, please return to the text to review the material and find the correct answer. When all
questions have been answered correctly, you can go to the next Chapter.
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
Question- 1
The following statements pertain to the requirements of the clutch. Mark each of the statement True or False.
.
1 It must engage the transaxle/transmission and the engine smoothly. True False
Question- 2
The following statements pertain to the manual transaxle/transmission functions. Mark each of the statements True
or False.
.
During starting-off, use gears with small drive force (small gear
3 True False
ratio) in order to improve the fuel consumption.
During the high-speed driving, use gears with large drive force
4 True False
(large gear ratio) in order to obtain high output.
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
Question- 3
The following statements pertain to the component parts of the clutch. Select the statement that is False as the
explanation of parts.
1. The clutch release cylinder transmits the hydraulic pressure from the master cylinder to the release fork.
2. The clutch disc is connected with the flywheel and pressure plate when the clutch pedal is depressed.
4. The clutch release bearing absorbs the rotational difference between the release fork and the diaphragm
spring.
Question- 4
The following illustration shows the power transmission passage for a manual transaxle. From the following word
group, select the appropriate word for each illustration.
1. 2.
3. 4.
Answer: 1. 2. 3. 4.
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Diagnosis Technicain - Manual Transaxle Manual Transaxle and Clutch
Question- 5
The following illustration shows the synchromesh mechanism parts. From the following word group, select the
words that correspond to 1to 4.
.
2
3
4
1
a) Speed gear b) Synchronizer ring c) Clutch hub d) Hub sleeve e) Shifting key f) Key spring
Answer: 1. 2. 3. 4.
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