Lesson 2: Transmission | Automotive Workshop

VIETNAM NATIONAL UNIVERSITY – HCM CITY Ho Chi Minh FACULTY OF TRANSPORTATION ENGINEERING Department
City University of Technology ---------- of Automotive Engineering ----------

AUTOMOTIVE WORKSHOP PRACTICE

REPORT
Lesson 2: Transmission
Instructor: …Dr.Duong Quoc Tri – Dr. Vo Tan Chau Class: ………
CC01…………………………………
Group: ……01…………………………………
HCMUT - …/ …/ 20…
TEAM MEMBER ASSIGNMENT
No Name ID Assignment Sectio Grade
. n
1 Trần Anh Kiệt 1852495

2 Đoàn Khánh Duy 1852291

3 Phạm Minh Hoàng 1852029

4 Nguyễn Lê Nhật 1752232

Huy

5 Lâm Huỳnh Phát 2053313

Contents
_Toc122132650
I. CHECKING AND MEASURING BASIC PARAMETERS OF 2-STAGE
TRANSMISSION................................................................................................................3
II. CHECKING AND MEASURING BASIC PARAMETERS OF 1-STAGE
TRANSMISSION..............................................................................................................11
III. TRANSMISSION ASSEMBLY-DISASSEMBLY PROCEDURE OF 2 STAGE
TRANSMISSION..............................................................................................................17
IV. TRANSMISSION ASSEMBLY-DISASSEMBLY PROCEDURE OF 1 STAGE
TRANSMISSION..............................................................................................................32
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Lesson 2: Transmission | Automotive Workshop

I. CHECKING AND MEASURING BASIC PARAMETERS OF 2-

STAGE TRANSMISSION
I.1. Determining the working principle and torque flow
❖ Draw the structure diagrams and torque flow of each gear
The strutre diagram

❖
Draw the shift pattern

1st gear
2nd gear

3rd gear
4th gear

5th gear
Reverse Gear

I.2. Identify specific transmission parameters

❖ Type of transmission
Table 1. Transmission parameters
No Parameter Value Note
.

1 Transmission type Synchronized/Contact

mesh

2 Number of gear 6
ratio

3 Number of shafts 3

4 Synchronizer type Blocker ring

❖ Pair of gears which is always meshed and gear ratio

- Pair of gears which is always meshed? Pair of 5th gear
- Number of gear teeth
 No. Pair of gear Drive gear Driven gear

1 #1 15 41

2 #2 22 37

3 #3 28 31

4 #4 33 25

5 #5 29 18

6 Reverse 12 35

❖ Gear ratio
Table 3. Gear ratio
Gear 1st 2nd 3rd 4th 5th Reverse

Ratio 4.4 2.71 1.78 1.22 1 4.7

I.3. Identify the transmission component’s parameters

❖ Gear
For the helix angle is α = 30 degrees, module of gear is calculated:
Table 4. Gear module

Drive Gear 1st 2nd 3rd 4th 5th

Module 5.04 3.08 1.87 0.99 1.39

❖ Shaft
- Shaft diameter measuring at the bearing journals
- Shaft overall length
Table 5. Shaft parameters
No. Shaft Diameter (mm) Length (mm)

1 Input 22 22.5 165

2 Countershaft 27 24 290

3 Output 18 25.2 201

❖ Bearing
Table 6. Bearing parameters
No. Shaft Bearings

Type Size (inner / outer diameter)

1 Input Roller 19.7/58.1

2 Countershaft Roller 24.7/55

3 Output Roller 23.4/52.1

m ( z 1 + z 1)
❖Shaft distance: a=
2 cosα

2 cos(��)=5.04(15 + 41)

2 cos(30)= 162.95
Table 7. List of transmission components
Ser. Element Quantity Ser Element Quantity
.

1 Input shaft 1 22 Front ball bearing layshaft 1

2 Seal on input shaft 1 23 1st constant mesh gear 1

3 Circlip 7 24 1st gear blocker ring 1

4 Front ball bearing input 1 25 Low speed synchronizer hub 1

shaft

5 Circlip 3 26 2nd gear blocker ring 1

6 Needle roller bearing 5 27 Low speed shift sleeve 1

7 3rd constant mesh gear 1 28 2nd constant mesh gear 1

8 High speed Shift sleeve 1 29 Back ball bearing layshaft 1

9 3rd gear blocker ring 1 30 Layshaft driven gear 1

10 Ring spring 6 31 Layshaft bushing 1

11 High speed synchronizer 1 32 Layshaft nut 1

hub

12 Strut 9 33 Output shaft 1

 13 4th gear blocker ring 1 34 Front ball bearing output shaft’s 1
cover

14 4th constant mesh gear 1 35 Front ball bearing output shaft 1

15 Back ball bearing input shaft 3 36 Helical gear for speed sensor 1

16 Reverse gear selector 1 37 Back ball bearing output shaft 1

17 Reverse gear’s blocker ring 1 38 Steel ball 2

18 5th gear synchronizer hub 1 39 Reverse idler gear 2

19 5th gear blocker ring 1 40 Seal 2

20 5th gear shift sleeve 1 41 Reverse idler gear shaft 2

Ser. Element Quantity Ser Element Quantity

.

III. TRANSMISSION ASSEMBLY- DISASSEMBLY PROCEDURE

OF 2 STAGE TRANSMISSION.
A. DISASSEMBLY 2 STAGE PROCEDURE
Step 1: Drain oil
Drain the transmission oil

Step 2: Remove the extension housing

- Use socket wrench #12 to remove bolts at the extension housing
- Use a hammer to tap gently and remove the extension housing.

Step 3: Remove the reversing lamp switch and shifter assay

Reversing lamp switch
Shifter assay
Step 4: Remove the shift fork and synchronizer No.5
= Use socket wrench #12 to remove shift fork’s retaining bolt

Remove the shift fork, shift fork shaft and synchronizer #5

- Use pliers to remove circlip.
Step 5: Remove snap ring
- Remove the bearing retainer: use socket wrench #12

- Remove circlip
Step 6: Remove main case
- Remove reverse gear’s retaining bolt.
- Remove 5 bolts No.1 between main case and clutch housing.
- Remove 3 bolts No.2 between main case and clutch housing.
- Use a hammer to tap gently and remove the main case.
Step 7: Remove shift detent ball and idle gear assy and idle gear shaft
- Remove 3 seats, 3 springs and 3 shift detent balls from the main case.

Use socket wrench to remove bolts and reverse shift arm bracket assy, remove idle gear assy and shaft.

Step 8: Remove the input shaft, countershaft and shift fork shaft
- Use pliers to remove circlip of the input shaft
- Remove shift fork shaft assy of the input and countershaft
- Remove shaft assembly

Step 9: Disassemble
- Disassemble input shaft with 3-jaw gear puller.

- Use pliers to tap out the snap ring at the end of shaft, then disassemble the countershaft.
- Disassemble the output shaft at the extension housing.

Note: Remember the location and direction (just one direction is correct) of the output ring (the big one being in
like-triangle shape). If not, it takes lots of time to reassemble the output shaft. Furthermore, we should take
pictures (closely and clearly) all the circlips during disassembling the shaft assys.
B. ASSEMBLY 2 STAGE PROCEDURE
Note: Cleaning all parts and components by diesel is required. After that, we use air gun to blow diesel and
debris on the components surface. This step will directly affect the operation of the transmission so it should be
done carefully.
Step 1: Assembly gear, synchronizer

Step 2: Assembly input shaft, lay-shaft, gear shift

Step 3: Assembly shift detent ball and idle gear subassay and idle gear shaft

Step 4: Assembly the body

Note: The whole set (including counter shaft, input shaft and 3 shift fork) need to be assembled at the same
time. We can install a reverse gear shaft and remember to reposition the plastic ring (in white or orange) the
same as when we uninstall it.
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Lesson 2: Transmission | Automotive Workshop
Step 5: Assembly snap ring

Note: This step may take time as the first time we practice. As we do not have enough space to install the snap
ring, we need to hold the countershaft (the longer one) while pushing the main case downward by using a
plastic hammer until we have enough space for the snap ring.
Step 6: Assembly the gear shift fork and synchronizer 5
Step 7: Assembly the selector lever

Step 8: Assembly the transmission case

Step 9: Checking
Note: We need to check all positions of the transmission to ensure the operation capability of it before tightening
all nuts (to save time if it cannot operate smoothly). As we change gear, we need to rotate the shaft continuously
so that the synchronizer can be at the right position. If not, the whole system could be st