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Learning Objective: State the operating principles, identify the components, and maintenance of a manual transmission. A manual transmission is designed with two purposes in mind. One purpose of the transmission is providing the operator with the option of maneuvering the vehicle in either the forward or reverse direction. This is a basic requirement of all automotive vehicles. Almost all vehicles have multiple forward gear ratios, but, in most cases, only one ratio is provided for reverse. Another purpose of the transmission is to provide the operator with a selection of gear ratios between engine and wheel so that the vehicle can operate at the best efficiency under a variety of operating conditions and loads. If in proper operating condition, a manual transmission should do the following: Be able to increase torque going to the drive wheel for quick acceleration. Supply different gear ratios to match different engine load conditions. Have a reverse gear for moving the vehicle backwards. Provide the operator with an easy means of shifting transmission gears. Operate quietly with minimum power loss. TRANSMISSION CONSTRUCTION Transmission Case A drain plug and fill plug are provided for servicing. The drain plug is located on the bottom of the case, whereas the fill plug is located on the side. Extension Housing Front Bearing Hub Transmission Shafts INPUT SHAFT.- The input shaft, also known as the clutch shaft, transfers rotation from the clutch disc to the countershaft gears (fig. 4-13). The outer end of the shaft is splined except the hub of the clutch disc. The inner end has a machined gear that meshes with the countershaft. A bearing in the transmission case supports the input shaft in the case. Anytime the clutch disc turns, the input shaft gear and gears on the countershaft turn. COUNTERSHAFT.- The countershaft, also known as the cluster gear shaft, holds the countershaft gear into mesh with the input shaft gear and other gears in the transmission (fig. 4-14). It is located slightly below and to one side of the clutch shaft. The countershaft does not turn in the case. It is locked in place by either a steel pin, force fit, or locknuts. REVERSE IDLER SHAFT.- The reverse idler shaft is a short shaft that supports the reverse idle gear (fig. 4-15). It mounts stationary in the transmission case about halfway between the countershaft and output shaft, allowing the reverse idle gear to mesh with both shafts. MAIN SHAFT.- The main shaft, also called the output shaft, holds the output gears and synchronizers (fig. 4-16). The rear of the shaft extends to the rear of the extension housing where it connects to the drive shaft to turn the wheel of the vehicle. Gears on the shaft are free to rotate, but the synchronizers are locked on the shaft by splines. The synchronizers will only turn when the shaft itself turns. |
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