CHAPTER-FOUR

POWER TRAIN

SYSTEM
 PART-3
Manual
Transmission
 Introduction
 Definition
 Transmission or Gearbox or is an assembly of
Transaxle gears
and shafts to transmit the rotation and torque of the
engine to the
driveline or final drive
 Functions of Transmission
 To provide a means to vary the torque ratio between the
engine
and the road wheels as required
 To provide a neutral position so that the engine and
road wheel are disconnected even with the clutch is in
engaged position
Necessity of Transmission
 To vary the torque to overcome the various
resistance acting against the vehicle motion at
various speeds
 To vary the tractive effort of the vehicle available at
various
speeds in order to overcome the various resistance
 to start the vehicle from rest, with the engine
running continuously
 To Stop the vehicle by disconnecting the
drive when appropriate
Types of Transmission
 Manual Transmission
 Sliding Mesh Gearbox
 Constant Mesh Gearbox
 With Dog Clutch
 With Synchromesh
 Automatic Transmission (AT)
 Continuously variable Transmission
(CVT)
 Infinitely Variable Transmission (IVT)
Sliding Mesh Gearbox
 The simplest type of Gearbox
 has two or more shafts mounted in parallel or in
line, with sliding spur gears arranged to mesh
with each other and provide a change in speed or
direction
Main Shaft
A F D

Lay
Shaft
B C G
E
Sliding Mesh Gearbox

2nd
Gear
1st Gear A F D
A F D

B E C G
B E C G

A F D A F D

B B E C G
E C G

Reverse
Top Gear
Sliding Mesh Gearbox
 The limitations
 Low mechanical efficiency
 The noise level id high
 The driver required considerable skill in
changing the gear
Constant Mesh- Dog Clutch
 also known as the collar shift
transmission
 In this types, all the gears are in
constant mesh with the
corresponding gears on the lay shaft

1st Gear
Position 1st Gear
Position
 Constant Mesh- Dog Clutch
 Five-speed manual transmission
Constant Mesh- Dog Clutch
 Advantages
 The length of the Gearbox reduced hence
less deflection of sliding fork
 It permit the use of helical gear, hence smooth
& silent operation
 No clashing of gear tooth hence no chance of
teeth failure
 Load per tooth is less (the load shared by all the
teeth)
Synchromesh Gearbox
 Manual transmissions in modern passenger cars
use
synchronizers to eliminate the need for double-
clutching
 A synchro's purpose is
 to allow the collar and the gear to make
frictional contact before the dog teeth
make contact.
 lets the collar and the gear synchronize their
speeds before the teeth need to engage
Synchromesh Gearbox
 The cone on the blue gear fits
into the cone-shaped area in
the collar, (bronze cone)and
 friction between the cone
and the collar synchronize
the collar and the gear.
 The outer portion of the collar
then slides so that the dog
teeth can engage the gear
Synchromesh Gearbox
 Advantages
 Simplifies the operation of
changing
the gears
occurrence of without
b/n the gear tooth
clashes consequent &
damages
 Avoid double clutching
TRANSAXLES
 A transaxle is a transmission and
differential combination in a single assembly.
 Transaxles are used in front-wheel (FF)or (RR)
drive vehicles.
 A transaxle allows the wheels next to the
engine to propel the vehicle.
TRANSAXLES
 Vehicle manufacturers claim that a transaxle and front-wheel
drive has several advantages over a vehicle with rear-wheel
drive
 Improved efficiency and reduced drive train weight
 Improved tractionon slippery surfaces because of
increased weight on the drive wheels
 Increased passenger compartment space (no hump in
floorboard
for rear drive shaft)
 Less un-sprung weight (weight that must move with
suspension action), thereby providing a smoother ride
 Quieter operation since engine and drive train noise is
centrally
located in the engine compartment
 PART-4
Automatic
Transmission
 Introduction
 What is An Automatic Transmission
 Like the manual transmission is designed to
Mach the load requirements of the vehicle to
the power & speed range of the engine.
 The conventional clutch and Manual
Synchromesh gearbox by a torque converter
and a compound epicyclical gear train

Conventional Torque
MANUAL Clutch Converter Automatic

Transmission Transmission
Manual Compound
Synchromesh Epicyclical
G. Box G. Train
Introduction

Manual
Planetary synchromesh
Gears Gear Train

Torque Clutch
Introduction- Automatic Transmission

Torque Converter of
Manual G. Box
Automatic
Clutch
Transmission
Introduction
 Gear shifting of Automatic transmission
depending on
 Throttle Position
 Vehicle Speed
 Position of the Shift Lever
 Automatic Transmissions can be divided in two
groups
 Fully Hydraulic Controlled Transmission (HCT)
 Electronically Controlled Transmission (ECT)
 Introduction
 Advantages of AT compared with Manual
Transmission
 free acceleration with out Interruption
 Reduces driver fatigue by eliminating Clutch
operation & Constant Shifting Gears
 Automatically & Smoothly shift gears at speed s
appropriate to the driving conditions
 Prevents the engine & drive line from becoming
overloaded, because it connect them Hydraulically
via torque converter rather than mechanically
Major Components of AT

 Torque Converter
 Planetary Gear Unit
 Hydraulic Control
Unit
 Manual Linkage
 Automatic
Transmission Fluid
Torque Converter
 Torque Converter
 provides a smooth and automatic take-up of the
drive and at the same time multiplies the output
torque from the engine,
 Roles of Torque Converter
 Multiplying the torque generated by the engine
 Serving as Automatic Clutch, which transmits (or
does not transmit) the engine torque to the
transmission
 Absorbing the torsional vibration of the engine and
drive train
Torque Converter Components

Inside a Torque Converter

• Impeller/ Pump/ Stator

•Turbine Transmission fluid
Torque Converter
Torque Converter
Planetary Gear Units
 Planetary Gear Unit
 It changes the transmission output rpm and/or the
direction of the output rotation and transmits it to the
final drive unit
 Consists of
 the planetary gears (which changes the output rpm)
 Clutches & Brakes (which are operated by hydraulic
pressure
to control the operation of the PGs
 Shafts (for transmitting the engine power
 Bearings (for facilitating the smooth rotation of each
Planetary Gear Units
 The rolls of Planetary Gear Unit
 Providing several gear ratios to obtain
proper torque & rotational speed in
accordance with the driving conditions &
drivers desires
 Providing the reverse gears for reverse
traveling
 Providing a neutral gear potion to allow the
engine to idle which the vehicle is
stopped.
Planetary Gear Units
 Planetary Gear Set
 Is a serious of
interconnecting
gears consisting of
a
 Sun Gear
 Several Planetary
pinion Gear
 A Ring Gear
 The Carrier
Planetary Gear Units

COMPOUND PLANETARY GEAR SET

 Hydraulic Control System
 Hydraulic Control System
 The hydraulic control system consists of
 Oil pan, which acts as the fluid reservoir;
 Oil pump, which generates the hydraulic pressure
 various valves having various functions
 fluid passages and tubes, which deliver the transmission
fluid to the clutches, brakes,
 Most valves in the hydraulic control system are
housed in the valve body assembly under the
planetary gears
Hydraulic Control System
 Roles of hydraulic control system
 Supplying transmission fluid to the torque converter.
 Regulating the hydraulic pressure generated by the
oil pump.
 Converting the engine load and vehicle speed into
hydraulic "signals".
 Applying hydraulic pressure to the clutches and
brakes to control planetary gear operation.
 Lubricating rotating parts with fluid.
 Cooling the torque converter and transmission
with fluid.
Manual Linkage
 The automatic transmission up-shifts and
down- shifts automatically. However, two
linkages allowing manual operation by
the driver are connected to the automatic
transmission.
 These linkages are
 the selector lever and cable,
 the accelerator pedal and throttle cable
Manual Linkage
 SHIFT SELECTOR LEVER (SHIFT LEVER)
 The shift selector lever corresponds to the gearshift
lever of the manual transmission
 It is connected to the transmission via a cable or
linkage
 The driver can select the driving mode –
 Forward,
 Reverse,
 Neutral,
 Parking
Manual Linkage
 In almost all automatictransmissions,the forward
mode consists of three ranges:
 "D" (Drive),
 "2" (second)
 "L" (low)
 For safety, the engine can be started only when
the shift selector lever is at the "N" (neutral) or
"P" (park) position; that is, when the transmission
cannot transmit power from the engine to the
drive train.
Manual Linkage
Manual Linkage
 ACCELERATOR PEDAL
 The accelerator pedal is connected to the throttle
valve of the carburetor (to the throttle body in an EFI
engine) by the accelerator cable.
 The degree of accelerator pedal depression that is, the
throttle valve opening is correctly transmitted to the
transmission by this cable.
 The automatic transmission up-shift and down-shift
speeds depend on the engine load (the throttle valve
opening), and the driver can vary these by controlling
the amount of accelerator pedal depression.
Manual Linkage
 When the accelerator pedal is depressed a little, transmission
up- and downshifting occur at relatively low vehicle speeds.
 When the accelerator pedal is depressed further, shifting
occurs at
relatively high speeds.
 The accelerator and throttle cables must be adjusted
correctly to the specified lengthsbecause correctly-timed
transmission shifting requires conversion of the amount
of accelerator pedal depression into the correct engine
throttle valve opening angle, and correct transmission of
that valve opening angle to the transmission.
 Manual Linkage

Engine throttle Correct Up or

Amount of
valve down Shifting
Acceleration
Opening of Gears
Pedal Depressed

Transmission Correctly
valve opening trimmed
angle Shifting
Transmission fluid
 AUTOMATIC TRANSMISSION FLUID (ATF)
 A special high-grade petroleum-based mineral oil
mixed with several special additives is
used to lubricate the automatic transmission
 Roles of ATF
 Transmission of torque in the torque converter.
 Control of the hydraulic control system, as well as
of clutch and brake operation in the transmission
section.
 Lubrication of the planetary gears and other
moving parts.
Gear Selection & Function
 Gear selection
position
 N - Neutral
 P- Parking
 R- Reverse
 D - Drive
 D 2- Manual 2
 Manual Low
Gear Selection & Function
 Neutral
 allows the engine to start and operate without driving the
vehicles.
 All the clutches and brakes are disengaged
 The torque converter drive is separated from the planetary
gear train output
 Park P
 A safety feature in that it locks the output shaft to the
transmission housing.
 This effect , locks the drive wheels, preventing the
vehicle from rolling forward or backward.
 This position should not be selected unless the vehicle
is at a complete stop
Gear Selection & Function
 Reverse (R)
 Allows the vehicle to back up. Can test for
maximum oil
pump
 The engine should not start in this position
 Drive (D)

 Is
Thethe only position in which
transmission has the transmission
three gear is &
automatic
ratios
gear reduction ratioforward. 1st
which provide for greater torque.
2nd
The 3 is direct drive & if the transmission has
rd

overdrives the 4th forward gear.

 There is no engine braking or the vehicle coasts
during
 PART-III

Drive Shaft
The main function

 To Transfers power (and torque)from

output of gear box to (usually
unsprung) rear drive axle
The Requirements
 It drive shaft line assembly must perform the
following:
 Send turning power from the transmission to
the rear axle assembly.
 Flex and allow up-and-down movement of the
rear axle assembly.
 Provide a sliding action to adjust for changes
in drive line length.
 Provide a smooth power transfer.
 Light weight and strong enough.
Components of drive line assembly
 SLIP YOKE
 connects the transmission output shaft to the front
universal joint
 FRONT UNIVERSAL JOINT
 the swivel connection that fastens the slip yoke to the drive
shaft.
 DRIVE SHAFT
 a hollow metal tube that transfersturningpower from
the front universal joint to the rear universal joint.
 REAR UNIVERSAL JOINT
 a flex joint that connects the drive shaft to the differential
yoke.
 REAR YOKE
Drive Shaft Assembly
Drive Shaft Assembly
 The Movements of Drive Line
 Up and down movement (the differential
movement)
 U-joint angle changes.

 Horizontal Movement (the distance b/n diff and trans

changed)
 U-joints permit change in angle.
 Slip yoke allows change in length

Rotational Motion
Torsional Vibration
Types of Drive shafts
 There are two types of drive
shafts,
 the Hotchkiss drive and
 the Torque Tube Drive
 Hotchkiss drive Shaft
 External shaft and u-joints
 Used with leaf or coil springs
 One or two piece
 Torque Tube drive shaft
 Drive shaft is enclosed Ridged
shaft
 Rear mounted transaxle
Propeller Shaft
 Importance of using hollow Shaft
 to improve strength to weight ratio
U-JOINTS
 The importance of using U-Joint
 To transmit torquebetween 2
shafts where they are connected at an
angle.
 Types of Drive shaft U-joint
 cross and roller,
 ball and trunnion, and
 double-cardan (constant velocity).
U-JOINTS
 Cross and Roller Universal Joint
 The cross and roller design is the most
common type of drive shaft U-joint. It
consists of four bearing caps, four needle
roller bearings
 Parts of U- Joint
 Cross Trunnion (spider)
 Needle bearings
 Driven and driving yokes
 Snap rings inside or outside
 Caps
 U-bolts or straps
Universal Joint
 The Vibration or maximum fluctuation in
speed of the driven shaft can be decrease
by
 Having a mass ( a sort of fly wheel) on the
driven shaft
 Double Hook Joint
 B/n driving and driven shafts an
intermediate shaft with a hook joints at
each end (Phasing of U-Joint)
Universal Joint
 Double Hook
Joint
Propeller Shaft Vibration
 Resonant frequency vibration or drum
 Propeller shaft factors
 Diameter & length of shaft (too Long and too small
dia)
 Degree of balance of assembly
 Bending resistance of shaft
 Vehicle body factors
 Type and shape of body structure, reinforcement,
etc.
 Position of components within body structure
 Drive–line clamping qualities (engine, transmission
mounts,
Propeller Shaft Configurations
 One piece with extended gear box
housing

 One piece with extended differential

housing
Propeller Shaft Configurations
 Two piece with single intermediate
support

 Three piece with two intermediate

supports
 PART-IV

Fi nal Drive
 Final Drive
 The Function of Final Drive
 Transmit torque from drive shaft to drive axles and rear
wheels
 Transmit torque at a 90 degree angle
 Provides a gear reduction between the
drive pinion and drive
axles.
 Split driving torque between the two wheels
 Allows drive wheels to turn at different speeds
when turning corners.
 Supports the Chassis, drive axles, and differentials
 Provides the means to attachthe suspensionsystem
 Final Drive Components
 Differential drive pinion yoke (flange)
 connects drive shaft to differential ring gear.
 Drive pinion:
 transmits torque from drive shaft to differential ring gear
 Ring gear
 transmit torque from drive pinion to differential case
 Differential case
 transmits torque from ring gear to differential
pinion shaft contains differential pinion shaft;
differential pinion gears, and axle side gears.
Final Drive Components
 Final Drive Components
 Differential case side bearings:
 Support differential case in axle housing
 Differential pinion shaft: (Pinion Gear)
 transmit torque from differential case to differential pinion gears.
 Differential pinion gears: (Sun Gear)
 transmit torque from differential pinion gears to axle gears, allow axle
gears to turn at different speeds when cornering.
 Axle side gears:
 transmit torque from differential pinion gears to drive axles
 Drive axles:
 transmit torque from axle side gears to drive wheels
 Axle housing
 supports and contains the differential assembly and drive axles and
support the chassis
Basic Construction Of The Differential Gear Unit

 Power Flow
 Crankshaft
rotation
 propeller shaft
 drive pinion
 ring gear
 differential case
 differential
pinion
 Side (Sun) gears
 axle shaft

Basic Function Of The Differential Gear Unit

 Straight Ahead Travel

 The rolling resistances of the two drive wheels are
almost identical when the vehicle is traveling
straight ahead on a level road
 Therefore, both side gears move equally with the
revolution of
the differential pinions
 all components rotating as one unit
 differential pinions themselves do not rotate but turn
as a unit with the ring gear, differential case and
pinion shafts
 the differential pinions only function to connect the
Basic Function Of The Differential Gear Unit
Basic Function Of The Differential Gear Unit
 Turning
 The inside wheel travels less distance (i.e., in a
shorter arc) than the outside wheel in comparison
with when the vehicle is traveling in a straight line
 Since a resistance is therefore applied to the
left-hand side gear, as illustrated below, each
differential pinion rotates around its own shaft and
also revolves around the rear axle
Basic Function Of The Differential Gear Unit
Axle shaft
 The axle shaft transmits the from
drive differential side gears to the the
rear hub
 The Axle Housing
Axle shaft
 The shaft is subjected to:
 Torsional stress due to driving and braking
torque
 Shear stress due to the weight of the

vehicle
 Bending stress due to the weight of the

vehicle
 Tensile and compressive stress due
to cornering forces
 Types of Axle Shaft
 Semi-floating
CHAPTER-FOUR

The
End