Selvam college of technology

Department of Mechanical Engg

UNIT 3 TRANSMISSION SYSTEMS

CONTENTS
CLUTCH
GEAR

BOX
TORQUE CONVERTER
DIFFERENTIAL

TRANSMISSION SYSTEM

Manual transmission system

Manual
gear box

Manual
gear knob

Manual
gear box

5-speed manual gearbox

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Green

shaft (input shaft) & gear turn at the

same rpm as the engine

Red

shaft (layshaft) & gears are directly

connected to the input so it spins when input
shaft spins

Yellow

shaft (output shaft) is splined shaft

connected directly to drive shaft through
differential to drive wheels (If wheels are
spinning output shaft spins)

If

engine is off with car coasting output shaft

turns inside blue gears (blue gears &
layshaft are motionless)

Collar

connects one of two blue gears to

output shaft via dog teeth

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Moving

knob forward & backward moves collar

to engage the gears

Reverse

(purple)

gear is handled by a small idler gear

Importance

of transmission:
Engine redline (max. rpm above which
engine explodes)
Engines have narrow rpm ranges
(horsepower & torque are at their maximum)

Synchronizers

allow collar & gear to make

frictional contact before dog teeth make
contact (collar & gear synchronize their speeds
before teeth need to engage

TRANSMISSION SYSTEM
A car

g
n
i
r
Sp

Pressure plate
Sp
rin
g

Clutch plate

engine spins all the time &

car wheels don't (to stop without
killing the engine wheels, engine
needs to be disconnected from the
engine)

Flywheel
Clutch

connected to engine

plate connected to the

transmission

TRANSMISSION SYSTEM
Springs

force on pressure plate

Clutch

plate springs - isolate transmission from shock of

clutch engaging

Friction

material on the clutch disc wears out (similar to the

friction material on the pads of a disc brake pads/shoes of a
drum brake; clutch slips & lost of power)

Driver

faster

Worn

who slips the clutch a lot will wear out clutch a lot

throw-out bearing (rumbling noise whenever the clutch

engages)

TRANSMISSION SYSTEM
Other

clutches:
Automatic transmission with several clutches used to
engage and disengage various sets of planetary gears
Car air conditioning compressor with magnetic clutch
Engine-driven cooling fan with thermostatically controlled
viscous clutch

TRANSMISSION SYSTEM
Ideally, transmission

should be flexible in its ratios that

engine runs at its single, best rpm value (continuously
variable transmission - CVT) Honda City

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Manual

transmission test drive

While driving at 2nd or 3rd gear, try to press down sharply

on the accelerator pedal for an instance (clutch should
not slip, any slipping i.e., engine rpm increases but
speed remains the same clutch most likely has to be
replaced)
Try to drive with acceleration & deceleration (there
should be no whining or humming noise under any
condition with all gears should shift easily & noiselessly)

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Automatic

transmissions:

no clutch pedal
no gear shift
Automatic

transmission (gearbox plus torque converter) like

manual gearbox & its clutch.

Torque
converter

Auto
gearbox

Auto transmission system

TRANSMISSION SYSTEM
In

automatic transmission, same set of gears produces all of

the different gear ratios (planetary gear-set)

Planetary

gear-set
A set of bands to lock parts of gear-set
Three wet-plate clutches to lock other parts of gear-set
Hydraulic system controlling clutches & bands
Large gear pump to move transmission fluid around

Planetary

gear-set has 3 main parts:

Sun gear
Planet gears & planet gears' carrier
Ring gear

TRANSMISSION SYSTEM

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Each

of these 3 parts can be input, output or stationary

(determines gear ratio)

First

Gear - 2.4:1

Second
3rd

Gear - 0.67:1

gear - 1:1 ratio in 3rd gear

Overdrive

has a faster output speed than input speed (output

of engine goes straight to transmission)

Ratio

= 1 / (1 + S/R) = 1 / ( 1 + 36/72) = 0.67:1 (an engine

turning at 2000 rev/min output speed is 3000 RPM allowing
cars to drive at freeway speed while the engine speed stays
nice and slow

TRANSMISSION SYSTEM (15)

Differential

TRANSMISSION SYSTEM
Final

drive ratio (gear ratio in the differential)

Open

differential always applies the same amount of

torque to each wheel

Two

factors determining how much torque can be applied

to the wheels:
equipment
traction

Dry conditions - torque applied to

wheels limited by engine &
gearing

Live-Axle

Rear Axle Torque Reaction