Table of Contents 302 Manual Transmissions & Transaxles Manual Transmission Section 3: Section 3 Topics ................................................................................. 35 Transmission Fundamentals ............................................................... 36 Torque ............................................................................................ 36 Determining Gear Ratios ................................................................ 37 Torque Multiplication ....................................................................... 38 Gear Types .....................................................................................
39 Bearings .......................................................................................... 40 Manual Transmission Components .................................................... 41 Shafts .............................................................................................. 41 Gears .............................................................................................. 42 Forward Gears ................................................................................ 42 Reverse Gears ................................................................................ 42 Simple Transmission ......................................................................
43 Transmission Powerflow ..................................................................... 44 Synchronizer Assembly ...................................................................... 45 Synchronizer Components ............................................................. 46 Synchronizer Gear Shift .................................................................. 47 1 st Stage – Synchronization ........................................................ 48 2 nd Stage – Synchronizing .......................................................... 50 3 rd Stage – Synchronized Meshing .............................................
51 Synchronizer Hub and Sleeve Splines ........................................... 52 Inertia Lock ..................................................................................... 52 Synchronizer Hub and Sleeve and Spline Damage ........................ 53 2-Cone Synchronizer ...................................................................... 54 3-Cone Synchronizer ...................................................................... 55 Synchronizer Cone Damage or Wear ............................................. 56 Synchronizer Inspection .................................................................
57 Gear Shift Mechanism ........................................................................ 58 Shift Detent Mechanism .................................................................. 59 Shift Interlock Mechanism ............................................................... 60 Shift Interlock Operation ................................................................. 60 Mis-Shift Prevention ........................................................................ 61 Reverse Mis-shift Prevention .......................................................... 62 Reverse One-way Mechanism ........................................................
63 Operation .................................................................................... 64 Reverse Pre-balk Mechanism ......................................................... 65 Operation .................................................................................... 65 Transmission Lubrication .................................................................... 66 Gear Lubrication ............................................................................. 66 Types of Lubricant .......................................................................... 67 Case Sealants .....................................................................................
68 ii Technical Training