Maintenance and repair of driveline and related components TOPIC 12

OBJECTIVES Explain the functioning of transmissions and related components Perform repairs on transmissions/gearboxes Describe the operation of a final drive and differential Perform repairs on a final drive Explain drive line components and arrangement Perform repairs on driveline components

Explain the functioning of transmissions and related components Purpose of drive lines Driveline components transmit and control power and motion.

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.1 Different types of gears Spur gear. It is used for sliding gears such as reverse gear. Advantage: Cheap to manufacture. Stay in-line when meshed. Disadvantage: Spur gears are noisier than helical gears. One tooth carrying the load at a time.

Spur Gear Animation

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.1 Different types of gears Helical Gear It is used for gears that are constant in mesh.   Advantage: Quieter and stronger than spur gears. More area of tooth contact Better power transfer across gear teeth. It is used for gears that are constant in mesh. Disadvantage: Expensive to manufacture.Tend to move away from each other when in mesh and rotating.

Helical Gear Animation

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 1. The advantage of helical gears are: Inexpensive More quiet Less lubricant is needed Easy to change

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.2 Relationship between the gear ratio and torque Gear Ratio. Increase in speed decrease torque Decrease in speed increase torque Gear Ratio Calculation Gear Ratio  

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 2. Gear ratios compares the number of teeth between the driver gear and the driven gear. True or false?

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.3 The functioning of a transmission/gearbox Provide a permanent neutral. Enable engine torque to be increased. Provide a forward and reverse. To allow road speed to be increased. To allow engine torque to increase to move a vehicle from a standing start.

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.3 Basic gearbox parts. Gearbox operation How transmissions work

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 3. What are the four gear groups in a manual transmission? Countershaft, input, output, and reverse idler Main shaft, output, synchronized, and reverse idler Input, countershaft, main shaft, and reverse idler Reverse, main shaft, countershaft, and output

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.4 Different types of gear lever arrangements. The purpose of a gear lever? The gear lever is what the driver uses to manually select and change gears.

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 4. How many selector rods would you expect to find in a four speed gearbox? Two Four Three

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.4 Different types of gear lever arrangements. Gear levers are typically located on the steering wheel column or between the two front seats.

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.4 Different types of gear lever arrangements. Modern variations of gear levers include finger tip buttons on the steering wheel, short shift and Tip-tronic levers on the dashboard

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 5. What is the difference in operation between a manual gear lever and a Tip-tronic levers on the dashboard Discuss amongst the class.

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.5 Different types of transmissions Sliding mesh The gears on the output shaft can slide from side-to-side on the main shaft Constant mesh All gears on the main shaft are constantly engaged/meshed Synchromesh Smooth and precise gear selection is carried out using synchronizers. These prevent the clashing or crunching of gears.

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.6 The power flow through different gears in a transmission/gearbox First gear Input shaft Cluster gear 1st gear synchro sleeve 1st gear synchro hub 1st gear Main shaft

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.6 The power flow through different gears in a transmission/gearbox Second gear Input shaft Cluster gear 2nd gear synchro sleeve 2nd gear synchro hub 2nd gear Main shaft

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.6 The power flow through different gears in a transmission/gearbox Third Gear Input shaft Cluster gear 3rd gear synchro sleeve 3rd gear synchro hub 3rd gear Mains haft

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.6 The power flow through different gears in a transmission/gearbox Fourth Gear Input shaft synchro sleeve synchro hub Main shaft

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.6 The power flow through different gears in a transmission/gearbox Reverse gear Input shaft Cluster gear Reverse idler gear (Change rotation direction) Reverse gear splined on main shaft

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 6 The function of the idler gear is to: Increase of engine power Increase gear torque Change rotational direction of mains haft Increase reverse speed.

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components Purpose of a clutch A clutch is used to connect and temporary disconnect the engine and manual transmission or transaxle. A clutch is a friction system.

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.7 The operational principles of different mechanical and hydraulic clutches used in cars. Mechanical System Mechanical clutches can be actuated through hand or foot-operated linkages or cables, which provide a "feel" for the amount of engagement.

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.7 The operational principles of different mechanical and hydraulic clutches used in cars. Hydraulic System Hydraulic clutches are mechanical friction clutches actuated with hydraulic oil acting on pistons.

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.8 Identify and describe the operation of different components of a clutch system. Clutch Components

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 7. What device is designed to disconnect the engine from the transmission? Universal joint Transfer case Clutch Differential

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.8 Identify and describe the operation of different components of a clutch system. Clutch Components Flywheel This is the mounting base for the clutch assembly and pilot bearing. The flywheel is also a friction surface for the clutch plate

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.8 Identify and describe the operation of different components of a clutch system. Clutch Components Pilot bearing It supports the engine side of the input shaft.

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.8 Identify and describe the operation of different components of a clutch system. Clutch Components Clutch plate It connects the engine and gearbox and transfers torque from the engine to the transmission.

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 8. What springs in the clutch disc absorb vibration and shock produced by clutch engagement? Facing Cushioning Torsion Friction.

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 9. Engine torque is transferred from the flywheel, through the friction facings, to the splined hub, and into the transmission. True or False

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.8 Identify and describe the operation of different components of a clutch system. Clutch Components Pressure plate It is bolted to the engine flywheel and provides the pressure needed to hold the clutch plate to the flywheel.

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.8 Identify and describe the operation of different components of a clutch system. Clutch Components Release bearing The release bearing is a sealed ball bearing that acts upon the diaphragm fingers or release levers of the pressure plate to disengage the clutch. Release bearing

Explain the functioning of transmissions and related components SO 12.1 Explain the functioning of transmissions and related components 12.1.8 Identify and describe the operation of different components of a clutch system. Clutch Components The clutch release fork . A clutch fork is used on some clutch assemblies to move the release bearing into and out of the fingers or levers of the pressure plate. Clutch release fork

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 10. A clutch connects and disconnects one rotating mechanical component from another. True or False

Perform repairs on transmissions/gearboxes 12.2 Perform repairs on transmissions/gearboxes 12.2.1 Safety procedures for working on transmissions/gearboxes are described. Dismantling. Wear PPE Use applicable tools Refer to workshop manual Secure components when dismantling Mark and store parts

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 11. The clutch fork transfers motion from the release mechanism to what components? Clutch linkage and release bearing Clutch slave cylinder and pressure plate Pressure plate and clutch disc Release bearing and pressure plate

Perform repairs on transmissions/gearboxes 12.2 Perform repairs on transmissions/gearboxes 12.2.2 Factory specifications on transmission/gearbox lubricants and service procedures on manual transmission. Best Practice Obtain applicable workshop manual Select appropriate equipment and tools

BASIC ENGINE CONDITION Question 12. A workshop manual refer to: The details of the client How to write a report The method of using specific equipment The procedures and sequences of removing components.

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 13. Choose the answer that does not fit. A service manual includes: the official factory service, repair, and training information Information for both the do-it-yourself owner and professional technician. information developed by the manufacturer primarily for the professionally trained technician. additional troubleshooting tips, routine maintenance hints.

Perform repairs on transmissions/gearboxes 12.2 Perform repairs on transmissions/gearboxes 12.2.3 The transmission/gearbox is removed from the vehicle. Best Practice Safely raise and secure vehicle Drain transmission oil Remove drive shaft Disconnect clutch links or hydraulic slave cylinder Remove speedo cable Disconnect and remove electrical connections Remove gear shaft lever Remove cross member Remove gearbox bell housing bolts Slide gearbox backwards Clean outside of gearbox Transmission Removal

Perform repairs on transmissions/gearboxes 12.2 Perform repairs on transmissions/gearboxes 12.2.4 The transmission/gearbox is disassembled and all relevant parts are inspected for wear Best practice Always consult workshop manual Clean all parts Lay out all parts Transmission - Disassembly and Inspection-1 Transmission - Disassembly and Inspection -2

Perform repairs on transmissions/gearboxes 12.2 Perform repairs on transmissions/gearboxes 12.2.5 Compile and submit a condition report. Best Practice List all parts Comment on condition of all parts Recommend on replacement of parts

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 14. A condition report serves as a warranty for future queries and claims. True or false?

Perform repairs on transmissions/gearboxes 12.2 Perform repairs on transmissions/gearboxes 12.2.6 Replace worn or damaged parts Best Practice Attach the checklist with the report to support the recommendations and parts required to repair or replace

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 15. When replacing a main shaft gear, you should also replace the matching gear on what shaft? Countershaft Reverse idler Input Output

Describe The Operation Of A Final Drive And Differential SO 12.2 Describe The Operation Of A Final Drive And Differential 12.2.7 Assemble the transmission/gearbox according to factory specifications Best practice Always consult workshop manual Never force components Pre-lubricate components Check gear selection prior to reinstalling the gearbox.

Describe The Operation Of A Final Drive And Differential SO 12.2 Describe The Operation Of A Final Drive And Differential 12.2.8 Re-install the complete transmission/transaxle driveline and test it. Best Practice Use a gearbox jack Align gearbox with engine Slide gearbox forwards Replace gearbox bell housing bolts and secure it Replace cross member and secure Refit gear shaft lever Connect and secure all electrical connections

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 16. You have completed reassembling a transmission. Which action should you take before reinstalling the transmission? Fill the case with proper lubricant. Ensure the transmission shifts properly. Measure end play clearance of the countershaft. Lightly coat all components with a medium-grade lubricating oil.

Describe The Operation Of A Final Drive And Differential-Continue SO 12.2 Describe The Operation Of A Final Drive And Differential-Continue 12.2.8 Re-install the complete transmission/transaxle driveline and test it. Best Practice Refit speedo cable Connect clutch links and secure hydraulic slave cylinder Refit drive shaft Refill the transmission with oil Safely remove vehicle from lift and lower to the ground Road test the vehicle and check gearbox performance Inspect for oil leaks.

Describe The Operation Of A Final Drive And Differential SO 12.2 Describe The Operation Of A Final Drive And Differential 12.2.9 Complete relevant documentation to record repairs Recording repairs Indicates the scope of work done Proof for any warranty Indicates the cost of repairs.

Describe the operation of a final drive and differential SO 12.3 Describe the operation of a final drive and differential 12.3.1 Describe different types of final drives Bevel drives and hypoid drives Spiral Bevel-Gear. The set incorporates a pinion and ring gear. Gears share the same centre line. Used on older trucks and cars. Hypoid-gear Gears do not share the same centre line. Improvement over spiral gears. Used on the modern cars and trucks.

Describe the operation of a final drive and differential SO 12.3 Describe the operation of a final drive and differential 12.3.2 Explain the operating principles of a final drive and differential Final Drive Provides drive from driving shaft at a right angle of 90* to drive shafts. Differential It allows the driveshaft’s to rotate at different speeds when cornering.

Describe the operation of a final drive and differential SO 12.3 Describe the operation of a final drive and differential 12.3.3 Explain the functioning of differential Components Function Pinion gear – Turns the crown wheel Crown wheel - Crown wheel carrier - Mounting place for crown wheel - Holds planet gears and side shaft gears Planet gear shaft- Holds planet gears in place Planet gears – Allow road wheel to turn at different speeds when cornering Side shaft gears - Turn the side shaft gears - Rotate the side shafts to turn axle and wheels

BASIC EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 17. The crown wheel transfers power directly from the drive pinion gear to the: axle flange ? differential case ? differential carrier ? differential pinion yoke ?

Describe the operation of a final drive and differential SO 12.3 Describe the operation of a final drive and differential 12.3.4 Explain different power flows through a differential Driving straight ahead.

Describe the operation of a final drive and differential SO 12.3 Describe the operation of a final drive and differential 12.3.4 Explain different power flows through a differential Left turn

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 18. When the drive wheels turn at different speeds the power between the wheels also changes. True or false?

Perform repairs on a final drive 12.4 Perform repairs on a final drive 12.4.1 Describe safety procedures for working on differentials and final drives Best practice Wear PPE Adhere to safe lifting procedures Support final drive when removing Discard final drive fluid according to the MSDS.

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 19. MSDS refers to the material safety disability system. True or false?

Perform repairs on a final drive 12.4 Perform repairs on a final drive 12.4.2 Obtain necessary factory specifications for repairs of differentials and final drives Best practice Always consult a workshop manual

Perform repairs on a final drive 12.4 Perform repairs on a final drive 12.4.3 Remove the final drive from the vehicle Follow guidelines from manufacturer.

Perform repairs on a final drive 12.4 Perform repairs on a final drive 12.4.4 Disassemble the final drive and inspect the components for wear Follow guidelines from manufacturer.

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 20. The following checks may be done prior to disassembly of the differential. Which procedure does not fit. Toot contact pattern Radial run-out on crown wheel Free play between pion gear and crown wheel Universal joint free play

Perform repairs on a final drive 12.4 Perform repairs on a final drive 12.4.5 Compile and submit a condition report Best Practice List all parts Comment on condition of all parts Recommend on replacement of parts

Perform repairs on a final drive 12.4 Perform repairs on a final drive 12.4.6 Replace worn or damaged parts Best Practice Attach the checklist with the report to support the recommendations and parts required to repair or replace

Perform repairs on a final drive 12.4 Perform repairs on a final drive 12.4.7 Assemble the differential and final drive Follow guidelines from manufacturer.

Perform repairs on a final drive 12.4 Perform repairs on a final drive 12.4.8 Re-install the differential and final drive in the vehicle Best practice. Follow guidelines from manufacturer. Re-installing the differential is a reversal of the removal procedures.

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 21. The axle half shaft is splined to the : Crown wheel Planet gear Pinion shaft Sun gear

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 2. The transmission case provides support for the bearings and shafts, as well as an enclosure for lubricating oil. True or false?

Explain drive line components and arrangement SO 12.5 Explain drive line components and arrangement 12.5.1 Describe different types of drivelines Open type propeller shaft (Hotchkiss drive) Open drive shaft Torque tube Enclosed drive shaft Semi- torque tube Has both features of the open and enclosed type of drive lines.

Explain drive line components and arrangement SO 12.5 Explain drive line components and arrangement 12.5.1 Describe different types of drivelines components. A Cross joints (Hooke universal joint) B Propeller shafts, C Slip yokes, A B C

Explain drive line components and arrangement SO 12.5 Explain drive line components and arrangement 12.5.1 Describe different types of drivelines A Rubber trunnion, B Ring joint C Layrub and D Constant velocity joint. A C B D

Explain drive line components and arrangement SO 12.5 Explain drive line components and arrangement 12.5.1 Describe different types of drivelines Four-Wheel Drive 4WD Animation How 4 Wheel Drive works

Explain drive line components and arrangement SO 12.5 Explain drive line components and arrangement 12.5.1 Describe different types of drivelines All-Wheel Drive All Wheel Drive

Explain drive line components and arrangement SO 12.5 Explain drive line components and arrangement 12.5.1 Describe different types of drivelines Front-Wheel Drive

Explain drive line components and arrangement SO 12.5 Explain drive line components and arrangement 12.5.1 Describe different types of drivelines Rear-Wheel Drive

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 23. Which factor is NOT an advantage of a vehicle with a transaxle and front-wheel drive? Increased passenger compartment space Quieter operation Greater sprung weight Improved traction on slippery surfaces

Explain drive line components and arrangement SO 12.5 Explain drive line components and arrangement 12.5.2 Explain the phasing of a propeller shaft. Driveshaft Phasing

Perform repairs on driveline components 12.6 Perform repairs on driveline components 12.6.1 Remove different driveline components 12.6.2 Disassemble different driveline components 12.6.3 Replace worn or damaged parts 12.6.4 Assemble different driveline components Best practice. All work must be carried out according to the workshop manual procedures. Adhere to all safety rule sand regulations

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 24. A propeller shaft is phased to: Reduce line-up of components Increase varying speed of the drive shaft Reduce vibration, noise Control the amount of lubrication

Perform repairs on driveline components 12.6 Perform repairs on driveline components 12.6.5 Replace different driveline components Best Practice Attach the checklist with the report to support the recommendations and parts required to repair or replace All parts that do not comply with manufacturer specifications have to be replaced.

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 25. What type of checks are done on the drive line components? Group work. Group compile a checklist.

Perform repairs on driveline components 12.6 Perform repairs on driveline components 12.6.6 Lubricate all necessary parts in the driveline according to factory specifications. To protect component against it has to be lubricated Grease point on universal joint Grease nipple.

EXPLAIN THE FUNCTIONING OF TRANSMISSIONS AND RELATED COMPONENTS Question 26. Find the most correct answer. Drive line components need to be lubricated due to: Their high speed operation High friction Some components not protected by an enclosed casing None of the above

SUMMARY You gained an understanding of the: Explain the functioning of transmissions and related components Perform repairs on transmissions/gearboxes Describe the operation of a final drive and differential Perform repairs on a final drive Explain drive line components and arrangement Perform repairs on driveline components