Name of Institution

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Submitted By:

Asha Kumari

B.Tech. Semester VII MAE

A

PRESENTATION ON

SUMMER TRAINING IN

Name of InstitutionCONTENTS

Introduction

Types of transmission

Manual Transmission

Components

Automatic Transmission

Auto Manual Transmission

Advance Features

Case study2

Name of InstitutionTYPES OF TRANSMISSION

Available in 4 types:

Manual Transmission

Automatic Transmission

Auto-manual Transmission

Continuous variable

Transmission

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Name of InstitutionMANUAL TRANSMISSION

• Driver-operated clutch &a gear selector.

• Parts of transmission system:

― Clutch

― Gear Box/Transaxle

― Differential

― Drive Shaft/Axle

― Transfer Gear Box

• Advantages

• Defects

― Abnormal noise

― Gear Engagement & Disengagement Problems

― Gear Jumping Out

― Oil Leakage 4

Name of InstitutionGEAR BOX

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Front wheel

Drive/transaxleRear wheel Drive

Name of InstitutionREVERSE GEAR SHAFT

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Reverse gear shaft is generally located in the gear boxabove the input shaft.The reverse idler gear is located on this shaft.The idler gear is meshed with the reverse gear to reversethe motion of the vehicle.

Output shaft reverse gear

Reverse Gear Shaft

Countershaft reverse gearCountershaft

Input ShaftIdler Gear

Name of InstitutionDIFFERENTIAL ASSEMBLY

It is contained in thetransmission unit in caseof a transaxle.

It is connected to thecountershaft.

The drive from thecountershaft istransmitted to thedifferential and is thenfurther transmitted to thedrive shaft and then tothe wheel.

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Name of InstitutionGEAR SHIFT LEVER The gear shift lever is present

inside the drive compartmentof the vehicle .

The purpose of a gear shiftlever is enable the driver toselect different gears duringthe drive.

The car may have 4 or 5forward gears and a reversegear which can be selected asper the driving needs .

Gear shift lever mechanism isof 2 types

1. Direct shift type

2. Indirect shift type

Direct Shift

Indirect shift

Name of InstitutionSYNCHROMESH

MECHANISM

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The synchromesh mechanism is used in the process of gear

selection i.e. to mesh the desired gear with the main shaft .

The speed of rotation of different set of gears is different due to

different gear ratios.

When the vehicle is in neutral there is a speed difference between

main shaft and the gears.

To synchronize the speeds of the main shaft and the desired gear the

synchromesh mechanism is used.

Name of InstitutionSHIFT FORK

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The shift fork is connected to the gear

shift shaft, it is used to engage the hub

assembly with the selected gear

The shift fork is connected to the gear

shift lever by the shift shaft

When the gear is selected the

corresponding shift forks which are

connected to the shift shaft also move.

During a gear change one shift fork

moves one hub assembly away from the

gear and another shift fork moves the hub

assembly for the newly selected gear.

Name of InstitutionTRANSFER GEAR BOX

The transfer gear box is controlled

by the driver, the control is located

in the vehicle compartment it is

either in the form of a transfer

lever or a button.

The transfer gear box connects the

drive from the engine to the second

propeller shaft which transmits

power to the front wheels of the

vehicle.11

The function of the transfer gear

box is to distribute the torque

generated in the engine to all

four wheels of the vehicle.

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Name of InstitutionAUTOMATIC TRANSMISSION

Automatic transmission or

A/T has no clutch.

Available in SX4, Vitara,

A-Star

Benefits:

―Smoother gear shifts

― Ideal for congested city

driving

―Less tiring to the driver

―Adds comfort to driving

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Name of InstitutionSPECIFICATION

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1st 2.875 Front sun gear 24

2nd 1.568 Rear sun gear 30

3rd 1.000 Long pinion gear 20

4th 0.697 Short pinion gear 19

Rev 2.300 Ring gear 69

Primary

Final

P

R

N

D

3

2

L

Type

Capacity

Gear ratio

LubricantLubrication

Oil pump

Cooling type

Type

Drive

Type

Type

Position

Transmission

Shift mechanism

5.8 litres

Type

Control components

Reduction

ratio

3 sets

3 sets

Internal involute gear (non-crescent)

Engine-driving

Type

Type

Stall torque ratio

Stall speed

Torque converter

Forced pumping type by oil pump

SUZUKI ATF 3317 or MOBIL 3309

Forward 1st <--->2nd<--->3rd (<---4th) automatic shift

Forward 1st <--->2nd(<---3rd) automatic shift

Forward 1st (<---2nd<---3rd) fixed

Radiator-assisted cooling (water cooling)

Neutral, output shaft fixed, engine start

Reverse

Neutral, output shaft free, engine start

Forward 1st <--->2nd<--->3rd<--->4th automatic shift

One way clutch

1.023

4.277

Direct cable shifting

2 sets

Number of teeth

Wet type multi-plate clutch

Wet type multi-plate brake

Forward 4-speed, rev. 1-speed, Ravigneau planetary gear

81-40LS

3-element, 1-step, 2-phase with lock-up mechanism

2.0

2400 +/- 150 rpm

Name of InstitutionFUNCTION OF COMPONENTS

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Symbol Part name Function

C1 Forward clutch Meshes intermediate shaft with front sun gear

C2 Direct clutch Meshes input shaft with planetary carrier

C3 Reverse clutch Meshes intermediate shaft with rear sun gear

B1 O/D & 2nd brake Fixes rear sun gear

B2 Second brake Fixes rear sun gear

B3 1st & reverse brake Fixes planetary carrier

F1 One-way clutch No.1 Prevents rear sun gear form turning counterclockwise when B2 is active

F2 One-way clutch No.2 Prevents planetary carrier from turning counterclockwise

1.Input shaft

2.Front sun gear

3.Rear sun gear

4.Planetary long pinion

5.Planetary short pinion

6.Planetary carrier

7.Ring gear

8.Counter drive gear

9.Counter driven gear

10.Differential drive pinion

Name of InstitutionELECTRONIC CONTROL

Valve Body Components

Solenoid Operation

Input / Output Table

Control Details

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S2

S1

ST

SLT

SL

Solenoid Operation

Name of InstitutionAMT – OVERVIEW This system automatically manages the

clutch and the gear engagement of a

traditional mechanical gearbox (as in the

image at right), it's an add-on kit that

usually doesn't require important

modifications to the vehicle/transmission

It’s main functions are:

—To automatically Operate the Vehicle

Clutch during the vehicle Start up (pick-

up) and during the gearshift maneuvers;

— To automatically command the Engine

Torque during gearshift maneuvers

avoiding the Drivers action on the

acclerator pedal;

—To decide the Gear ratio in order to

properly manage the Vehicle Drive. 17

Name of InstitutionBENEFITS

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Fuel consumption

Comfort:

• No clutch pedal

• Easy to use gearshift lever

• No need to release the accelerator

pedal during the gearshift

Fun to drive:

• Power-train still under driver control

• “Perfect” gearshift in all conditions

Safe:

• Avoid the “wrong gearshift”

• Avoid the engine stalls

Durability increase of:

• Clutch

• Synchronizer

Name of InstitutionADVANCE FEATURES

For gear shifting mechanism “Detent Pin”

technology is being used for reduced

friction, smoother gear shift & better gear

shift feel

Functions of Detent pin

— Location and positioning of the required

gearshift position;

— Locking in place once the gearshift position has

been located

— Ensuring precise and secure gearshift by means

of a defined gearshift resistance;

— Communicating a positive gearshift feel to the

driver and a clear sensation that the gear has

been engaged19

Name of InstitutionDIAGONAL SHIFT

ASSISTANCE

Gear shift pattern

Gear shift mechanism has been changed

from rod type to cable type mechanism for

smooth gear shift

Weight for New reverse gear actuation

mechanism has been reduced by 150gm

making lightest in all MSIL models

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Name of InstitutionREVERSE SHIFT

PREVENTION

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1. Gear shift and select lever

2. Reverse shift limit yoke

[A] : 5th

[B] : Reverse

[C] : 4th

The cubic projection on the gear shift and select

lever is blocked by the projection of reverse shift

limit yoke when gear shift control lever is

shifted from 5th position to reverse position.

As cubic projection of gear shift and select

lever pushes the reverse shift limit yoke, the

yoke rotates and pushes the cubic projection

of the lever toward the neutral position.

Gear is shifted into 4th position if gear shift

and select lever is still pushed toward

reverse position. Reverse shift limit yoke

returns to original position by spring force.

Name of InstitutionCASE STUDY

Problem: fifth gear slippage in SX4-D

vehicle

Action Taken:

• 5th gear snap ring was found damaged.

• It caused improper meshing between

fifth gear and its counter gear, which

caused chipping off or deep scoring on

the gears.

• All the affected parts( Gear,

countershaft 5th, Gear,input Shaft 5th,

Circlip, Hub Assy, 5th Speed Sync,

Bearing,5th Gear Needle , Ring,

Synchronizer) were replaced. 22

Model Mileage Vehicle System

SX4 VDI 3664 kms Transmission

Name of Institution

THANK YOU!!

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