2Transmission System Maruti.49131942

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Transmission system


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Components Name


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Transmission Disassembly


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Shifting Shaft & Fork


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TRANSMISSION ASSY: M/TThe transmission provides

four forward speeds and one

reverse speed by means of

our sync ron zers, wo u

& Sleeve and three shafts:

. ,

2. Counter shaft

3. Differential Gear

All forward gears are in

constant mesh withHub and Sleeve

Synchronizer and reverse

uses a sliding

gear

Counter Shaft gears

idler gear arrangement.


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TRANSMISSION ASSY: M/T

Reverse gear shaft

High speed sleeve &

hub

Input shaftspeed sleeve &

hub

Low s eed sleeveoun er a

& hub

Differential bevel

Ring gear

gear


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PARTS DISCRIPTIONSpeed Gear:

shaft to other as per gearratio.

Synchroniser ring:Facilitates smooth engagement

sliding sleeve.

Hub & Sleeve:Sleeve moves over hub andengaging gear withhub so as transmit power from

.

Gear Shi f t Fork :roug gear s or s eeve

moves over hub.


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PARTS DISCRIPTION

Gear Shi f t Shaf t :a It selects the gear as per the movement of gearselector shaft. Fork (a) and (b) is fixed on the shaft.Fork (a) takes the movement from gear selector shaftand moves gear shift shaft and fork (b) results inbengagement of gear.

I nput Shaft (1) :Takes ower from en ine throu h clutch ass andtransmits the power to countershaft through gears.

Gear Selector Shaf t :

Takes movement from gear shifting rod and facilitatesselection of gearby transmitting motion to fork.


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Ist Gear IInd GearPOWER TRANSMISSION

Input from

Engine

Out ut

to Wheels

Indicates Power flowHub and Sleeve

Input Shaft gears / Rev

gear

Counter Shaft gears


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IVth GearIIIrd Gear

POWER TRANSMISSION



gear

Counter Shaft gears


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Reverse Gear

POWER TRANSMISSION



gear

Counter Shaft gears


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GEAR RATIO

Gear Ratio MT

s ear .

2nd Gear 1.894

3rd Gear 1.28

ear .

Reverse 3.583

Final Gear 3.789


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Counter Shaft Gear Assy

Counter ShaftSpeed gear

Synchronizer ring SleeveNeedle bearing Hub


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GEAR SELECTION

Neutral Position ngag ng n ear

( 1 st gear)

ngag ng n ear

( 2 nd gear)

Speed gearGear shift guide shaft

Spring loaded ball

Indicates movement of the sleeve

Sleeve

Gear shift forkSynchroniser ring

ear se ec on roug gear s gu e s a


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INSPECTION WHILE REASSEMBLY

.

2. Synchronizer ring

a) Clearance a: Standard 1.01.4 mm

Service limit 0.5 mm( By Checking

Feeler Gauge)


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Assemble 3rd

& 4th ear

ASSEMBLING TRANSMISSION UNIT

synchroniser sleeve and hub w it h

keys and spr ings.

Note: Short sideCin k eys, longbossDin hub and chamfer splineF

in sleeve should face inw ard .


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I nstall countershaft t o counter shaft

ASSEMBLING TRANSMISSION UNIT

A.

posit ion and high speed gear shif t shaftt o 3rd gear posit ion as show n .

Tight en of Counter shaft nut .


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TROUBLE SHOOTINGDIAGNOSIS

on t on oss e ause orrect on

Worn shift fork shaft Replace.

Worn shift fork or synchronizer sleeve Replace.

.

out of mesh Worn bearings on input shaft or countershaft Replace.

Worn chamfered tooth on sleeve and gear Replace sleeve and gear.

Inadequate lubricant Replenish.

Improper clutch pedal free travel Adjust.

Distorted or broken clutch disc Replace.

Damaged clutch pressure plate Replace clutch cover..

Worn chamfered tooth on sleeve or gear Replace sleeve or gear.

Worn gear shift control shaft joint bush Replace.

Distorted shift shaft Replace.

Inadequate or insufficient lubricant Replenish.Noise Damaged or worn bearing(s) Replace.

Damaged or worn gear(s) Replace.

amage or worn sync ron zer par s ep ace.


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2Transmission System Maruti.49131942

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