Auto 1

1. Clutches &
Manual Transmissions

2. Flywheel
 Bolted to output flange of crankshaft
 Can be balanced by itself or with crank assembly
 Heavy weight adds inertia
 Dampens engine power pulses
 Mounting for clutch pressure plate
Clutch side
Crank flange side
with balance pads

3. Clutch pieces and bits…
Pressure Plate
Driving part
Friction Plate
Driven part
Release Bearing
Pilot BearingInstallation Tool

4. Basic Types of Clutches
 Diaphragm Type Clutch

5. Basic Types of Clutches
 Coil-Spring Type Clutch

6. Typical old school linkage

7. Clutch Hydraulic System

8. Clutch Operation

9. Clutch Problems
 Slipping Clutch
 Worn Clutch Disk
 Misadjusted linkage-Clutch pedal releases too high
 Oil or contaminates on disk
 Leaking rear engine seal, trans input shaft seal
 Chattering Clutch
 Warped flywheel or Hot Spots (hard areas on surface)
 Been racing lately, Honda boys?
 Contaminates on clutch disk
 Loose motor / trans mounts
 Broken Damper Springs

10. Clutch Problems
 Clutch will not release or gear clash
 Low fluid in clutch master cylinder
 Leaking master or slave cylinder, flex hose
 Air in clutch hydraulic system
 Fluid level too low
 Misadjusted linkage-Clutch pedal releases too low
 Worn bushings, clevis pivot
 Warped friction disc
 Still racing…
 Pilot bearing seized

11. Clutch Problems
 Clutch Noise
 In Neutral with clutch pedal up:
 Possible input shaft bearing wear
 In Neutral with clutch pedal down:
 Trans gears turning slowly, should be quieter
 In gear with clutch pedal down:
 Possible pilot bearing dry or worn
 Squeaking as clutch pedal is just being pressed:
 Release (Throw-out) bearing dry
 Squeaking in neutral, out of gear
 Clutch pivot at release arm dry

12. RWD & FWD Manual Transmission
Let’s Take a look at how it works!

13. MTM-Manual Transmissions

14. Purpose of Manual Transmission
 To allow driver input for matching engine
torque and speed to demand
 Upshifting – Accelerate vehicle to desired speed
 Downshifting – Reduce vehicle speed and add
control

15. Five Speed RWD

16. 1st Gear

17. 2nd Gear

18. 3rd Gear

19. 4th or Direct Gear

20. 5th Gear

21. Reverse Gear

22. Synchronizer Parts

23. How does a Synchro do what it do?

24. How does a Synchro do what it do?

25. How does a Synchro do what it do?

26. Can we see that again?

27. What moves the Synchro?

28. But can I select two gears at once?
NO!
Here is why you can only select ONE gear!

29. Shift Interlock saves your
transmission’s butt when you
blow a speed shift!

30. MTX-Manual Transaxles

31. FWD Basic Design
 Compact design saves weight and space
 Pretty much the same concept as a RWD trans
 Some engine/trans combinations cause power
flow to turn 90 deg. and exit stage left….and
right
 Differential also contained in trans case, but
that’s for another day.
 Trans and diff may use the same lubricating oil

32. 1st Gear

33. 2nd Gear

34. 3rd Gear

35. 4th Gear-No Direct Drive!

36. 5th Gear

37. Reverse Gear

38. Let’s take a peek inside…

39. Transmission Problems
 Noise
 Bearings
 Noise in all gears but 4th, usually countershaft bearings
 In one gear
 Chipped/missing teeth
 Some noise in reverse is normal due to gear design
 In all gears
 Low or lack of gear oil
 Gear Grind
 Wrong Fluid
 Bad Synchronizer Ring
 Poorly timed left foot work

40. End Manual Transmission