The document describes the components and operation of manual transmissions. It discusses the relationship between gears and torque, and describes the basic types of gears. It outlines the power flow through 3, 4, and 5-speed transmissions. It also names common transmission parts like the synchronizer and driveshaft. Finally, it lists some common transmission troubles like leakage, difficulty shifting, and noise, along with their potential causes and troubleshooting steps.

1. Transmission System
Ubaid Shah

2. Objectives
• Describe the relationship between gears and torque
• Understand the basic types of gears
• Calculate gear ratios
• Trace the power flow through three-, four-, and five-speed
transmissions
• Name all of the transmission parts

3. Introduction
• Manual transmission
• Used with clutch
• Shifted between gears manually
• Transmission
• Used in rear-wheel-drive cars
• Transaxle
• Used in front-wheel-drive cars

10. N----Synchroniser

21. Typical driveshaft (also called a propeller shaft). The drivershaft transfers
engine power from the transmission to the differential.

33. Troubles and Troubleshooting
Troubles Troubleshooting
1. Leakage of oil
i. Excessive or high level of lubricant Drain the lubricant oil to proper level
ii. Breaking or missing gaskets Replace the gaskets
iii. Damaged oil seals Replace oil seals
iv. Loose cover bolts Replace it
2. Difficulty in gear shifting
i. Clutch is not releasing Inspect, adjust and repair
ii. Distorted splines of main shaft Repair or replace
iii. Defective synchroniser Repair or replace
iv. Faulty shift linkages Readjust
3. Transmission sticks in gear
i. Clutch not disengaging Adjust the clutch pedal linkages
ii. Stuck synchroniser Inspect, adjust and repair
iii. Insufficient or incorrect lubricant Fill to proper level with correct lubricant

34. Troubles and Troubleshooting
Troubles Troubleshooting
4. Slips out of gear
i. Worn out or defective synchroniser Repair or replace it
ii. Worn out bearing Replace the bearing
iii. Insufficient mesh Excessive clearance, check and readjust
iv. Faulty gear shift linkage Adjust the shifting linkages
5. Gear jumps out
i. Incorrect setting of gear shift Check and set the gear shift
ii. Excessive wear of gear shift control Replace
iii. Worn out input or output bearng Replace the worn out bearing
iv. Misaligned transmission Check and correct the alignment
6. Noisy transmission in the neutral condition
i. Worn out or damaged gears Replace the worn out gears
ii. Worn out or damaged bearings Replace the damaged bearing
iii. Improper lubrication to bearing or gears Provide proper lubrication

35. Troubles and Troubleshooting
Troubles Troubleshooting
7. Transmission noisy in gear
i. Defective clutch disk Replace the disk
ii. Misaligned transmission Check and correct the alignment
iii. Excessive clearance between shaft and gears Replace gears or shaft
iv. Defective synchroniser Repair or replace synchroniser
8. Transmission noisy in revers
i. Damaged reverse gear Replace the gear
ii. Damaged counter gear Replace
iii. Damaged reverse idler gear or idler bushing Replace the worn out bearing
iii. Improper lubrication to bearing or gears Provide proper lubrication