Summer Training in Maruti Suzuki Training Centre on Automobile Transmission

1. Name of Institution
1
Submitted By:
Asha Kumari
B.Tech. Semester VII MAE
A
PRESENTATION ON
SUMMER TRAINING IN

2. Name of Institution CONTENTS
Introduction
Types of transmission
Manual Transmission
Components
Automatic Transmission
Auto Manual Transmission
Advance Features
Case study
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3. Name of Institution TYPES OF TRANSMISSION
Available in 4 types:
Manual Transmission
Automatic Transmission
Auto-manual Transmission
Continuous variable
Transmission
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4. Name of Institution MANUAL 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

5. Name of Institution GEAR BOX
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Front wheel
Drive/transaxle
Rear wheel Drive

6. Name of Institution REVERSE GEAR SHAFT
 Reverse gear shaft is generally located in the gear box
above the input shaft.
The reverse idler gear is located on this shaft.
The idler gear is meshed with the reverse gear to reverse
the motion of the vehicle.
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Output shaft
reverse gear
Reverse Gear Shaft
Countershaft reverse gear
Countershaft
Input Shaft
Idler Gear

7. Name of Institution DIFFERENTIAL ASSEMBLY
 It is contained in the
transmission unit in case
of a transaxle.
 It is connected to the
countershaft.
 The drive from the
countershaft is
transmitted to the
differential and is then
further transmitted to the
drive shaft and then to
the wheel.
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8. GEAR SHIFT LEVERName of Institution
 The gear shift lever is present
inside the drive compartment
of the vehicle .
 The purpose of a gear shift
lever is enable the driver to
select different gears during
the drive.
 The car may have 4 or 5
forward gears and a reverse
gear which can be selected as
per the driving needs .
 Gear shift lever mechanism is
of 2 types
1. Direct shift type
2. Indirect shift type
Direct Shift
Indirect shift

9. Name of Institution SYNCHROMESH
MECHANISM
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.
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10. Name of Institution SHIFT 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.

11. TRANSFER GEAR BOX
Name of Institution
 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.
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The function of the transfer gear
box is to distribute the torque
generated in the engine to all
four wheels of the vehicle.

12. Name of Institution
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13. AUTOMATIC TRANSMISNSamIeO of NInstitution
 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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14. Name of Institution SPECIFICATION
81-40LS
3-element, 1-step, 2-phase with lock-up mechanism
2.0
2400 +/- 150 rpm
Forward 4-speed, rev. 1-speed, Ravigneau planetary gear
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
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Primary
Final
P
R
N
D
3
2
L
Type
Type
Capacity
Gear ratio
Position
Lubricant
Oil pump
Lubrication
Cooling type
Type
Drive
Type
Transmission
Shift mechanism
One way clutch
1.023
4.277
Direct cable shifting
Neutral, output shaft fixed, engine start
Reverse
Neutral, output shaft free, engine start
Forward 1st <--->2nd<--->3rd<--->4th automatic shift
Forward 1st <--->2nd<--->3rd (<---4th) automatic shift
Forward 1st <--->2nd(<---3rd) automatic shift
Forward 1st (<---2nd<---3rd) fixed
Radiator-assisted cooling (water cooling)
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
2 sets
Number of teeth
Wet type multi-plate clutch
Wet type multi-plate brake

15. FUNCTION OF COMPONENTS
Name of Institution
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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

16. Name of Institution ELECTRONIC CONTROL
 Valve Body Components
 Solenoid Operation
 Input / Output Table
 Control Details
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S2
S1
SLT
ST
SL
Solenoid Operation

17. Name of Institution AMT – 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

18. Name of Institution BENEFITS
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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

19. Name of Institution ADVANCE 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 engaged
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20. Name of Institution DIAGONAL 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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21. Name of Institution REVERSE SHIFT
PREVENTION
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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.
1. Gear shift and select lever
2. Reverse shift limit yoke
[A] : 5th
[B] : Reverse
[C] : 4th
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.

22. Name of Institution CASE STUDY
Model Mileage Vehicle System
SX4 VDI 3664 kms Transmission
 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

23. Name of Institution
THANK YOU!!
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