CONCORDIA UNIVERSITY Department of Mechanical and Anatomy of Engineering Laboratory emanual LAB 4: TRANSMISSION Manual Transmission
BEGINNING MAKE SURE YOU 1. WILL BE ABLE TO RETURN THE TOOLCART to its ORIGINAL CONFIGURATION [ie, study the toolcart] 2. Know how to use all the tools [ASK if you are not sure] 3. KNOW WHAT YOU ARE LOOKING FOR [as in DATA and RESULTS] 4. Have safety glasses 5. Are aware of the dangerous steps 6. Have a plan for any difficult steps 7. Have necessary cleaning materials Lets begin! Manual Transmission
Transmission Manual Transmission 3
Remove housing bolts Manual Transmission 4
You may need to use pry bars and screwdrivers to remove cover Manual Transmission 5
Reverse gear mounting bracket Manual Transmission 6
Remove reverse gear mounting bracket bolts Manual Transmission 7
Remove reverse gear mounting bracket bolts Manual Transmission 8
Remove reverse gear Manual Transmission 9
Shift mechanism access cap Manual Transmission 10
Remove shift mechanism access cap Manual Transmission 11
Remove differential subassembly This process involves several steps Manual Transmission 12
Operation Remove ring gear Manual Transmission 13
Manipulate shifter linkage to observe motion Manual Transmission 14
Remove shifter mechanism bolts Manual Transmission 15
Remove shifter mechanism bolts Manual Transmission 16
STOP NOW ask an instructor, programmer on duty [POD] or technician to supervise the next step. Failure to do this will result in a 5 MARK PENALTY in the performance grade. Manual Transmission
Remove shifter mechanism (slide out) Manual Transmission 18
Keep your finger on the hole to prevent ball and spring from being launched Manual Transmission 19
Do not lose any of the small parts Manual Transmission 20
Remove differential subassembly Manual Transmission 21
Examine differential subassembly Manual Transmission 22
Examine shifting mechanisms Manual Transmission 23
Observe motion of different parts Manual Transmission 24
Bonus: what is the physical difference between a Spur gear and a Helical gear? Observe Understand the different mechanisms Sketch parts (i.e gears, bearings) Manual Transmission 25
Observe Understand the different mechanisms Sketch parts (i.e gears, bearings) Manual Transmission 26
MIDDLE You have finished disassembly Make sure you have 1. Accumulate as much data as possible 2. Analyze and synthesize as many results as possible 3. CLEANed and ORGANIZed before resuming assembly Now on to reassembly Manual Transmission
Replace gear assemblies Manual Transmission 28
Replace gear assemblies Manual Transmission 29
Ensure mating parts line up and smooth rotation is possible Manual Transmission 30
Replace differential subassembly Manual Transmission 31
Replace differential subassembly Manual Transmission 32
STOP NOW ask an instructor, programmer on duty [POD] or technician to supervise the next step. Failure to do this will result in a 5 MARK PENALTY in the performance grade. Manual Transmission
Replace PART (For more details see step 36 & 37) Manual Transmission 34
Adjustment will be required to successfully insert the ball and link (For more details see step 36 & 37) Manual Transmission 35
Clarified view of the PART Manual Transmission 36
Replacing the ball and link may be difficult and might require several minutes Manual Transmission 37
Replace shifter mechanism Manual Transmission 38
STOP NOW ask an instructor, programmer on duty [POD] or technician to supervise the next step. Failure to do this will result in a 5 MARK PENALTY in the performance grade. Manual Transmission
Bonus: what is the purpose of the ball and spring? Use a screwdriver to hold down ball and spring Manual Transmission 40
Slide in shifter mechanism Manual Transmission 41
Pliers may be required to rotate and slide the shaft Manual Transmission 42
Replace shifter mechanism bolts Manual Transmission 43
Replace shifter mechanism bolts Manual Transmission 44
Replace reverse gear and shaft Manual Transmission 45
Reverse gear located behind differential subassembly Manual Transmission 46
Replace reverse gear mounting bracket and bolts Manual Transmission 47
Operation Replace ring gear Manual Transmission 48
Ensure gears are properly engaged Manual Transmission 49
Replace transmission housing and bolts Manual Transmission 50
Ensure no optional parts remain on workbench Manual Transmission 51
END BEFORE YOU LEAVE Make sure you have 1. CLEANed and ORGANIZed your area. 2. Returned all tools as you found them. 3. HAD YOUR DATA SHEETS SIGNED for AUTHENTICITY TIME FOR A NAP Manual Transmission