MANUAL TRANSMISSIONS

Ephesians 3:8-9
 To me, the very least of all saints, this grace was given, to preach to the
Gentiles the unfathomable riches of Christ, and to bring to light what is the
administration of the mystery which for ages has been hidden in God who
created all things;
 A manual transmission (MT), is known by different names in different places.
 For example it is known as manual gearbox, or as standard transmission (in
Canada, the United Kingdom, and the United States), or stick shift (in the
United States.
 This is a is a multi-speed motor vehicle transmission system, where gear
changes require the driver to manually select the gears by operating a
gear stick and clutch (which is usually a foot pedal for cars or a hand lever for
motorcycles).
MANUAL TRANSMISSIONS
The history of manual transmission
1890s to 1940s
 Early automobiles used sliding-mesh manual transmissions with up to three forward
gear ratios.
 Since the 1950s, constant-mesh manual transmissions have become increasingly
commonplace and the number of forward ratios has increased from 5-speed to 6-speed
for current vehicles manual transmissions.
 A manual transmission requires the driver to operate the gearstick and clutch in order
to change gears (unlike an automatic transmission or semi-automatic transmission,
where one (typically the clutch) or both of these functions are automated).
 Most manual transmissions for cars allow the driver to select any gear ratio at any
time, for example shifting from second to fourth gear, or fifth to third gear.
 However sequential manual gearboxes such as used in motorbikes and racing cars, only
allow shifting from lower to high or high to low
MANUAL TRANSMISSIONS
 The design of most manual transmissions for cars is that gear ratios are selected by locking
selected gear pairs to the output shaft inside the transmission.
 Contemporary manual transmissions for cars typically use five or six forward gears ratios and one
reverse gear, however, transmissions with between two and seven gears have been produced at
times.
 A manual transmission has several shafts with various gears and other components attached to
them.
 Most modern passenger cars use 'constant-mesh' transmissions consisting of three shafts: an input
shaft, a countershaft (also called a layshaft) and an output shaft.[1
 In a transmission for longitudinal engined vehicles (e.g. most rear-wheel-drive cars), it is common
for the input shaft and output shaft to be located on the same axis, since this reduces the
torsional forces to which the transmission casing must withstand.
MANUAL TRANSMISSIONS
 In a transmission for transverse engined vehicles (e.g., front-wheel-drive cars), there are usually
only two shafts: input and countershaft (sometimes called input and output).
 The input shaft runs the whole length of the gearbox, and there is no separate input pinion.
These transmissions also have an integral differential unit, which is connected via a pinion gear
at the end of the counter/output shaft.
Dog clutch[edit]
 In a modern constant-mesh manual transmission, the gear teeth are permanently in contact with
each other, and dog clutches (sometimes called dog teeth) are used to select the gear ratio for
the transmission.
 When the dog clutches for all gears are disengaged (i.e. when the transmission is in neutral), all
of the gears are able to spin freely around the output shaft.
 When the driver selects a gear, the dog clutch for that gear is engaged (via the gear selector
rods), locking the transmission's output shaft to a particular gear set.
 This means the output shaft rotates at the same speed as the selected gear, thus determining the
gear ratio of the transmission.[16]
MANUAL TRANSMISSIONS
synchromesh
 In order to provide smooth gearshifts without requiring the driver to
manually match the engine revs for each gearshift, most modern passenger car transmissions use
'synchromesh' (also called 'synchronizer rings') on the forward gears.
 These devices automatically match the speed of the input shaft with that of the gear being
selected, thus removing the need for the driver to use techniques such as double-clutching.
 The synchromesh transmission was invented in 1919 by Earl Avery Thompson and first used on
production cars by Cadillac in 1928.[17]
MANUAL TRANSMISSIONS
Parts of Manual Transmission
Following are the parts of manual transmission:
 Transmission or Transfer case
 Input shaft
 Output shaft
 Lay shaft
 Synchronizers
 Gears
 Stick shift
 Shift fork
 Bearing
 Extension Housing
MANUAL TRANSMISSIONS
Parts of Manual Transmission
MANUAL TRANSMISSIONS
Parts of Manual Transmission
Transmission or Transfer Case
It is part of the drivetrain that is used to transfer power from the transmission to the rear
axles by using a drive shaft.

#2 Input Shaft
The input shaft of the transmission is connected to the layshaft, having gears on both
shafts. Whenever the input shaft turns, the countershaft also rotates and is always in a
fixed speed ratio.

#3 Output Shaft
The function of the output shaft is to send the power out of the transmission system to
the wheels. The output shaft gears are in mesh with the countershaft gear and rotate
independently. It will rotate according to the power transferred by the layshaft gear.
MANUAL TRANSMISSIONS
Parts of Manual Transmission
#4 Countershaft
This is also known as countershaft. It rotates in the opposite direction to
the input shaft. They spin whenever the engine is running and the clutch is
engaged. Whenever a gear is selected by the driver they drive gear on the
mainshaft.

#5 Synchronizers
Synchronizers facilitate engagement between the collar and gear to
synchronize their motion. Plus, they help to adjust the shaft speed so that
the gears align faster as you shift. Sometimes the speed can vary, so the
synchronizer helps to avoid that happening.
MANUAL TRANSMISSIONS
Parts of Manual Transmission
#6 Gears
Basically, the manual transmission has three shafts with gears of different
sizes. There are some large gears that have lots of teeth and some small
gears which have few teeth.
The large gears generate extra torque, which helps in slowing the vehicle.
Whereas smaller gears generate less torque, which helps the vehicle to
travel at high speed.
#7 Stick Shift
It is located on the center console, the shift lever is connected to the
transmission by a linkage and you can control it with your hand. With the
shift lever, you can control and switch gears with ease. The function of the
stick shift is to change gears manually as they accelerate and slow down a
vehicle.
MANUAL TRANSMISSIONS
Parts of Manual Transmission
#8 Shift Fork
The selector fork is a type of gear that looks like a mechanical arm. The
gear selector forks slide along the manual transmission’s layshaft. This
permits the collars to move on the output shaft.
#9 Bearings
In a transmission system, the gears are in rotation and interlock to each
other at all times with help of bearings. They also allow the input shaft and
output shaft to rotate at different speeds.
#10 Extension Housing
The transmission has an extension housing that protects the output shaft at
the rear of the transmission and also supports the bearings.
MANUAL TRANSMISSIONS
Types of Manual Transmission
Following are the types of manual transmission:
Sliding mesh transmission
MANUAL TRANSMISSIONS
Types of Manual Transmission
Following are the types of manual transmission:
Sliding mesh transmission
 These transmissions are commonly seen in the old types of
vehicles. In sliding gearboxes when the transmission is in a
neutral state, the only things that move are the main drive
gear and cluster gear. However To send power to the drive
wheels, the clutch pedal must be depressed.
 The sliding mesh transmission can provide relatively high
efficiency compared to sliding mesh transmission because only
one gear is in mesh, unlike the constant mesh transmission in
which all gears are in mesh. Its design is simple which is one of
its advantages.
MANUAL TRANSMISSIONS
Types of Manual Transmission
Constant mesh transmission
 The continuous-mesh transmission maintains the motion of the
gears, cluster gears, and main shaft gears as they are free to
rotate around the main shaft. It has a dog clutch to lock these
gears when required.
 When the shift linkage moves, the teeth on the clutch and the
main shaft gear lock onto each other and keep the gear stable.
Synchronizers are used to prevent any collisions or grinding
during transfer.
 It uses helical gears to avoid vibrations and noises. They are
highly beneficial due to their quiet operating capabilities. Since
it uses two dog clutches, different gear ratios can be obtained.
MANUAL TRANSMISSIONS
Types of Manual Transmission
Following are the types of manual transmission:
Constant mesh transmission
MANUAL TRANSMISSIONS
Types of Manual Transmission
Following are the types of manual transmission:
Dual-clutch transmission
 A dual-clutch transmission is a modified version of a manual transmission
with two sets of gears, each operated by a separate clutch. Basically, it
uses two clutches which can be either wet or dry.
 One clutch operates the even number of gears (2, 4, 6) while the other
clutch operates the odd number of gears (1, 3, 5, and reverse gear).
 These types are very popular in older cars but are still found in modern
race cars. DCTs offer better fuel economy than ATs.
Types of Manual Transmission
Following are the types of manual transmission:
Types of Manual Transmission

DCT TRANSMISSION
Benefits
 DCTs offer better fuel efficiency compared to any other
transmissions
 Delivers smoother and seamless performance
 Allows smooth and swift ger shifts which has made them
ideal for performance driving such as In formula one.
Demerits
 More complex in design and operation compared to other
transmissions
MANUAL TRANSMISSIONS

Automated manual transmission

 With the introduction of a number of vehicles recently,
automation of synchromesh, ‘manual’ transmissions is becoming
more popular.
 The reason for the development of these transmissions is
twofold; firstly, they can show an economy benefit over both
manual and ATs.
 This is because they are more efficient than automatics and can
be programmed to change gear more effectively than most
drivers would.
MANUAL TRANSMISSIONS

Automated manual transmission

 Secondly, automated manual transmissions are gaining in
popularity in the performance car market, probably because of
the links to Formula 1 racing and as a result of clever
marketing! Examples include: BMW M3, MMC Smart, VW Lupo
and Alfa 156.
 These developments started some time ago with the
introduction of automated clutches on several vehicles including
the Renault Twingo, Saab 900 Sensonic and Ferrari.
MANUAL TRANSMISSIONS
Automated manual transmission
 It is also known as then direct shift gearbox (DSG) AND FIRST GAINED pre-eminence in
the 1983 release of the Porsche 956 with computer built-in functionality.
 Thiss computers sensors and actuators thus eliminated the need for maual input to
shift gears.
 Instead the computer anticipates the next gear change ratio when the output shft runs
at a specific gear ratio ( by use of acceleration, deceleration, engine speed and on
going speed).
 These cars retained the normal gear lever but automated the clutch so that no pedal
was required in order to shift.
 At start-up, they operate as an automatic with the control system actuating the clutch
to achieve a start from rest when the accelerator pedal is depressed. During gear
changes, the clutch is operated in response to movement of the gear lever.
MANUAL TRANSMISSIONS
Types of Manual Transmission
Following are the types of manual transmission:
Pre-selector Transmission
 These are older models that were used in the 1930s. A pre-
selector has a vacuum or hydraulic shift control and a
planetary gear system to pre-select the gear ratio using a
lever on the steering column.
 The driver presses a foot pedal to shift gears that contact one
of the gears already selected. As this happens, the rear gear
stops while the new gear is engaged.