UNIT

3 Gear Box

Contents

3.0 Introduction 3.7 Gear Ratio

3.1 Gear Box Location 3.8 Overdrive
3.2 Gears 3.9 Parts Of The Gear Box
3.2.1 Types Of Gears 3.9.1 Gear Box Casing
3.3 Needs of the Gear Box 3.9.2 Gear Box Input Shaft
3.4 Gear Box Operating Principle 3.9.3 Lay Shaft
3.5 Types Of Gear Boxes 3.9.4 Gear Box Output Shaft
3.5.1 Sliding Mesh Gear Box 3.9.5 Reverse Gear Shaft
3.5.2 Constant Mesh Gear Box 3.9.6 Speedometer Drive
3.5.3 Synchromesh Gear Box 3.9.7 Gear Selector Mechanism
3.5.4 Synchronizing Unit 3.10 Gear Box Maintenance
3.6 Properties Of Gear Box 3.11 Transfer Case

Learning objectives

1. Understanding different types of gear boxes used in the automobile vehicle.

2. Understanding different gear teeths are used in gear boxes.
3. Understanding the problems occurred in gear boxes and methods to rectify
those problems.

3 - Gear Box 30

BAE_ENG_Chapter_03.indd 30 12/10/2019 11:28:11 AM

 3.0 Introduction 3.2.1  Types of gears
The road conditions are not uniform Gears are of many different types.
whenever we are in travel in the vehicle. The following are some of the important
Moreover we do not drive the vehicle gears
always at the same speed. The vehicle
1. Spur gear
must be operated at lower speed when it
2. Helical gear
needs more pulling power. Moreover based
3. Double helical gear
on the operating conditions, the vehicle
4. Bevel gear
requires different speed and torque. To
5. Rack and pinion gear
perform this, a box containing different
6. Worm and worm gear
gears, shafts and bearings is required. This
7. Internal gear
box is called as the gear box. It can be
8. Sprocket wheel
also called as teeth wheel box. By using
this box, the driver can achieve different 3.2.1.1  Spur gear
speeds and torques for a vehicle. Gear
It is like a circular shaped one made
box is the one which comprises of various
on a cylindrical metal having teeth cut
teethed gears for different vehicle speed
in parallel to the axis of the cylinder. It
conditions.
is called as spur gear.

3.1 Gear box location

Gear box is located at the second
place of the vehicle’s transmission system.
In the vehicle after the engine, clutch
is located. After the clutch gear box is
located. It is located in between the clutch
and the propeller shaft.

3.2 Gears
The commonly used gears and
their arrangements can be seen in this
section. With a help of teethed wheels
we can transmit the energy in rotational,
Figure 3.2.1.1  Spur gear
parallel and in perpendicular directions.
In machines gears are used in places This gear is used to transmit the
wherever the transmission of rotational rotary power only between two parallel
force is taking place. Moreover the gears shafts. It is capable of transmitting
are used to transmit the rotational force moderate force and speed. A smaller
without any slip. It is used in places where gear is called as pinion. Normally in gear
there is a small distance for transmitting box this type of gear is used for first and
the rotational force (torque). reverse gear speed operations.

3 - Gear Box 31

BAE_ENG_Chapter_03.indd 31 12/10/2019 11:28:11 AM

 3.2.1.2  Helical gear gear is used in differential, pinion, crown,
It is also a circular shaped metal wheel, planet and sun gears.
made on a cylindrical metal having the
teeth cut not parallel to the axis but in
helical shaped cut at certain angle inclined
to the cylinder’s axis. This type of gear
is called as the helical gear.

Figure 3.2.1.3  Bevel gear

3.2.1.4  Rack and pinion gear

In this arrangement teeth are cut
on a long flat metal bar called as rack. A
small wheel called as pinion is in mesh
with rack. In this way the rotating power
of the pinion is transformed into a straight
Figure 3.2.1.2  Helical gear
line or reciprocating motion. This type
We can transmit the rotational of gears are used in the gear boxes in the
power to two shafts which are either steering system and in many mechanical
parallel or non parallel through the helical machines.
gear. Compared to straight spur gears
more power can be transmitted through
helical gears. This type of gear is used
in synchromesh gear box and constant
mesh gear box.

3.2.1.3  Bevel gear

In this gear the teeth are cut on the
top surface of the shaft in tapper. This
type of gear is generally used to connect Figure 3.2.1.4  Rack and pinion gear
the shafts which are perpendicular to
each other and transmit the power in the
perpendicular i.e. at 90 o angle direction. 3.2.1.5  Worm and worm gear
Bevel gear is capable of withstanding It is used to transmit the rotational
more power than other gears. The bevel power by connecting two shafts that are

3 - Gear Box 32

BAE_ENG_Chapter_03.indd 32 12/10/2019 11:28:11 AM

 perpendicular to each other. The gear 3.2.1.7  Internal gear
which looks like a spur gear is called The internal gear is the one in
as the worm. The small shaft with the which the teeth are cut internally on the
single start thread or multi start thread inner circular metal pipe. This is called
cut made on it is called the worm shaft. as the internal gear. This gear could
This type of gear is used in places where transmit more power in short places.
high speed reduction and high power They are strong in structure. They are
transmission are obtained. It is used in used in a small mechanisms and tractor
steering gear box in automobiles. mechanism.

Figure 3.2.1.5  Worm and worm gear

Figure 3.2.1.7  Internal gear
3.2.1.6 Double helical gear or
herringbone gear
3.2.1.8  Sprocket wheel
On the circular periphery of the
On a rounded metal wheel plate
cylindrical metal teeth are cut in the
teeth are cut outside. This wheel is not
shape of the English letter “V”. This
in direct contact with the other wheel. In
gear is called as double helical gear or
between the two wheels a chain is placed
herringbone gear. This type of gear is used
and the rotational power is transmitted
where more rotational power (torques)
through the chain. It is used in timing
is transmitted.
gears. Moreover it is also used in motor
cycles.

Figure 3.2.1.6  Double helical gear of

herringbone gear Figure 3.2.1.8  Sprocket wheel
3 - Gear Box 33

BAE_ENG_Chapter_03.indd 33 12/10/2019 11:28:11 AM

 3.3 Needs of gear box 1. Sliding mesh gear box
1. For reducing the engine speed and 2. Constant mesh gear box
increasing the torque. 3. Synchromesh gear box
2. For reducing the engine torque and 4. Epicyclic gear box
increasing speed. 5. Automatic gear box
3. For the selection of speed levels There are many types of gear boxes
according to the driver’s requirement. available. The important gear boxes are
4. For pushing the vehicle in the discussed below.
backward direction.
5. For neutralizing the vehicles when there
3.5.1 Sliding mesh gear box
is no need to transmit the engine power.
Sliding mesh gear box was used
3.4 P
 rinciple of gear box in  earlier day’s vehicles. Figure 3.5.1
mechanism presents  the details of the sliding mesh
gear box. In this gear box spur gears are
Gear box works on the principle
present. This box is suitable for heavy
of lever mechanism.
vehicles. By sliding the gears this type
of gearboxes move the gears and mesh
3.5 Types of gear box them and hence it is called as sliding
The following are the gear boxes mesh gear box.
used in automobiles,

Gear shift
Clutch fork
gear
Clutch
Output
shaft

Input
shaft

Idle gear

Counter shaft

Figure 3.5.1  Sliding mesh gear box

3 - Gear Box 34

BAE_ENG_Chapter_03.indd 34 12/10/2019 11:28:12 AM

 An exciting car fact is that cars that do not require drivers should
be on the roads by 2020. Google has already developed a driverless
car, and many other prototypes are in the works. It is believed that
these driverless cars will reduce the frequency of accidents, and will
reduce the number of vehicles needed on the road.

3 - Gear Box 35

BAE_ENG_Chapter_03.indd 35 12/10/2019 11:28:12 AM

 Construction
In the gear box, lay shaft or counter
shaft is present. This shaft is supported
by the bearings in the gearbox. The gear
teeth are fixed as stationary in this lay
shaft. In the main shaft, splines are made
in such a way that the gears are free to
move on the slots. The gear teethed wheel
(1) in the clutch shaft is always in mesh
with the gear in the lay shaft wheel (2). Figure 3.5.1.1  First gear power
The gear (7) in the lay shaft is always transmission
in mesh with the idler gear (8). A three
speed sliding mesh gear box is shown in c) Second gear
Figure 3.5.1.
During second gear, the gear shift
fork is moved right as shown in Figure
Working principle 3.5.1.2 to mesh the gear 6 in the output
a) Neutral position shaft with gear 3 in the lay shaft gear 1, 2,
The gear teeth (1) in the input 3 and 6 will get contact and rotate. Now
(clutch) shaft is in mesh with the counter the power is transmitted from the gear
shaft gear 2. Hence the counter shaft 1-2-3-6. Now the speed becomes more
rotates. However the gears (3 or 4) are than the first gear and the gear ratio of
not in mesh with the output shaft gears 2:1 is achieved.
(5 or 6) as shown in Figure 3.5.1.1. Hence
the power will not be transmitted to the
output shaft. This condition is called as
neutral position.

b) First gear
The gear (1) in the clutch shaft is
in mesh with the gear in the counter shaft
(2). As the gears 3 and 4 are in the counter
shaft they also rotate. When the gear shift Figure 3.5.1.2  Second gear power
fork is moved towards left as shown in transmission
Figure 3.5.1.1 to engage the gear 5 in the
output shaft with the gear 4 in the lay shaft,
then the output shaft rotates. The rotary d) Third gear
power is now transmitted to the output Dog Clutch is located on the gear
shaft from gear 1-2-4-5. Now we can get 1 in the input (clutch) shaft and the
first gear ratio 3:1. gear 6 in the output shaft as shown in

3 - Gear Box 36

BAE_ENG_Chapter_03.indd 36 12/10/2019 11:28:12 AM

 Figure 3.5.1.3. Now by moving the gear Advantages of sliding mesh
shift fork on the left as shown in Figure gearbox
the dog clutch is allowed to mesh with 1. Simple in construction
the dog clutch in the clutch shaft. 2. Simple in maintenance
3. Suitable for heavy vehicles
4. Low cost
5. Higher mechanical efficiency
6. Production cost is low

Disadvantages
1. Gear changing is difficult
2. Noisy in operation
3. Experience is required for changing
Figure 3.5.1.3  Third gear power gear
transmission 4. The edges of teeth wear rapidly.
Now the output shaft rotates at the
speed same as the clutch (main) shaft. This 3.5.2 Constant mesh
is the maximum speed and the gear ratio gear box
in this condition is 1:1. The rotational In constant mesh gear box the
power is now directly transmitted from teeth in the main shaft and lay shaft are
the clutch shaft to the output shaft. always in constant mesh with each other.
Hence it is called as constant mesh gear
e) Reverse gear box. Helical gears are used in this type
For reverse gear, the gear shift fork of gear box. The gear arrangements in
is moved towards the right direction as the constant mesh gear box can be seen
shown in the Figure 3.5.1.4. Hence the in Figure 3.5.2.
gear 5 in the output shaft is in mesh with
the gear 8 in the lay shaft which is the Construction
idler gear. Now the power transmission is In the constant mesh gear box the
from gear 1-2-7-8-5 to the output shaft. gears 6, 7 and 8 in the output shaft are
always in mesh with the gears 5, 4 and 3
in the lay shaft. In the clutch shaft and
in the lay shaft there are gears 1 and 2
respectively which are always in mesh
with each other. The gears in the main
shaft are supported by bushes. Gear 5 in
the lay shaft is in mesh with an idler gear.
After the clutch gear in the clutch shaft
and before the reverse gear in the main
Figure 3.5.1.4  Reverse gear power shaft there are dog clutches (D 2  and D 1
transmission respectively) present. These dog clutches
3 - Gear Box 37

BAE_ENG_Chapter_03.indd 37 12/10/2019 11:28:13 AM

 Second gear
First gear
Reverse gear
Sliding dog
Clutch clutch
gear Output
shaft

Clutch
shaft
Idler gear

Lay
shaft

Figure 3.5.2 (a)  Gear arrangements in the constant mesh gear box

Figure 3.5.2 (b)  Constant mesh gear box

are allowed to move on the slots made All gears in the shafts 1,2 & 3,4 & 5,6 &
on the main output shaft. All the shafts 7,8,9 rotate. However the main output
in the gear box are supported by the shaft does not rotate as the dog clutches
bearings in the housing. are not in engagement with any of the
gears. Hence rotational power is not
Working principle transmitted.
Neutral position
During neutral condition both First gear
the dog clutches (D 1 and D 2) are not in By actuating the gear shift lever,
mesh with any gears as shown in Figure. the dog clutch D 1 is moved towards left
3 - Gear Box 38

BAE_ENG_Chapter_03.indd 38 12/10/2019 11:28:13 AM

 side to engage gear 7 in the main shaft Third gear
as shown in Figure. Now the rotational To achieve the third gear the dog
power is transmitted to the main shaft clutch D 2 is moved left to engage with
through the dog clutch. Now the speed the clutch shaft gear directly. Now the
is low. The power transmission from output shaft rotates at the speed same
the clutch shaft to the output shaft is as the clutch shaft speed. The rotational
by gear1-2 is means rotational power is power is transmitted to the main shaft
transmitted to main shaft by 1-2-4-7-D 1. directly through the gear1-D 2.

Figure 3.5.2.1  Power transmission in Figure 3.5.2.3  Power transmission in

first gear third gear
Second gear Reverse speed
For obtaining the second gear, by To obtain the reverse gear, the dog
actuating the gear shift lever, the dog clutch clutch D1 is actuated to move right towards
D 2 is moved towards right as shown in the reverse gear 6 to engage as shown in
Figure to engage the gear 8 in the output Figure 3.5.2.4. As the idler gear is placed
main shaft. Now the rotational power is between the gears 5 in the lay shaft and 6
transmitted to the main shaft through in the main shaft the idler gear changes the
the dog clutch D 2. Now the speed of the direction of rotation of the gear 6 in the
main shaft is higher than the speed of main shaft. Now the vehicle moves in the
the first gear. The power transmission reverse direction. The power transmitted
from the clutch shaft to the output shaft from the cluth shaft to the main shaft is
is through the gears1-2-3-8-D 2. through gears 1-2-5-Idler-6-D 1.

Figure 3.5.2.2  Power transmission in Figure 3.5.2.4  Power transmission in

second gear reverse gear
3 - Gear Box 39

BAE_ENG_Chapter_03.indd 39 12/10/2019 11:28:13 AM

 Advantages of constant mesh box but differs slightly. Instead of dog
gear box clutch used in constant mesh gear box, a
1. Gear changing is simple synchronizing unit is used in synchromesh
2. Less noise gear box. In the synchromesh mesh gear
3. Less chance for the teeth of the gears box the gears 6, 7 and 8 in the output
to break up. shaft are always in mesh with the gears
4. Smoothness in operation 5, 4 and 3 in the lay shaft. In the clutch
5. Low maintenance shaft and in the lay shaft there are gears
1 and 2 respectively which are always
Disadvantages in mesh with each other. The gears in
1. For changing gears from one speed to the main shaft are supported by bushes.
other speed, double de clutching has Gear 5 in the lay shaft is in mesh with
to be done. an idler gear. After the clutch gear in the
2. More wear clutch shaft and before the reverse gear
3. Possibility of wear in dog clutch. in the main shaft there are synchronizers
(S 2 and S 1 respectively) present. These
3.5.3 Synchromesh gear synchronizers are allowed to move on the
box slots made on the main output shaft. All
Synchromesh gear box is similar the shafts in the gear box are supported
in construction as constant mesh gear by the bearings in the housing.

3-4 synchronizer

Third gear
Input (clutch) gear
Second gear (fourth gear)

1-2 synchronizer

First gear
Fifth gear

Countershaft

Fifth gear
synchronizer

Third gear
Fifth gear
Input (clutch) gear
Second gear
First gear
Reverse
idler gear
Reverse gear

Figure 3.5.3 (a)  A view of gear arrangements of a 5 speed synchromesh gear box
3 - Gear Box 40

BAE_ENG_Chapter_03.indd 40 12/10/2019 11:28:14 AM

 Figure 3.5.3 (b)  The photographic view of a synchromesh gear box

Female cone Ball lock

Synchronizing
Inner sleeve
unit

Main shaft

Helical
gears
Outer sleeve

Male cone

Figure 3.5.3 (c)  Layout of a synchromesh gear box

The photographic view of a the synchromesh gear box for different

synchromesh gear box can be seen in vehicle speed is explained below.
Figure.
Neutral position
Working principle During neutral condition both
The layout of the synchromesh gear the synchronizers (S 2 and S 1) are not in
box is shown in Figure. The operation of mesh with any gears as shown in Figure.
3 - Gear Box 41

BAE_ENG_Chapter_03.indd 41 12/10/2019 11:28:14 AM

 All gears in the shafts 1,2& 3,4 clutches are not in engagement with any
& 5,6 & 7,8,9 rotate. However the main of the gears. Hence rotational power is
output shaft does not rotate as the dog not transmitted.

Figure 3.5.3.1  Neutral condition S1 and S2 are held stationary

First gear Now t h e r o t at i o n a l p o w e r i s

By actuating the gear shift lever, transmitted to the main shaft through
the synchronizer S 1 is moved towards left the dog clutch. Now the speed is low.
side as shown in Figure 3.5.3.2 to engage The power transmission from the clutch
gear 7 in the main shaft. shaft to the output shaft is by gear 1-2 is

Figure 3.5.3.2  First gear condition

3 - Gear Box 42

BAE_ENG_Chapter_03.indd 42 12/10/2019 11:28:14 AM

 means rotational power is transmitted to gear 8 in the output main shaft. Now the
main shaft by 1-2-4-7-S 1. rotational power is transmitted to the
main shaft through the synchronizer S 2.
Second gear Now the speed of the main shaft is higher
For obtaining the second gear, by than the speed of the first gear. The power
actuating the gear shift lever, the synchronizer transmission from the clutch shaft to the
S 2 is moved towards right to engage the output shaft is through the gears 1-2-3-8-S2.

Figure 3.5.3.3  Second gear condition

Third gear the output shaft rotates at the speed same

To achie ve t he t hird ge ar t he as the clutch shaft speed. The rotational
synchronizer S 2 is moved left to engage power is transmitted to the main shaft
with the clutch shaft gear directly. Now directly through the gear 1-S 2.

Figure 3.5.3.4  Third gear condition

3 - Gear Box 43

BAE_ENG_Chapter_03.indd 43 12/10/2019 11:28:15 AM

 Reverse Speed in the main shaft the idler gear changes the
To obtain the reverse gear, the direction of rotation of the gear 6 in the
synchronizer S1 is actuated to move right main shaft. Now the vehicle moves in the
towards the reverse gear 6 to engage as shown reverse direction. The power transmitted
in Figure 3.5.3.5. As the idler gear is placed from the clutch shaft to the main shaft is
between the gears 5 in the lay shaft and 6 through gears 1-2-5-Idler-6-S1.

Figure 3.5.3.5  Reversed gear condition

3.5.4  Synchronizing unit power to the main shaft. The cone 2 is

In synchronizing unit two cone locked under different states by the ball
shaped parts are present. One cone is a and spring in the cone 1. It is connected
part of the collar and the second cone is to the gear changing fork in the slot which
a part of the gear. Both the cones rotate is located in the outer sliding sleeve.
at different speeds. An exploded view of
the synchronizer unit is shown in Figure. Uses of synchromesh unit
When the cone 2 is rotated, cone 1. For operating the gears smoothly by
1 start to rotate and move towards the synchronizing two different speeds of
cone 2 and be in contact with the cone 2. the gears.
Because of this action friction occurs in 2. For changing gears easily
the contact area of the cones and hence it 3. No need of double de clutching
increases the speed of gear. Now the both 4. For transmitting power efficiently
cone speeds come to the same. Further 5. Gears will not wear rapidly
moving the collar makes the outer drum 6. Less noise in operation
to contact with the dog clutch in the gear.
Now the rotational power is transmitted De merits of synchromesh unit
to the main shaft. By the same way it 1. Low cost
moves on left hand side and contacts 2. Maintenance is difficult
with the another gear and transmits the 3. Difficult repair
3 - Gear Box 44

BAE_ENG_Chapter_03.indd 44 12/10/2019 11:28:15 AM

 Ring Synchronizer
Key spring
grooves sleeve Speed gear

Synchronizer Clutch hub Synchronizer

ring ring

Figure 3.5.4  Exploded view of a synchronizer unit

3.6. P
 roperties of gear N 2 = speed of the Driven gear
box T 1 = No of teeth’s in driver gear
1. Gear box should have long life. T 2 = No of teeth’s in driven gear
2. Noise should be lower in the gear box. 12 Teeth

3. Fitting the gears in the gear box should

be simple. 8 Teeth
4. Replacing the worn out and broken
parts should be easy in the gear box.
5. It should transmit the torque and
speed according to the requirement.
Drive
gear
3.7 Gear Ratio Driven
gear

The ratio between the speed of the Figure 3.7  Gear ratio
driver gear to the speed of the driven
gear is called as the gear ratio or it is a
3.8 Over drive
ratio between number of gear teeth in the
The method of increasing the speed of
driver gear to the number of gear teeth
propeller shaft more than that of the engine
in the driven gear.
speed is called as the over drive. A view of
N2 T
rG = or 2 the overdrive can be seen in Figure 3.8 (a).
N1 T1

Gear ratio = c lutch shaft speed / main Outer ring gear

shaft speed
speed of the driven gear
Gear ratio = or Orbiting planetary gears
speed of the driven gear
No of teeth’s in driven gear
No of teeth’s in driven gear Center sun gear

Where,
r G = Gear Ratio Figure 3.8 (a)  A view of automobile
N 1 = speed of the Driver gear overdrive
3 - Gear Box 45

BAE_ENG_Chapter_03.indd 45 12/10/2019 11:28:16 AM

 One two-wheeler comes out of the production line every two seconds
in India

The part which performs this action to the gear box. It is placed in between
is called as the overdrive unit. If the main the gear box and the propeller shaft.
shaft in the gear box rotates at higher
speed than the clutch shaft, then the Construction
transmission system is said to be with the In over drive two shafts are present.
over drive. Over drive unit is fixed next They are input shaft and output shaft.
3 - Gear Box 46

BAE_ENG_Chapter_03.indd 46 12/10/2019 11:28:16 AM

 Input shaft is the main shaft of gear box. train, a sun gear, three planet gears, a
Output shaft is the propeller shaft. The planet carrier and a ring gear are present.
parts of the overdrive can be seen in This can be seen in the above Figure.
Figure 3.8 (b).
Working Principle
The casing is stationary when the
sun gear is locked with casing. Now the
overdrive unit starts functioning and the
speed of the output shaft is increased.
When the sun gear is locked with the
planet carrier, the usual input shaft speed
is given to the output shaft.

Advantages of overdrive
1. Engine life is increased
2. Achieves reduction in fuel consumption.
3. Less vibration
4. Low noise
Figure 3.8 (b)  Parts of overdrive
5. Excess gear ratio can be achieved
An epicyclic gear train is mounted 6. Wear of engine is lower.
on the input shaft. In this epicyclic gear 7. Connecting over drive unit is easy.

Trouble shooting of gear box

1. Gear box noise
Causes Remedies
1. Bearing may get damaged Need to change bearing
2. Lubricating oil level may be low Fill the required amount of lubricating oil
3. Teeth’s may be broken in the gear Need to change the gear
4. Misalignments between gearbox and Need to correct it
engine

2. Hard Gear Shift

Causes Remedies
1. Improper clutch adjustments Need to correct it
2. The spring in the gear changing arrangement may Need to change with a new
not working spring
3. There may be sticking or jamming in the main shaft Should correct the shaft
4. There may be a sticking of fork in the gear shifting Need to clean and lubricate.
system

3 - Gear Box 47

BAE_ENG_Chapter_03.indd 47 12/10/2019 11:28:16 AM

 3. Gear slip
Causes Remedies
1. Fork in the gear shifting mechanism may Have to correct it
not be working
2. Dog clutch in the gearbox or synchronizer Need to change with a new one
may have worn out
3. Spring in the gear shifting mechanism Have to change the spring
may have loosened
4. Gears in the main shaft may have Need to change the gear with a new one
worn out

4. Lubricating oil leakages in the gear box

Causes Remedies
1. Fault in the oil seal in the gear box Have to change with a new oil seal
2. Lubricating oil level may be higher than Need to discharge the excess oil
the required amount
3. Oil leakage seal may be broken Need to change with a new one
4. There may be loosen in bolts on the Gear Need to tighten it
box cap

3.9 Parts of the gear box 3.9.2 Gear box input or clutch

3.9.1  Gear box housing shaft
The Box like arrangement where It is connected with the clutch plate
the bearings (which support the shafts) at one end supported by the flywheel and
are mounted, filler plug with air vent hole, a gear fitted at the other end. The view
oil drain plug are present is called as the of input shaft can be seen in Figure 3.9.2.
gear box housing. This box is generally
made of cast iron as shown in Figure 3.9.1.

Figure 3.9.1  Gear box housing Figure 3.9.2.  Gear box input shaft
3 - Gear Box 48

BAE_ENG_Chapter_03.indd 48 12/10/2019 11:28:17 AM

 3.9.3  Lay shaft The picture of a speedometer drive can
It is mounted at the bottom of be seen in Figure 3.9.6.
the gear box casing. Different gears are
mounted on the lay shaft depending on
the speed of the gear box. The picture
of lay shaft can be seen in Figure 3.9.3.

Figure 3.9.3  The picture of a lay shaft of Figure 3.9.6  A picture of a speedometer
an automobile gear box drive

3.9.4 Gear box output shaft or 3.9.7  Gear selector mechanism

main shaft On the top of the gear box, an
It is located at the top of the gear box arrangement with a lever with a gear
casing at straight line with the input shaft. knob, selector rod and shifting fork are
Slots are present in this shaft. Through connected. This arrangement is called as
this shaft the power is transmitted to the the gear (shifting) selecting mechanism.
propeller shaft. Gear selector mechanism is used for
selecting the required gear for the required
3.9.5  Reverse gear shaft speed of the vehicle. The picture of a
gear selector mechanism can be seen in
The smallest shaft in the gear box
Figure 3.9.7.
is the reverse gear shaft which has only
one gear called as the idler gear. It is
fitted on the gear box casing. This shaft
is used for transmitting the power from
the lay shaft to the main shaft.

3.9.6  Speedometer drive

Skew gear is connected with the
main shaft. With the skew gear a cable
with a small gear is connected at one end
and the other end of the cable is fitted at
the dashboard of the driver. This drive is
used for knowing the speed of the vehicle. Figure 3.9.7  Gear selector mechanism
3 - Gear Box 49

BAE_ENG_Chapter_03.indd 49 12/10/2019 11:28:17 AM

 Types of gear shift mechanisms The transfer case is fitted on the
1. Floor gear shifting Mechanism vehicles with four wheel drive. This
2. Steering Gear Shifting Mechanism arrangement is generally used in military
vehicles and jeeps. A photographic view
Floor gear shifting mechanism of an automobile transfer case can be seen
If the gear shifting mechanism is located in Figure 3.11.1.
at the top of the gearbox, then it is called
as the floor gear shifting mechanism
Steering gear shifting mechanism
If the gear shifting mechanism is located
at the sideway of the steering column, then
it is called as the steering gear shifting
mechanism

3.10 G
 ear box lubrication
1. In the gear box, lubricating oil of SAE Figure 3.11.1  Photographic vie of an
90 has to be filled. automobile transfer case
2. The lubricating oil must be filled until
Construction
the lay shaft is (dipped) covered by the
oil. The lubricating oil must be highly In the main shaft of the gear box
viscous. two gears are present. Between the two
3. When the gears are rotating, the gears a sliding gear is present. The gear
lubricating oils is sprayed on all the in the main shaft is in mesh with the
parts of the gear box and lubricated. idler gear. With this front axle drive gear
4. After 1000 kilo meters of the vehicles and rear axle drive gear are connected. A
run lubricating oil top up must be done. clutch is fitted with the front axle drive
5. After 10000 kilometers of the vehicle gear. The important parts of the transfer
the lubricating oil must be completely case can be seen in Figure 3.11.2.
replaced by the new lubricant.
6. To pour the oil filler cap is provide on Operation
the top of the gear box. An air vent is With the help of the gear shift
also provide to allow the atmospheric mechanism when the sliding gear in the
air to enter. main shaft is shifted to right or left, through
7. A drain plug is provided at the bottom the idler gear the power is transmitted
of the gear box to drain the lubricating to the front or rear wheels with low or
oil. high speeds. In addition to this, when
there is no need for drive power to the
3.11 Transfer case front wheels, with the help of the clutch
The arrangement used for arrangement the drive power can be
transmitting the engine’s power to all the disengaged. If necessary the four wheel
four wheels is called as the transfer case. drive can be also obtained.
3 - Gear Box 50

BAE_ENG_Chapter_03.indd 50 12/10/2019 11:28:17 AM

 Figure 3.11.2  Important parts of a transfer case

Student Activity

1. To collect news papers, owners manual and service manual and submit the information
regarding the gear box.
2. Ask the students to visit nearby workshop to collect and submit the trouble shooting
procedure of the gear box used in two wheelers.
3. Ask the students to visit nearby heavy vehicle workshop to collect and submit the gear
ratio, number of speed and type of gear box used in the heavy vehicles.

G Glossary

1. Gear – பற்சக்கரம்
2. Gear box – பற்சக்கர பெட்டி
3. Lever – சுண்டி
4. Shaft – தண்டு
5. Axis – அச்சு
6. Idle Gear – பயனற்ற பற்சக்கரம்
7. Main Shaft – முக்கிய தண்டு
8. Link – இணைப்பு
9. Cable – வடம்
10. Gear Ratio – பற்சக்கர விகிதம்
11. Counter Shaft – இடைச் சுழல் அச்சு
12. Spur Gear – நேர் பற்சக்கரம்

3 - Gear Box 51

BAE_ENG_Chapter_03.indd 51 12/10/2019 11:28:18 AM

 References

1. S.K. Gupta, A Text Book of Automobile Engineering, S. Chand and Company, New
Delhi, ISBN 978-93-837-4691-0, First Edition 2014, Reprint 2016.
2. Automobile Engineering, 2nd Edition, Sci Tech Publications (India) Pvt Ltd, 2011.
Ramalingam. K.K.
3. Kirpal Singh, Automobile Engineering, Vol 1, Standard Publisher and distributor, ISBN
– 13 – 978-8180141966
4. Jack Erjavec- Automotive Technology_ A Systems Approach -Delmar Cengage Learning
(2009) ISBN-13: 978-1428311497
5. James D. Halderman, Automotive Technology, Principles, Diagnosis and service, fourth
Edition, 2012, Prentice Hall, ISBN - 3: 978-0-13-254261-6
6. K.K.Jain and R.B.Asthana, Automobile Engineering, Tata McGraw-Hill Publishing
Company Limited, New Delhi
7. R.K.Rajput, A Text Book of Automobile Engineering, Laxmi Publications, New Delhi.
8. A.K. Babu & Er. Ajit Pal Singh, Automobile Engineering, S.Chand Publishing, New
Delhi.
9. Internal Combustion Engines by V. Ganesan, Tata McGraw-Hill Education, 2004
10. Automotive Mechanics by William Crouse, Donald Anglin

Webliography

1. https://www.brighthubengineering.com/fluid-mechanics-hydraulics/17345-lubricant-
properties-for-a-gearbox-part-two/
2. https://www.anaheimautomation.com/manuals/forms/gearbox-guide.php
3. http://noengwks.org/3-most-common-gearbox-problems/
4. http://noengwks.org/5-types-of-industrial-gearboxes-their-strengths-and-applications/
5. http://knowhow.eriks.co.uk/top-10-tips-for-industrial-gearbox-inspection-and-
maintenance
6. https://khkgears.net/new/gear_knowledge/gear_technical_reference/gear_materials.
html
7. https://www.howacarworks.com/basics/how-manual-gearboxes-work
8. http://www.mech4study.com/2014/03/what-is-gear-box-what-are-main-components-
of-gear-box.html
9. http://mechanicalmania.blogspot.com/2011/07/types-of-gear.html

3 - Gear Box 52

BAE_ENG_Chapter_03.indd 52 12/10/2019 11:28:18 AM

 Evaluation

PART - A

One mark questions

Choose the correct answer 6. The second component of the
transmission system is.
1. The basic principle involved in gear a) Clutch
box operation is. b) Gear Box
a) Friction c) Propeller shaft
b) Faraday’s Lay d) Universal Joint
c) Pascal’s Law
7. Reducing the rotational speed and
d) Lever
increasing the torque is done by.
2. The type of gear used in sliding a) Clutch
mesh gear box is. b) Gear Box
a) Bevel Gear c) Propeller shaft
b) Spur Gear d) Universal Joint
c) Worm Gear
d) Helical Gear 8. The gear oil must be replaced for
every ______ kilometers.
3. Top Gear Ratio is. a) 1000
a) 2:1 b) 2000
b) 1:2 c) 5000
c) 1:1 d) 10000
d) 1.5:1
9. The gear Box which
4. The method of increasing the transfers the power through the
vehicle speed than the engine speed dog clutch is.
is called as. a) A Sliding mesh Gear Box
a) Power change method b) Constant Mesh Gear Box
b) Overdrive c) Synchromesh Gear Box
c) Gear Ratio d) Epicyclic Gear Box
d) Synchronizing
10. The part in between the clutch and
5. The lubricating oil used in gear propeller shaft.
box is. a) Engine
a) SAE 50 b) Gear box
b) SAE 60 c) Differential
c) SAE 90 d) Real axle
d) SAE 120

3 - Gear Box 53

BAE_ENG_Chapter_03.indd 53 12/10/2019 11:28:18 AM

 PART – B

Three mark questions

1. List out the types of gears used in 6. What are all the types of gear
gear boxes. boxes?
2. What is the need of gear box? 7. What is meant by gear ratio?
3. Where is the location of gear box? 8. What is meant by over drive?
4. Explain the advantages of sliding 9. What is called gear box?
mesh gear box.
10. What are the disadvantages of
5. What are all the general types of sliding mesh gear box?
gears?

Part - C

Five mark questions

1. Describe about spur gear. 3. Describe about synchromesh Unit.

2. Explain the advantages and 4. What are the advantages and
disadvantages of constant mesh disadvantages of synchromesh gear
gear box. box?
5. Write about Bevel gear?

Part - D

Ten mark questions

1. Explain the sliding mesh gear box 3. Explain the synchromesh gear box
construction and working principle construction and working principle
with neat diagram. with neat diagram.
2. Explain the Constant mesh
gear box construction
and working principle with neat
diagram.

3 - Gear Box 54

BAE_ENG_Chapter_03.indd 54 12/10/2019 11:28:18 AM