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19 views17 pages

ch1_drive_train

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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 17

Chassis Course 1 Drive Train

Drive Train
Chapter Outline

This chapter explains the mechanism and operation of drive train components.

• Outline
• Clutch
• Transaxle
• Manual Transaxle
• Automatic Transaxle
• Differential
• Propeller Shaft
• Drive Train
• Axle

ã2002 TOYOTA MOTOR CORPORATION. All right reserved.

-1-
Chassis Course 1 Drive Train

Outline

Outline

The drive train transmits the power of the engine to the wheels.
It is broadly divided into the following classifications:

• FF (Front engine Front - wheel drive vehicle)


• FR (Front engine Rear - wheel drive vehicle)
• Manual transmission
• Automatic transmission

HINT:
In addition to FF and FR, there are 4WD (4-Wheel Drive) and MR
(Midship engine Rear-wheel drive) vehicles.

FF
FR
Engine Transaxle Transmission

Drive shaft Propeller shaft Differential

Axle shaft Axle Tires & wheels

(1/2)

Power Transmission

FF (Front-engine Front-wheel drive vehicle) with MT


1.Engine

2.Clutch

3.Manual transaxle

4.Drive shaft

5.Axle

6.Tires & wheels

FF (Front-engine Front-wheel drive vehicle) with AT


1.Engine

2.Torque converter

3.Automatic transaxle

4.Drive shaft

5.Axle

6.Tires & wheels

-2-
Chassis Course 1 Drive Train

FR (Front-engine Rear-wheel drive vehicle) with MT


1.Engine

2.Clutch

3.Manual Transmission

4.Propeller shaft

5.Differential

6.Rear axle

7.Tires & wheels

FR (Front-engine Rear-wheel drive vehicle)with AT


1.Engine

2.Torque converter

3.Automatic Transmission

4.Propeller shaft

5.Differential

6.Axle

7.Tires & wheels

(2/2)

Clutch

Clutch Construction

The clutch of a manual transmission vehicle enables the power of


the engine to be engaged or disengaged by the operation of the
clutch pedal.

Clutch pedal
Push rod
Master cylinder
Hydraulic hose
Release cylinder
Release fork
Clutch cover

(1/1)

-3-
Chassis Course 1 Drive Train

REFERENCE:
Parts of the Clutch

Boot
Release fork
Clip
Release bearing
Clutch cover
Clutch disc
Fly wheel
Diaphragm spring
Pressure plate

(1/1)

Construction Operation Flow

Clutch operation flow


The clutch consists of a portion that operates mechanically to
transmit power, and a portion that utilizes hydraulic pressure to
transmit power.

Mechanical operation
Hydraulic operation

Clutch pedal
Push rod
Master cylinder
Hydraulic hose
Release cylinder
Release fork
Release bearing
Diaphragm spring
Pressure plate
Clutch disc

(1/1)

Transaxle

Transaxle

A transaxle, in which the transmission and differential are


integrated, is used on front-wheel drive vehicles & midship
vehicles.

Transmission
Differential

Input shaft
Output shaft

(1/1)

-4-
Chassis Course 1 Drive Train

Manual Transaxle

Manual Transaxle

A manual transaxle engages and disengages the power and


changes the combinations of the gears that are meshed. As a
result, it can change the power strength, rotational speed, and the
direction of the rotation.

Engine
Clutch
Input shaft
Hub sleeves
Shift lever
Output shaft
Differential
Drive shafts
Tires

(1/1)

REFERENCE:
Manual transaxle operation

• Neutral
• 1st gear
• 3rd gear
• Reverse

Input shaft
Output shaft
Differential

Blue arrow: transmission of power


Red arrow: direction of rotation

The width of arrows expresses the size of torque. The wider the
width of the arrow is, the larger the torque is.

Neutral

-5-
Chassis Course 1 Drive Train

1st gear

3rd gear

Reverse

(1/1)

-6-
Chassis Course 1 Drive Train

REFERENCE:
SMT (Sequential Manual Transmission)
The SMT operates the throttle valve, clutch, and shift operation
during a gear change through a ECU (Electronic Control Unit).

Features:
• There is no clutch pedal.
• Gear changes are effected by operating a switch.

Shift Lever (Switch)


Sensors
ECU (Electronic Control Unit)
Hydraulic pump
Actuator
Engine
Clutch
Transmission

(1/1)

Automatic Transaxle

Automatic Transaxle

An automatic transaxle consists of a torque converter, planetary


gear unit, and hydraulic control system.

It uses hydraulic pressure to automatically shift gears in


accordance with the vehicle speed, accelerator opening, and shift
lever position. Therefore it is unnecessary to shift gears as in the
manual transaxle; it is not even equipped with a clutch.
It also uses a computer to regulate shifting in accordance with the
driving conditions detected by sensors. This system is called ECT
(Electronically Controlled Transmission).

Torque Converter Oil Pump


Planetary Gear Unit Vehicle speed sensor
Counter gear speed Input turbine speed sensor
sensor
Sensors Engine & ECT ECU
(Electronic Control Unit)
Solenoid valves Hydraulic Control Unit
Shift Lever

(1/1)

REFERENCE:
Full hydraulically-controled automatic transaxle

The construction of the full hydraulically-controlled automatic


transaxle is basically the same as the ECT (Electronically
Controlled Transmission). However, this transaxle mechanically
controls shifting by detecting the vehicle speed hydraulically from
the governor valve, and detects the accelerator opening from the
amount of movement of the throttle cable.

Torque Converter
Oil Pump
Planetary Gear Unit
Governor valve
Accelerator pedal
Engine
Throttle cable
Hydraulic Control Unit
Shift Lever

(1/1)

-7-
Chassis Course 1 Drive Train

Torque Converter

The torque converter of an automatic transaxle vehicle transmits


the power of the engine to the transaxle by utilizing the force of
the fluid. Its principle can be equated to a pair of fans that face
each other. One fan blows air to turn the other fan. The rotation of
the pump impeller applies a centrifugal force to the fluid, which
transmits the power to the turbine runner.

HINT:
There is also a type of torque converter that has a lockup
mechanism to mechanically transmit the power without using the
fluid. This is accomplished by the operation of the clutches that
switch the paths of power transmission, and by directly coupling
the turbine runner with the front cover.

Pump impeller (from engine) Turbine runner


(to transaxle)
Stator Front cover
Lockup clutch

(1/1)

Oil Pump

The oil pump is driven by the torque converter to supply the


hydraulic pressure that is required for the operation of the
automatic transmission.

Front body
Driven gear
Drive gear

(1/1)

Planetary Gear Unit

This unit shifts the gears in the automatic transmission. It uses


hydraulic pressure to hold one of the three types of gears (pinion
gear, sun gear, or ring gear) stationary in order to create the
following conditions as desired: deceleration, direct coupling, and
reverse rotation.

HINT:
The reference uses a model to explain the operation using
different input and output shafts. In an actual vehicle, the
construction is more complex in order to enable the planetary gear
unit to appropriately shift gears, as shown by the left diagram.

Intermediate shaft Planetary carrier Front sun gear


Rear sun gear Ring gear Pinion gear (short)
Pinion gear (long)

(1/1)

-8-
Chassis Course 1 Drive Train

REFERENCE:
The shifting operation is explained by a model comprising a set of
planetary gears.

Deceleration

Power input: ring gear


Power output: planetary carrier
Stationary: sun gear

When the sun gear is held stationary, only the pinion gear rotates
and revolves. Therefore, the output shaft decelerates in proportion
to the input shaft only by the rotation of the pinion gear.

(1/1)

Direct Coupling

Power input: sun gear, ring gear


Power output: planetary carrier

Ring gear rotates with the locked planetary carrier, the input and
output shafts rotate at the same rate.

(1/1)

Reverse Rotation

Power input: sun gear


Power output: ring gear
Stationary: Planetary carrier

When the planetary carrier is fixed in position and the sun gear
turns, the ring gear turn on its axis and the rotational direction is
reversed.

HINT:
The reference uses a model to explain the operation using
different input and output shafts. In an actual vehicle, the
construction is more complex in order to enable the planetary gear
unit to appropriately shift gears, as shown by the left diagram.

(1/1)

-9-
Chassis Course 1 Drive Train

Hydraulic Control Unit

This component controls the hydraulic (line) pressure that


operates the planetary gear unit.

Representative valves
Primary regulating valve
Regulates the hydraulic pressure from the oil pump to create line
pressure.

Shift valve
Shifts gears.

Manual valve
Switches the line pressure paths in accordance with the
movement of the shift lever.

Solenoid valve
Switches hydraulic paths to shift gears by receiving the signals
from the ECU (Electronic Control Unit).

Oil pump
Engine & ECT ECU (Electronic Control Unit)
Shift lever

(1/1)

Engine & ECT ECU (Electronic Control Unit)

This computer receives electric signals from the sensors,


transmits them to the solenoid valves in the hydraulic control unit,
and controls the shifting of the gears.

Sensors
Detect the vehicle speed and accelerator opening among other
things, and transmit electrical signals to the ECU.

Representative sensors
Neutral start switch
Detects the shift lever position.

Throttle position sensor


Detects the throttle opening.

Speed sensor
Detects the vehicle speed.

Input shaft speed sensor


Detects the speed of the input shaft.

Engine
Automatic transaxle
Solenoid valve
Shift lever

(1/1)

- 10 -
Chassis Course 1 Drive Train

Differential

Differential

The differential has the following three functions:

Deceleration function
Further decelerates the rotational movement that has been
changed by the transmission in order to increase torque.

Differential function
This function adjusts the rotational differential between the right
and left wheels while the automobile is cornering. Without the
differential function, the tires will slip and the vehicle will not be
able to smoothly complete the turn.

Drive force direction conversion function


(on an FR vehicle)
This function changes the rotational force from the transmission in
a right angle and transmits it to the drive wheels.

(1/1)

Operation

The differential gears consist of side gears and a pinion gear.


These gears automatically regulate the rotational difference
between the right and left wheels while the automobile is
cornering.

FF (Front-engine front-wheel drive vehicle)


FR (Front-engine rear-wheel drive vehicle)

Propeller shaft
Drive gear / Drive pinion
Ring gear
Pinion gear
Side gear
Drive shaft

(1/1)

LSD
(Limited Slip Differential)

A vehicle will not be able to move when one of its wheels


freewheels in the mud, etc, due to the function of the differential.
The LSD restrains the function of the differential in order to apply
the power to both wheels.

(1/1)

- 11 -
Chassis Course 1 Drive Train

REFERENCE:
Types of LSD

Viscous coupling type


This type uses highly viscous silicone oil between disc plates to
transmit torque. When a differential movement is generated in the
differential, a differential limiting torque is generated in the viscous
coupling.

(1/3)

Torque sensing type


This type uses the friction force that is created between the tooth
flank of the worm gear and the thrust washer to restrain the
rotation of the freewheeling wheel and to transmit the rotational
force to the other wheel.

(2/3)

Preload type
This type uses a spring to push the friction material between the
side gear and differential case, and uses the resulting friction to
generate a differential limiting force.

(3/3)

- 12 -
Chassis Course 1 Drive Train

Propeller Shaft

Propeller Shaft (For FR Vehicle)

The propeller shaft transmits the power from the transmission to


the differential on an FR (Front-engine, Rear-wheel drive) vehicle.
Universal joints are used at the areas where the shaft joins in
order to smoothly transmit the power even if the angle of the
propeller shaft changes due to the vertical movement of the
differential.

The propeller shaft comes with two or three joints.


Flexible couplings may be used at the joints.

3-joint type
2-joint type

Universal Joints
Center Bearing
Sleeve Yoke
Flexible Coupling

(1/1)

Universal Joint

This joint smoothly transmits the power by adapting to the joining


angle of the propeller shaft.

Yoke
Spider Bearings
Spider

(1/1)

Drive Shaft

Drive Shaft

The drive shafts transmit the rotation of the engine to the wheels
via the transmission and differential. They are used on vehicles
with drive wheels that are supported by an independent
suspension system.

HINT:
An axle shaft is used on a vehicle with a rigid type suspension.

Differential
Drive Shafts
Axle Shafts
Axle Housing

(1/1)

- 13 -
Chassis Course 1 Drive Train

REFERENCE:
Type of drive shaft joints
Rzeppa (Birfield) Joint
Uses several steel balls and excels in constant velocity
performance.

Tripod Joint
Uses three sliding rollers and is slightly inferior to the Rzeppa joint
in constant velocity performance. It has a simple construction and
can be slid axially.

Cross Groove Joint


Uses several steel balls and excels in vibration, noise, and
constant velocity performance.

Steel balls
Sliding rollers

(1/1)

Axle

Axle

The axle and axle shaft support the wheel and the drive shafts.

A. Tapered roller bearing type


B. Angular ball bearing type
C. Housing type rigid suspension type

A. Tapered roller bearing type


Axle
Tapered roller bearing

- 14 -
Chassis Course 1 Drive Train

B. Angular ball bearing type


Axle shaft (drive shaft)
Axles
Angular ball bearing

C. Housing type rigid suspension type


Axle housing
Axle shaft
Bearing
Wheel hub

Full-floating type
3/4 floating type
Semi-floating type

(1/1)

- 15 -
Chassis Course 1 Drive Train

Exercises

Use the Exercises to check your level of understanding for the material in this Chapter. After answering each Exercise,
you can use the reference button to check the pages related to the current question. When you get a wrong answer,
please return to the text to review the material and find the correct answer. When all questions have been answered
correctly, you can go to the next Chapter.

- 16 -
Chassis Course 1 Drive Train
Exercise
Question-1

Select the name of each part shown in the illustration from the word group below.

a) Clutch release bearing


b) Flywheel
c) Clutch cover
d) Clutch disc

Answer: 1. 2. 3. 4.

Question-2

Which one of the following statements concerning a torque converter is correct?

In a torque converter, the turbine runner rotates to allow the fluid to flow, in order to transmit power to the
n 1.
j
k
l
m
pump impeller.
j 2.
k
l
m
n Similar to the clutch, a torque converter disengages the power.

n 3.
j
k
l
m A torque converter uses a computer to operate the accelerator and clutch while the gear changes.
In a torque converter, the pump impeller rotates to allow the fluid to flow, in order to transmit power to the
j 4.
k
l
m
n
turbine runner.

- 17 -

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