Gears and Transmissions

Why Is a Transmission Necessary?

Provide torque multiplication at low speeds Reduce engine RPM at highway speeds Allow the engine to operate within its most efficient RPM range Allows the engine to be disengaged from the rear wheels while the vehicle is not moving (torque converter & clutch)

What Does a Transmission Do?

The basic purpose of a transmission breaks down into 3 parts
Ability to alter shaft RPM Ability to multiply torque Ability to reverse the direction of shaft rotation

How Does the Transmission Produce Torque Multiplication And/or RPM Reduction
Transmissions use gears
Spur Helical Planetary

Gears are able to change the RPM and the torque of the power moving through the transmission as well as the direction of rotation

 Spur
Simplest gear design Straight cut teeth Noisy operation

Types of Gears

Helical
Spiral cut teeth At least two teeth are in mesh at any time
Distributes the tooth load Quieter operation

Planetary
Most complex design Used in almost all automatic transmissions Contains three parts
Sun gear Planet gears Internal gear (ring gear)

How Stuff Works

Power Vs. Torque

Torque measurement of twisting force Power measurement of how quickly work can be done
Power is dependent on torque and RPM Horsepower = Torque x RPM 5252 Mustang Cobra VS. Caterpillar Diesel

How Stuff Works

Gear Ratios
When two gears are in mesh, a gear ratio exists Driven Gear = Ratio Drive Gear Example:
Drive gear has 14 teeth Driven gear has 28 teeth 28 14 = 2:1 ratio (two to one ratio) The drive gear must rotate twice to make the driven gear rotate once

Reversal of Direction
When two gears are in mesh one will spin the opposite direction of the other Idlers are used to reverse direction

Speed Change
The change in RPM from the input gear to the output gear is directly proportional to the gear ratio Example: 3:1 gear ratio
Input gear turns at 900 RPM Output gear turns at 300 RPM

Torque Multiplication
The change in torque from the input gear to the output gear is directly proportional to the gear ratio Example: 3:1 gear ratio
Engine turns input gear at 900 RPM with 50 lb/ft of force Output gear turns driveshaft at 300 RPM with 150 lb/ft of force

Torque Multiplication

1 inch

3 inches

Multiple Gear Ratios

Individual gear ratios can be multiplied to calculate a total gear ratio
Example: Chevy caprice with a TH-350 transmission and a 305 engine
By removing the differential cover and inspecting the gearset you are able to count 10 teeth on the input gear and 41 teeth on the output gear 41 10 = 4.1:1 You are able to find the 1st gear ratio of the TH-350 in a manual which is listed as 2.52:1

Multiple Gear Ratios

Rear end ratio x 1st gear ratio = total gear ratio 4.1 x 2.52 = 10.33:1
This tells us that the engine turns 10.33 revolutions for every 1 revolution of the tires (speed reduction)

Torque multiplication can also be calculated

The 305 engine produces 245 lb/ft of torque at 3200 RPM @ 3200 RPM in 1st gear the torque acting on the rear tires = 230 lb/ft x 10.33 = 2375.9 lb/ft torque !!!

Gear

Engine Output Torque

Engine Speed

Gear Ratio

Transmission Transmission Output Torque Output Speed

1 2

200 ft/lbs 200 ft/lbs

2000 RPM 2000 RPM 2000 RPM 2000 RPM

4:1 2:1

800 ft/lbs 400 ft/lbs

500 RPM 1000 RPM

Underdrive Underdrive

200 ft/lbs

1:1

200 ft/lbs

2000 RPM

Direct Drive

200 ft/lbs

.5:1

100 ft/lbs

4000 RPM

Overdrive

Automatic Transmission I.D.

Most automatics are identified by the oil pan.
Look at the shift indicator to determine if the transmission is a 3-speed, 4-speed etc.

Different transmissions may have been installed in otherwise identical vehicles. Shopkey and other manuals list transmission application by vehicle.

Automatic Transmission I.D.

Automatic Transmission I.D.

GM I.D.
1 2 3 4 5

Aluminum Powerglide TH200 Metric TH350 TH400 TH200-4R TH700-R4, 4L60, 4L60E

14 bolts 11 bolts 13 bolts 13 bolts 16 bolts 16 bolts

4L80E

17 bolts

Planetary Gearsets
Simple planetary gearsets contain three components
Internal (ring) gear / (annulus gear) Planet gears (and carrier) Sun gear

One component will be the drive member, one the driven, and one will be held (except direct drive and neutral) Unlike other types of gears, planetary gears are able to operate on one single axis

Planetary Action
Direct Drive
Any two of the components are driven 1:1 Ratio

Planetary Action
Underdrive
Planet carrier is the output
Minimum reduction
Ring gear is held Sun gear is the input

Maximum reduction
Ring gear is input Sun gear is held

Planetary Action
Overdrive
Planet carrier is the input
Minimum overdrive
Ring gear is the input Sun gear is held

Maximum overdrive
Ring gear is held Sun gear is the input

Planetary Action
Reverse
Planet carrier is held
Underdrive
Ring gear is the output Sun gear is the input

Overdrive
Ring gear is the input Sun gear is output

Sun
Input Held Output Held Input Output

Carrier
Output Output Input Input Held Held

Internal
Held Input Held Output Output Input

Speed
Maximum Reduction Minimum Reduction Maximum Increase Minimum Increase Reduction Increase

Torque
Maximum Increase Minimum Increase Maximum Reduction Minimum Reduction Increase Reduction

Direction
Same as Input Same as Input Same as Input Same as Input Opposite as Input Opposite as Input

Calculating Planetary Gear Ratios

Direct Drive = 1:1 Underdrive
Carrier is output # of sun gear teeth + #of ring gear teeth = Ratio # of teeth on the driving member

Calculating Planetary Gear Ratios

Overdrive
Carrier is input # of teeth on the driven member . = Ratio # of sun gear teeth + #of ring gear teeth

Calculating Planetary Gear Ratios

Underdrive
Carrier is held # of teeth on driven gear # of teeth on driving gear = Ratio