MANUAL TRANSMISSIONS/ TRANSAXLES
Contents
1. lead chnology Fifth Edition P E A RS O N nan ALWAYS LEARNING Automotive Te James Halde rr EPI MANUAL TRANSMISSIONS TRANSAXLES B TA Figure 122 26 In second gear the 1 2 synchronizer sleeve is moved forward which locks the second speed gear to the output shaft SECOND GEAR _ Automotive Technology Fifth Edition P ALWAYS LEARNING oY James Halderman EARSON 10 rr IEP MANUAL TRANSMISSIONS TRANSAXLES B TA Figure 122 27 To achieve third gear the shaft linkage first centers the 1 2 synchronizer sleeve and then moves the 3 4 synchronizer sleeve rearward locking third speed gear to the output shaft THIRD GEAR hnology Fifth Edition P E A RS 0 N an ALWAYS LEARNING Ufomotive James Hald ETE IEP MANUAL TRANSMISSIONS TRANSAXLES a Ta Figure 122 28 In fourth gear the 3 4 synchronizer sleeve is moved forward which locks the fourth speed gear to the output shaft FOURTH GEAR err ALWAYS LEARNING Ufomotive James Hald hnology Fifth Edition P E A RS 0 N man ETE IEP MANUAL TRANSMISSIONS TRANSAXLES EO Figure 122 29 To achieve fifth gear the shift linkage first centers the 3 4 synchronizer sleeve and then moves the fifth synchronizer sleeve toward the fifth speed gear locking it to the output shaft FIFTH GEAR ALWAYS LEARNING 4Utomotive Technology Fifth Edition P E A RS O N James Hald man ed EPI MANUAL TRA2. Edition ALWAYS LEARNING Automotive Technolog Eaton PEARSON MANUAL TRANSMISSIONS TRANSAXLES gt __ TA Figure 122 11 Idler gears affect the direction of rotation in a gear train but not the final drive ratio FLOATING OR IDLER GEAR DRIVEN DRIVE GEAR GEAR ALWAYS LEARNING Automotive Technology Fifth Edition James Halderman PEARSON ETE IEP MANUAL TRANSMISSIONS TRANSAXLES a MO B TA Figure 122 12 Gears apply torque in the same way a wrench applies torque the force applied multiplied by the distance from the center of the gear equals the torque TORQUE 20 LB FT Automotive gy Fifth Edition ALWAYS LEARNING Uu PEARSON rr 2 MANUAL TRANSMISSIONS TRANSAXLES O dE y Figure 122 13 A lever can be used to multiply torque but it does so at the expense of distance or speed OUTPUT DISTANCE DISTANCE 1 FOOT FULCRUM ogy Fifth Edition PEARSON ALWAYS LEARNING EC EHEC James Halderman ETE EPI MANUAL TRANSMISSIONS TRANSAXLES do Figure 122 14 Cross section of a five speed manual transmission showing the main parts GHFT LEVER SFT COVEN ASSEMRLY EETERTION HORING J ee TPT GATT SERAIT MATT IMANSERU HON CASE Automotive Technology Fifth Edition p ALWAYS LEARNING oY James Halderman EARSON 2 MANUAL TRANSMISSIONS TRANSAXLES do Figure 122 15 Cutaway of a six speed manual transmission showing all of its internal parts Automotive Tec
3. TECH TIP ALWAYS LEARNING ZA bo MG Fifth Edition PEARSON ETE EPI MANUAL TRANSMISSIONS TRANSAXLES gt a Figure 122 40 It often requires two people to assemble a transaxle because the shaft with the shifter forks needs to be placed into the case as an assembly as on this unit Ge HOE o diatu URRE e j Automotive Technology Fifth Edition D ALWAYS LEARNING 9y James Halderman EARSON ETE IEP MANUAL TRANSMISSIONS TRANSAXLES Ta Figure 122 41 a During the disassembly of any manual transmission transaxle carefully check for the location of the snap rings Often they are hidden Consult the factory service manual or unit repair manual for information and procedures for the unit being serviced Lael a Automotive Technology Fifth Edition P ALWAYS LEARNING oY James Halderman EARSON ETE GE MANUAL TRANSMISSIONS TRANSAXLES e Figure 122 41 b Using snap ring pliers to remove a snap ring Many snap rings have an up side Be sure to reinstall any snap rings in the correct direction Automotive Technology Fifth Edition P ALWAYS LEARNING IY James Halderman EARSON 16 EPI MANUAL TRANSMISSIONS TRANSAXLES Figure 122 41 c After the snap ring is removed some components can be simply lifted off the main shaft while other gears may require the use of a press ALWAYS LEARNING 4utomotive Technology Fifth Edition P E A RS O N James Halderman IEP MANUAL
4. TRANSMISSIONS TRANSAXLES Figure 122 42 a Many gears require that a hydraulic press be used to separate the gear s from the shaft After double checking that all snap ring retainers have been removed and after checking in the service manual to see which gear needs to be pressed off carefully position the bearing splitter as far inward as possible to avoid damaging the teeth during the pressing operation ia ALWAYS LEARNING 4Utomotive Technology Fifth Edition D E A RS O N James Halderman GE MANUAL TRANSMISSIONS TRANSAXLES TA Figure 122 42 b For safety place an old brake drum over the gear s being pressed off If the gear were to shatter the parts will be trapped inside the brake drum ALWAYS LEARNING 4Utomotive Technology Fifth Edition P E A RS O N James Halderman 17 EPI MANUAL TRANSMISSIONS TRANSAXLES dk b Figure 122 42 c Some transmission disassembly and reassembly procedures require the use of special pullers such as this tool being used on a NV 4500 transmission Automotiv OO Fifth Edition ALWAYS LEARNING James Halderman PEARSON ETE GE MANUAL TRANSMISSIONS TRANSAXLES GA LAL WORLD Fin i i The Worn Gift Fort Mystery A wahisi equ ped pt a manual UKITU Nag DO Ee rtuz berrea rr buz mur iu beko Ter Hun He eaten Ur pegi Erai Pr The repe Seat fee itame eri Hz mein Oen Derri ore Corer re bur Me rira batiows A jer br rgranrn Ixilen TE pre uit to wee A pen pr or urdail
5. The synchronizer ring stop ring engages the cone on the speed gear causing both assemblies to reach the same speed 4 The shift is completed when the internal teeth of the sleeve mesh with the gear clutch teeth of the speed gear SLEEVE stor SPEED DEA RLERVE CONTACTS X ANG STOP ANG G FULL ENOAQEMENT STOP FONG iS PUSHED INTO GEAR Cont ALWAYS LEARNING 4Utomotive Technology Fifth Edition P EA RS O N James Halderman rr EPI MANUAL TRANSMISSIONS TRANSAXLES FREQUENTLY ASKED QUESTION What Do the Keys Do The keys are there to limit the amount of rotation of the ring from 1 2 tooth misaligned in the forward direction to 1 2 tooth misaligned in the coast direction so that both upshifts and downshifts can be made The detent key springs are designed to push up on the keys which have a bump on them that aligns with a notch in the inside center of the sliding sleeve This upward pressure tends to keep the sliding sleeve in the neutral position and prevents unwanted movement toward another unwanted gear Automotive Technology Fifth Edition P ALWAYS LEARNING 9Y James Halderman EARSON rr ZEZ MANUAL TRANSMISSIONS TRANSAXLES UTE Figure 122 22 Before reassembling the transmission transaxle carefully inspect the splines on gn the synchronizer sleeves for wear The shape of the splines helps prevent the transmission transaxle from jumping out of gear during acceleration and decelera
6. right the output shaft center and the input shaft left plus the shift linkage are installed and checked for proper positioning SS ALWAYS LEARNING Neal de GO Fifth Edition PEARSON 29 MANUAL TRANSMISSIONS TRANSAXLES Sk JEA NV 350 TRANSAXLE SERVICE 16 The case halves being reinstalled The bearings top must be pressed back onto the input and output shafts using a press ALWAYS LEARNING E Fifth Edition ALWAYS LEARNING MANUAL TRANSMISSIONS TRANSAXLES PEARSON PEARSON NV 350 TRANSAXLE SERVICE 18 The completed assembly Notice the bearing cover top has already been installed ALWAYS LEARNING Fifth Edition PEARSON 30
7. rreran ATXI b Tn bch Sven Ere Pamane jaku E t i pururik eien TST were Lik fu letter el Ie alii tarta wes garri m Afs fu Pura pri he serve ISTE rice sith Me cuntorer t sss thie cole Chuti be determine Ac fe sore ITR got Pin the dnem t seer re cloced ter hele of her pyne cower thee pile on Ore loer swi db the azor ty Parry burn thee stille The he Durumu porke tee urare If ate Mk EE TEK bal Tp Lee nr Eo le aal a rie pn reu Ie Har Dra hw mielga De ebe i ile wom Edi torts Ths prus arriz s hons on Ea ISTE Gi the tma Tisa terete DUT jhe MD IKZ pI fhe rn TTUT paren Hegia the chesse prates st the iyne lhe veica ju m ete ter the thi tn err qichiy pren The merece be Trat eid have gerrari Me pri cane of Pe protien sir Be fort repar The tudi r be Tesi a li Mz Tegi prse po MS De Tide Where Ou adi Peet Ea Automotive Technology Fifth Edition p ALWAYS LEARNING IY James Halderman EARSON ETE IPI MANUAL TRANSMISSIONS TRANSAXLES b Pd E Figure 122 43 Some manual transmissions transaxles require synchromesh transmission fluid e uae CAUTION ui Tra I CAUSE IYE ESTAITT eri tre ory Vocternery on i f HEI oy gua ONTENTS ONE j EA _ ee ALWAYS LEARNING 4Utomotive Technology Fifth Edition PEARSON James Halderman 18 MANUAL TRANSMISSIONS TRANSAXLES TECH TIP ALWAYS LEARNING Fifth Edition PEARSON MANUAL TRANSMISSIONS TRANSAXLES Figure 122 44 Headless long bolts can be used to help install a transmis
8. the stop ring synchronizer ring against the cone area of the speed gear The friction between the stop ring and the speed gear causes the speed of the two to become equal permitting the sleeve to engage the gear clutch teeth of the speed gear When this engagement occurs the shift is complete SYNCHRONIZER CLUTCH GEAR SPEED SLEEVE TEETH GEAR STOP RING Automotive Technology Fifth Edition p ALWAYS LEARNING IY James Halderman EARSON rr EPI MANUAL TRANSMISSIONS TRANSAXLES ALWAYS LEARNING E motiv no Fifth Edition PEARSON ETE IEP MANUAL TRANSMISSIONS TRANSAXLES hr Figure 122 20 Synchronizer keys are attached to the clutch hub and push against the 5 synchronizer ring when the sleeve is being moved during a shift Notice the grooves on the synchronizer ring These grooves prevent lubricating oil from becoming trapped between the ring and the cone surface of the speed gear The grooves also help the ring release from the cone surface when a shift is made out of a gear DETU ODOL ESTE alda KEY SPRINGS GROOVES SLEEVE GEAM ZANTZU mun chnology Fifth Edition D E A RS OO N nan ALWAYS LEARNING Automotive Te James Halde ETE GE MANUAL TRANSMISSIONS TRANSAXLES EE Figure 122 21 A shift sequence starts when the shift fork is moved by the driver 1 applying a force on the sleeve that moves it toward the speed gear 2 The sleeve and the inserts contact the stop ring blocking ring 3
9. AL TRANSMISSIONS TRANSAXLES tr Aia om NV 1500 MANUAL TRANSMISSION SERVICE 6 The shift shaft and forks can now be removed ALWAYS LEARNING Automotiv chno Fifth Edition PEARSON James d nan IPI MANUAL TRANSMISSIONS TRANSAXLES a Pd A D y NV 1500 MANUAL TRANSMISSION SERVICE 7 The reverse idle gear is unbolted from the case and removed ALWAYS LEARNING 4vtomotiv chnology Fifth Edition P E A RS O N 21 02 MANUAL TRANSMISSIONS TRANSAXLES a IIT NV 1500 MANUAL TRANSMISSION SERVICE 8 The output shaft assembly fifth gear far left and the synchronizer assemblies Automotive Technology Fifth Edition ALWAYS LEARNING James Halderman PEARSON IEP MANUAL TRANSMISSIONS TRANSAXLES a s IIT NV 1500 MANUAL TRANSMISSION SERVICE 9 The bearing is being removed using a bearing splitter and a hydraulic press Automotiv chnology Fifth Edition ALWAYS LEARNING James Halderman PEARSON EPI MANUAL TRANSMISSIONS TRANSAXLES EE NV 1500 MANUAL TRANSMISSION SERVICE 10 A speed gear bottom along with the double gi row needle bearing used between the shaft and the speed gear The hub center is splined and rotates with the output shaft B EA Ld Automotive Technology Fifth Edition ALWAYS LEARNING gida D ARESO N James Halderman E 22 d dia NV 1500 MANUAL TRANSMISSION SERVICE 11 A synchronizer assembly being reassembled It often takes several hands to hold the hub center and the s
10. ETE GE MANUAL TRANSMISSIONS TRANSAXLES e Figure 122 4 A pinion gear meshed with an internal ring gear rotates in the same direction around a parallel axis of rotation Co wor PINION GEAR OA o amp e dd Ze E INTERNAL RING GEAR ALWAYS LEARNING GON Fifth Edition PEARSON MANUAL TRANSMISSIONS TRANSAXLES Figure 122 5 When two external gears mesh they rotate in opposite directions DRIVEN GEAR ALWAYS LEARNING Fifth Edition PEARSON pra EZK a de Figure 122 6 Bevel gears are often used to change the direction of rotation and are typically used in differentials ALWAYS LEARNING A a d PEARSON MANUAL TRANSMISSIONS TRANSAXLES PINION GEAR ALWAYS LEARNING a dre 3 Fifth Edition PEARSON 2 MANUAL TRANSMISSIONS TRANSAXLES Figure 122 8 Gear ratio is determined by dividing the number of teeth of the driven output gear 24 teeth by the number of teeth on the driving input gear 12 teeth The ratio illustrated is 2 1 24 TEETH ON DRIVEN GEAR ALWAYS LEARNING Ufomotive James Hald PEARSON MANUAL TRANSMISSIONS TRANSAXLES Figure 122 9 This gear combination provides a gear reduction of 3 1 24 TEETH ALWAYS LEARNING 4Ufomotive Ti Fifth Edition Halderma Segi PEARSON rr 02 MANUAL TRANSMISSIONS TRANSAXLES edi E EE Figure 122 10 This gear combination provides an overdrive ratio of 0 33 1 24 TEETH DRIVEN af GEAR DRIVE GEAR Automotive hnology Fifth
11. MANUAL TRANSMISSIONS TRANSAXLES ALWAYS LEARNING Automotive Technology Fifth Edition James Halderman ALWAYS LEARNING Automotive Technology Fifth Edition James Halderman ALWAYS LEARNING Automotive Technology Fifth Edition James Halderman PEARSON PEARSON PEARSON rr GE MANUAL TRANSMISSIONS TRANSAXLES FREQUENTLY ASKED QUESTION What ts the Difference Between a Transmission and a Transaxle A transmission is used on rear wheel drive vehicles whereas a transaxle is usually used on front wheel drive vehicies A vehicle equipped with a transmission uses a separate differential to split the torque equally to the drive wheels A transaxle includes a differential assembly In a transaxie the differential sometimes called the final drive unit is Incorporated in the construction of the transmission Automotive Technology Fifth Edition P ALWAYS LEARNING 9Y James Halderman EARSON ETE GE MANUAL TRANSMISSIONS TRANSAXLES a gt A y Figure 122 3 A spur gear has straight cut teeth This design is very strong and is used where strength is important Spur gears are noisy during operation Helical cut gears on the other hand operate quietly but create a force in line with the axis of the gears due to the angle of the gear teeth SPUN GEAR AXIAL THAUST WRLICAL GEAR OF ORIVEN GEAR AMAL THRUST OF Derived GOLAN Automotive Technology Fifth Edition D ALWAYS LEARNING 9Y James Halderman EARSON
12. NSMISSIONS TRANSAXLES gt ITA Figure 122 30 Torque flows through the transmission in reverse gear Note that the idler gear drives the 1 2 synchronizer sleeve gear which is splined to the output shaft REVERSE ALWAYS LEARNING 4Utomotive Technology Fifth Edition P E A RS O N James Halderman IEP MANUAL TRANSMISSIONS TRANSAXLES Figure 122 31 Cutaway of a T56 six speed transmission showing all of its internal parts ALWAYS LEARNING 4Utomotive Technology Fifth Edition PEARSON James Halderman IPI MANUAL TRANSMISSIONS TRANSAXLES a de Figure 122 32 Notice that this five speed transaxle from a Dodge Plymouth Neon uses synchronizers on both the input and output shafts 3AD 4TH 5TH REVERSE SYNCHRONIZER SYNCHRONIZER ISTAND SYNCHRONIZER SHAFT ALWAYS LEARNING 4vtomotive Technology Fifth Edition P E A RS O N James Halderman 12 EPI MANUAL TRANSMISSIONS TRANSAXLES d pi dde Figure 122 33 Cutaway of a typical manual transaxle showing all of its internal parts including the final drive assembly Automotive Technology Fifth Edition P ALWAYS LEARNING 9Y James Halderman EARSON fr Figure 122 34 When the transmission transaxle is removed from the vehicle the engine must be LK Ta supported In this case the engine oil pan is supported with a block of wood to spread the load across the entire oil pan to prevent damage The block of wood is placed on top of a tall safety stand that a
13. TRANSMISSIONS TRANSAXLES a ne S NV 350 TRANSAXLE SERVICE 9 The gear clutch teeth should be inspected for wear ALWAYS LEARNING gg de MG Fifth Edition PEARSON 2 02 MANUAL TRANSMISSIONS TRANSAXLES AST a NV 350 TRANSAXLE SERVICE 10 An assembled synchronizer assembly containing a sleeve keys springs and detent ALWAYS LEARNING 4utomotiv chno Fifth Edition PEARSON James Hal an ETE IEP MANUAL TRANSMISSIONS TRANSAXLES a EE NV 350 TRANSAXLE SERVICE 11 The input shaft left and the output shaft right are checked for proper assembly before being installed into the case ALWAYS LEARNING ne no Fifth Edition PEARSON IPI MANUAL TRANSMISSIONS TRANSAXLES n nA a NV 350 TRANSAXLE SERVICE 12 The differential bearing preload is determined by measuring for zero end play then adding the thickness shim under the bearing cup Ta b A ALWAYS LEARNING SEO otiv chno Fifth Edition PEARSON 28 MANUAL TRANSMISSIONS TRANSAXLES a bp a NV 350 TRANSAXLE SERVICE 13 The bearing cup is being installed using an installation tool and a hammer ALWAYS LEARNING gb mat B PEARSON d Ja NV 350 TRANSAXLE SERVICE 14 AI of the shift forks and shift arms must be aligned properly before installing the components into the case ALWAYS LEARNING GR i no Fifth Edition PEARSON EE MANUAL TRANSMISSIONS TRANSAXLES f BO NV 350 TRANSAXLE SERVICE 15 All of the components including the differential
14. g center and the input shaft front bearing smaller bearing on the left ALWAYS LEARNING MANUAL TRANSMISSIONS TRANSAXLES berr d TU w ALWAYS LEARNING tomo E hn Fifth Edition PEARSON PEARSON 25 AST Bia NV 350 TRANSAXLE SERVICE 4 The input and output shafts are a press fit into the bearings and are also retained with a snap ring which must be removed ALWAYS LEARNING E motiv 0 Fifth Edition PEARSON IEP MANUAL TRANSMISSIONS TRANSAXLES am i i MIT NV 350 TRANSAXLE SERVICE 5 Using a special tool the input and output shafts are pressed out of the housing using a hydraulic press ALWAYS LEARNING ebe f no Fifth Edition PEARSON IPI MANUAL TRANSMISSIONS TRANSAXLES Ae H5 NV 350 TRANSAXLE SERVICE 6 The input shaft can be disassembled using a bearing splitter and a press or two screwdrivers to pry the gears off the shaft ALWAYS LEARNING egika dee Me Fifth Edition PEARSON 26 MANUAL TRANSMISSIONS TRANSAXLES d Ja NV 350 TRANSAXLE SERVICE 7 This transaxle uses both brass and powdered metal synchronizer rings with a fiber paper inner cone surface w Pia Fifth Edition P E A RS O N ALWAYS LEARNING 1 MANUAL TRANSMISSIONS TRANSAXLES d Aa NV 350 TRANSAXLE SERVICE 8 Synchronizer ring gaps are being measured using a feeler thickness gauge The factory specifications are usually 0 040 in to 0 069 in ALWAYS LEARNING Atomen no Fifth Edition PEARSON ETE EPI MANUAL
15. hnology Fifth Edition P ALWAYS LEARNING IY James Halderman EARSON ETE GE MANUAL TRANSMISSIONS TRANSAXLES FREQUENTLY ASKED QUESTION What ts Meant by a 77 mm Transmission The size 77 mm Gr about 3 inches is the distance between the center of the input shaft and the center of the countershaft The greater this distance the larger the transmission and the more torque it is capable of handling due to the larger gears Automotive Technology Fifth Edition P ALWAYS LEARNING IY James Halderman EARSON ETE EPI MANUAL TRANSMISSIONS TRANSAXLES dde Figure 122 16 Notice that the countershaft and the main shaft both use gears of increasing size that mesh together Automotive Technology Fifth Edition P ALWAYS LEARNING 9Y James Halderman EARSON ETE IEP MANUAL TRANSMISSIONS TRANSAXLES Figure 122 17 A typical shift mechanism showing the shift detents designed to not only give the a driver a solid feel when shifting but also to prevent two gears from being selected at the same time The shifter also prevents shifting into reverse except from the neutral position SHIFT LEYER BALL SOCKET SHIFT FORK Automotive Technology Fifth Edition P ALWAYS LEARNING oY James Halderman EARSON ETE IPI MANUAL TRANSMISSIONS TRANSAXLES 5 Ta Figure 122 18 The shifter fork fits into the groove of the synchronizer sleeve When a shift is e made the sleeve is moved toward the speed gear The sleeve presses
16. leeve outer ring ALWAYS LEARNING d ifth Edition PEARSON 1 MANUAL TRANSMISSIONS TRANSAXLES d H5 NV 1500 MANUAL TRANSMISSION SERVICE 12 A hydraulic press is used to reassemble output shaft and bearing ALWAYS LEARNING Atomom l no Fifth Edition PEARSON 1 MANUAL TRANSMISSIONS TRANSAXLES ao Aa NV 1500 MANUAL TRANSMISSION SERVICE 13 The assembled output shaft is held against the counter shaft to double check that all of the gears have been correctly assembled MO i f JN MK ALWAYS LEARNING oe de MG Fifth Edition PEARSON 23 d Je NV 1500 MANUAL TRANSMISSION SERVICE 14 The assembled output shaft and counter shaft are being reinstalled in the transmission case ALWAYS LEARNING E motiv no Fifth Edition PEARSON Fifth Edition PEARSON ALWAYS LEARNING IPI MANUAL TRANSMISSIONS TRANSAXLES gt da NV 1500 MANUAL TRANSMISSION SERVICE 16 The last step is to assembly the shift lever and check for proper operation in all gear positions ALWAYS LEARNING SEO dde e Fifth Edition PEARSON 24 MANUAL TRANSMISSIONS TRANSAXLES fluid drained place the transaxle on a work surface ALWAYS LEARNING EA ot E hn Fifth Edition MANUAL TRANSMISSIONS TRANSAXLES HE Zk AL NV 350 TRANSAXLE SERVICE 1 After the transaxle has been removed from the vehicle and the PEARSON i l JE NV 350 TRANSAXLE SERVICE 2 The bell housing case half containing the large output shaft front bearin
17. llows room for the service technician to work while standing TALL SAFETY STAND Automotive Technolo Fifth Edition ALWAYS LEARNING James Halderman PEARSON IPI MANUAL TRANSMISSIONS TRANSAXLES a Pd p Aia Figure 122 35 A transmission from a restored muscle car from the 1970s Notice the use of external control rod shift linkage Automotive Technology Fifth Edition P ALWAYS LEARNING 9Y James Halderman EARSON 13 02 MANUAL TRANSMISSIONS TRANSAXLES d ALWAYS LEARNING 4Utomotive Technology Fifth Edition James Halderman ETE IEP MANUAL TRANSMISSIONS TRANSAXLES pm Figure 122 37 a Saturn drive train is removed as an assembly along with the cradle ALWAYS LEARNING Automotive Technology Fifth Edition James Halderman IPI MANUAL TRANSMISSIONS TRANSAXLES e TT ALWAYS LEARNING Automotive Technology Fifth Edition James Halderman Figure 122 36 Typical cable operated shift linkage used on a front wheel drive transaxle PEARSON PEARSON Figure 122 37 b The transaxle can now be easily removed from the cradle and the engine PEARSON 14 MANUAL TRANSMISSIONS TRANSAXLES ALWAYS LEARNING o 0 Fifth Edition PEARSON ETE 2 MANUAL TRANSMISSIONS TRANSAXLES d i b Figure 122 39 The cost to replace these gears may exceed the cost of a replacement transmission ALWAYS LEARNING do OE E Fifth Edition PEARSON rr 1 MANUAL TRANSMISSIONS TRANSAXLES be Lu Ge
18. sion to the engine AFTER CUTTING HEAD OF BOLT CUT SLOT FOR SCREWDRIVER IN END WITH HACKSAW ALWAYS LEARNING GITEA blogy Fin edition PEARSON MANUAL TRANSMISSIONS TRANSAXLES gt A b NV 1500 MANUAL TRANSMISSION SERVICE 1 A NV 1500 five speed manual transmission is used in two wheel drive applications only ALWAYS LEARNING E omo 0 Fifth Edition PEARSON 19 ETE GE MANUAL TRANSMISSIONS TRANSAXLES AS Jie NV 1500 MANUAL TRANSMISSION SERVICE 2 The shifter assembly has been removed Note the roll pin in the center of the shift lever socket ALWAYS LEARNING 4utomotiv chnoloc Fifth Edition D E A RS O N James Hal nan IEP MANUAL TRANSMISSIONS TRANSAXLES d Ma NV 1500 MANUAL TRANSMISSION SERVICE 3 Snap ring pliers are being used to remove the snap ring retaining the input shaft bearing ALWAYS LEARNING Automotiv chno Fifth Edition PEARSON James d nan ETE GE MANUAL TRANSMISSIONS TRANSAXLES ANN Aa NV 1500 MANUAL TRANSMISSION SERVICE 4 The upside down case is being separated showing the countershaft top and shift forks ALWAYS LEARNING 4vtomotiv chnology Fifth Edition P E A RS O N 20 GE MANUAL TRANSMISSIONS TRANSAXLES AL IIT NV 1500 MANUAL TRANSMISSION SERVICE 5 Before further disassembly can be accomplished the shift lever socket roll pin must be driven out using a punch and a hammer ALWAYS LEARNING 4vtomotiv chnoloc Fifth Edition P E A RS O N James Hal nan ETE GE MANU
19. tion i rA INSPECT SPLINES FOR WEAR TORQUE LOCK TORQUE LOCK HELPS CONTROL POP OUT DURING ACCELERATION AND DECELERATION ALWAYS LEARNING 4Utomotive Technology Fifth Edition PEARSON James Halderman rr IEP MANUAL TRANSMISSIONS TRANSAXLES Figure 122 23 A three piece synchronizer assembly This type of synchronizer uses two cones LN TA which helps achieve a smooth shift with less driver effort Many newer transmissions transaxles use a paper lining similar to that of the clutches in an automatic transmission The transmissions transaxles that have these paper linings must use automatic transmission fluid ATF for proper operation and long life Automotive Technology Fifth Edition P ALWAYS LEARNING 9Y James Halderman EARSON rr GE MANUAL TRANSMISSIONS TRANSAXLES 7 B TA Figure 122 24 In neutral the input shaft and the countershaft are rotating if the clutch is engaged clutch pedal up but no torque is being transmitted through the transmission OUTPUT NEUTRAL SHAFT INPUT SHAFT COUNTER SHAFT REVERSE IDLER SHAFT Automotive Technology Fifth Edition P ALWAYS LEARNING oY James Halderman EARSON ETE IEP MANUAL TRANSMISSIONS TRANSAXLES NE Figure 122 25 In first gear the 1 2 synchronizer sleeve is moved rearward locking the first on speed gear to the output shaft Torque is transmitted from the input shaft to the countershaft and then to the output shaft FIRST GEAR
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