CHAPTER NO. – 1

1. LOCATION OF CLUTCH

2. FUNCTIONS OF CLUTCH

3. TYPES OF CLUTCH

4. PARTS OF CLUTCH

5. CLUTCH PLATE LINING AND MATERIAL

6. CLUTCH ADJUSTMENT

CLUTCH

Clutch is fitted between engine flywheel

and

Clutch/Bell Housing.

LOCATION OF CLUTCH

1. Engine 2. Clutch3. Clutch Paddle4. Transmission

2. FUNCTIONS OF CLUTCH :

To Engage Gear or Disengages gears hence

no Gear Crashing sound occurs.

To Balance vehicle on wheels. While initial

starting the vehicle.

To stop Engine from Stalling (stopping)

while Braking.

To let or not to let power transmit from

Engine to gear Box.

TYPES OF CLUTCH :

Friction Clutch

Single Plate Clutch

TYPES OF CLUTCH :

Friction Clutch

Multi Plate Clutch

1) Wet 2) Dry

Cone clutch Gear free to recive on shaft

Cone clutch sliding on splines in shaft

This face has a lining of some sort

TYPES OF CLUTCH :

Centrifugal Clutch

TYPES OF CLUTCH :

Diaphragm Clutch

Hydraulic Clutch

1. Pressure Plate2. Pressure Plate Cover3. Pressure Spring4. Clutch Plate5. Clutch Lining

Single Plate Clutcho Common type of clutch used in Motor vehicles.o Consist of only one clutch plate mounted on the splines of clutch shaft.o Pressure plate bolted to flywheel through clutch springs.o Clutch plate is gripped between flywheel and pressure plate.o Clutch shaft is connected to the transmission.

Release Lever ForkClutch Plate

Release Bearing

Pressure Plate Assembly

Flywheel

Pilot Bearing

Angage of Single Plate Clutch:

• Clutch remains Engage due to the spring forces.

Disangage of Single Plate Clutch:

• When the clutch pedal is pressed, the pressure

plate moves back against the force of the springs,

and the clutch plate becomes free between the

flywheel and the pressure plate.

Multi Plate Clutch

• When the clutch is operation in an oil both it is

called wet clutch.

• When the clutch is operated dry it is called dry clutch.

Multi plate clutch works in the same way as the

single plate.

• Pressed by strong coil springs

and assembled in a drum .

• Works in the same way as the

single plate clutch, by operating

the clutch pedal.

• Used in heavy commercial vehicles,

racing cars and motor cycles.

Multiplate Wet Clutch

Cone Clutch

• Consist of friction surfaces in the from of cones.

• Engine shaft consists of female cones.

• Male cone is mounted on the splined clutch shaft.

• When the clutch pedal is pressed, the male cone

slides against the spring force and the clutch is

disengaged.

•Heavy in weight hence not used in modern Automobiles

Gear free to recive on shaft

Cone clutch sliding on splines in shaft

This face has a lining of some sort

Centrifugal Clutch

• Uses centrifugal force instead

of springs force.

• No clutch pedal is required for

operating the clutch.

• Clutch is operated automatically

depending upon the Engine

speed.

• Vehicle can be stopped without stalling the Engine.

• Used in Mopeds.

Diaphragm Clutch:

The spring is either tapered

finger type or crown type

and is mounted on the

pressure plate. Clutch plate remains gripped

between the flywheel

and the pressure plate.1. Pressure Plate2. Pressure Plate Cover3. Pressure Spring4. Clutch Plate5. Clutch Lining

Diaphragm Clutch:

It needs no release levers the

spring itself acts as a series of

levers. Driver does not have to exert

heavy pedal pressure to disengage

clutch. Mostly used in all modern Automobiles.

1. Pressure Plate2. Pressure Plate Cover3. Pressure Spring4. Clutch Plate5. Clutch Lining

Hydraulic Clutch

• Used for assistance in single plate clutch.

• Operated by oil pressure instead of

mechanical linkages.

• Consists of clutch master cylinder, fluid line

and slave cylinder.

• Easy to operate.

• Used in modern automobiles.

Clutch plate assembly

Pressure plate assembly

Release bearing

Clutch Pedal Mechanism

4. PARTS OF CLUTCH:

Clutch disk- steel

Clutch lining – Asbestos and copper wire grit.

Rivets – Aluminum – copper.

Torson spring – steel.

Hub – steel.

5. CLUTCH PLATE LINING AND MATERIAL

6. CLUTCH ADJUSTMENT

A. Floor board clearance adjustment – To prevent from

resting against floor board when the clutch is engaged.

B. Clutch pedal travel adjustment – To ensure complete

clutch disengagement when the clutch is thrown out.

C. Free - adjustment play - To keep a specified amount

of free play in the pedal after the clutch has been

engaged. Normally 1" to 1.5" free play is adjusted.

D. Clutch release lever adjustment :

* Done only after removing the clutch from the vehicle.

* The adjustment should be made every time the clutch

is removed.

* Make it as per company's specification.

CHAPTER NO. – 2

GEAR BOX

INTRODUCTION :-

Next to the clutch is the transmission system

of a motor vehicle.

The word " Transmission" is used for a device

that is located between the clutch and the

propeller shaft.

It may be a Gear Box, a Torque converter, Over

drive, fluid drive or hydraulic drive.

GEAR BOX

PURPOSE OF TRANSMISSION :-

To provide high torque at the time of starting,

hill climbing, accelerating and pulling a load.Obtained by the set of ears called a transmission

or gear set.Gear set is enclosed in a metal box called a

gear box. Vehicle speed can be changed with the help of

Gear Box keeping the engine speed same with

certain limit.

TYPES OF TRANSMISSION :-

The transmission are classified as follows :

1.Manually operated selective transmission –

Which are of three types;

1) Constant mesh 2) Sliding mesh 3) Synchro mesh

2. Over Drive : A semi automatic type used in conjunction with

manual transmission.3. Automatic transmission – Different ratio between the Engine crankshaft and the wheels are achieved by automatic means

a)Constant Mesh Gear Box :

* Gear remains in contact constantly with corresponding Gear of counter shaft .

* Engagement is made by cone clutch .

* Gear are fitted on main shaft.

* Because all the Gears are constant mesh , they are

safe from being damaged.

* Unpleasant grinding sound does not occur while

engaging and disengaging them.

* Used in scooters and motor cycles.

* Unpleasant grinding sound does not occur while engaging and disengaging them.* Used in scooters and motor cycles.

All the Gears and shifts are fitted in a gear housing.

Consist of four shafts :

• Clutch shaft

• Counter shaft

• Main shaft

• Reverse shaft

b. Sliding Mesh Gear Box

Clutch shaft is connected to the drive gear of counter

shaft always. Three other gears are rigidly fixed to counter shaft. Two or more gear are mounted on the Splined Main

shaft. Gear can be slided by shifter Yoke when the shaft

lever is operated. Reverse idler gear is mounted on the Reverse shaft

for Reverse motion. Used in cars, buses and trucks of old models.

In Modern cars, Helical Gears and synchromesh

devices as used in Gear Box . Eliminates clashing of gears and make shifting easier. Seemlier to the Constant Mesh Gear Box but provided

with a synchro mesh devised. Two Gears to be engaged are first brought into

frictional context which equalizes their speed. Engagement is done without noise or damaged to

the dogs.

C. Synchro Mesh Gear Box

* The clutch shaft gear is connected to the counter shaft gear.* Others gears are free hence the transmission main shaft is not turning.* Need : To stop the vehicle after braking without strolling the Engine.* To bring the vehicle in motion from neutral the vehicle is stationary.

NEUTRAL

* FIRST GEAR

# Shifted by operating the gear shift lever # Larger gear of Main Shaft mesh with the first Gear of counter shaft.# Gear Reduction of approximately 3:1 is obtained.

First Speed

Gear Shifting Lever

From Engine

To Rear Axel

# Operated by gear shift lever.

# Larger gear of main shaft is

demeshed from the first gear.

# Gear Reduction of approximately

2:1 is obtained .

SECOND GEAR

Gear Shifting Lever

Second Speed

Main Shaft

Lay Shaft

From Engine

To Rear Axel

To Rear Axel

# By operating the Gear shift lever

the second gear demishes.

# The second or top gear of the

main shaft is forced axially

against the clutch shaft gear .

* THIRD OR HIGH SPEED GEAR

High Speed

From Engine

# The main shaft turns with the clutch shaft.

# Gear Ratio of 1:1 is obtained.

* THIRD OR HIGH SPEED GEAR

# By gear shift lever, the larger lever of the

main shaft

is meshed with reverse idler gear.

# Hence the main shaft turns in the

direction opposite

to that of clutch shaft .

# Reverse Rotation of wheels makes the

vehicle back.

* REVERSE GEAR

CHAPTER NO. 3

PROPELER SHAFT & UNIVERSAL JOINT

PROPER SHAFT AND UNIVERSAL JOINTINTRODUCTION:

# Next to gear box in transmission system# Connected between Gear Box and differential# Universal joint at each end.

# Torque is transmitted to rear Axle to which the rear wheels are connected.

PROPELLER SHAFT:

# Transmits the drive from the output shaft of

Gear Box to the Real Axle.

# It must be strong enough to stand up to all the strains.

# It must be light in weight.

# Carefully balanced otherwise at high speeds a

distressing vibration or thrashing will be set up.

# Generally constructed in tubular form.

# Propeller will have to transmit power between two points

at varying vertical and horizontal distances from

each other .

* TYPES OF PROPELLER SHAFT:

* TYPES OF PROPELLER SHAFT:

TYPES OF PROPELLER SHAFT:

1. Solid:- # Heavy in weight.

# Bond to be twisted by force.# Mostly not used in modern Automobile.

2. Hollow:- # With stand the torsional stresses of transmitting

torque. # Light in weight. # Well balanced so that vibration do not occur

at high speeds. # Made from strong steel tube.

Shaft is in two section – Supper by a centre bearing.

Propeller Shaft is coupled together by Universal joint.

APPLICATION OF PROPELLER SHAFT:

One or more Universal joints are used to permit

variations in angle of drive.

It is also provided with a sliding joint

to compensate the length.

APPLICATION OF PROPELLER SHAFT:

UNIVERSAL JOINT:

# Angular (vertical) movements

provided for by the

provision of universal joints.

# Acts as a universal hinge.

# Slight alternation in length is

accommodated by one and

of the shaft being free to slide on splines.

USES:# Used where two shaft are connected at an angle to transmit torque.# Transmission main shaft, propeller shaft and differential pinion are not in one line hence connected by universal joint.# One universal joints connects main shaft and propeller shaft. # Other universal joint connects propeller shaft and differential pinion shaft.# Universal joint permits the torque transmission not only at angle but also while this angle is changing constantly.

* DESIGN:

# Simple Universal joint consists of two shaped yokes.

# A cross piece called a spider.

# Four arms of spider known as trunnions.

# Trunnions assembled into bearing in the ends of

two shaft yokes.

# The bearing in the yokes permits the yokes to swing

around on the grunions with each revolution.

# lubrication is provided to lubricates the bearing and

sliding end which should receive regular attention.

TYPES OF UNIVERSAL JOINTS

1. Cross type or spider or two yoke type.

2. Ball and trunninon type.

3. Constant Velocity type 1. CROSS TYPE:* Because it consists of a cross piece or spider it is

known as cross type. * There are four needle bearings one for each

trunnion the spider.

2. BALL AND TINNION TYPE:

Consists of a ball head fastened to the end of the

propeller shaft. Through which a pin is pressed.

Two steel balls fit over the ends of the pin.3. CONSTANT VELOCITY TYPE:

Consists of two individual universal joints

linked

by a ball and socket.

These type of joint permits uniform motion.

CHAPTER NO. 4

REAR AXLE & FINAL DRIVE

REAR AXEL AND FINAL DRIVE* REQUIREMENT:

# It is one of cross bars supporting a vehicle on which the driving wheels turns.# The Axle increases the torque delivered by the transmission and transmits it to the driving wheels via the differential.# The Axle drive transmits torque at right angle to

the drive shaft.# Differential can allow one driving wheel to turn

faster than the other during turning.# The assembly consists of a housing an Axle drive a differential, two Axle shaft and final drive

TYPES OF REAR AXLES:

Depending upon the method of supporting the rear

Axles and mounting the rear wheels the Rear Axles

are of three types:

1. Semi-FLOATING Axles

2. Three Quarter footing Axles

3. Full FLOATING Axles.

1. SEMI FLOATING AXLE:

Semi Floating axle has a

bearing located on the axle

and inside the axle casing.

It has to support all the load

of the vehicle.

It has to be of larger size for

the same torque output than

any other type.

1. SEMI FLOATING AXLE:

The hub of the wheel is

keyed to the outer end

of the Axle.

Semi Floating Axle is the

simples and cheapest of

all other types.

Widely used on cars.

Hub

Axle Shaft

Bearing

Housing

2. THREE QUARTER FLOATING AXLE:

Three Quarter floating axle has bearing located

between the hub and the axle casing.

The weight of the vehicle is transferred to the axle

casing.Bearing

2. THREE QUARTER FLOATING AXLE:

keyed rigidly to the hub.

It is more reliable.

Not simple use semi floating axle as to remove the

axle the vehicle needs to be jacked up.

Bearing

3. FULL FLOATING AXLE:

Full Floating axle has

two deep-groove ball

or topper roller bearing,

located between the axle

casing and wheel hub.

The outer of the axle

is made flanged to which

the wheel hub is bolted.

The weight of the vehicle

on end thrust.

3. FULL FLOATING AXLE: The axle is relieved of all

strain caused by the weight

of the vehicle on end thrust.The axle may be removed

from the housing without

disturbing the wheel by

removing the nuts.This type of axle are more

expensive and heavier.It is usually fitted on commercial

vehicles and buses.

Bearing

FINAL DRIVEFinal drive is embodied in the rear axle.

One form of final drive commonly used

in motor vehicle is the chain drive.

Other form of the final drive commonly

used in four wheeled vehicles is the

shaft drive.

Final drive help to turn the drive through

90 from propeller shaft to the rear Axles.

It provides a permanents gear reduction

TYPES OF REAR AXLE (DRIVE):

Mainly these are two principal types

of design of Rear Axle housing:

1. Banjo Axle: Most popular types of rear axle and used

on most of the popular priced production models.

2. Split Case Axle: Axle case is usually built up in two

separate halves hence for any the opening and removed

of the axle casing is necessitates.

CONSTRUCTION OF DEFFERENTIAL:

Sun gears are mounted on the

inner end of each rear axle.Ring gear (called the crown gear)

is attached to the cage.

CONSTRUCTION OF DEFFERENTIAL: The cage rotates with the

crown gear.Crown gear is driven by the

bevel pinion.

Thus when the differential

cage is rotated both the

sun gears rotate and thus

both the wheels turns.

When the vehicle is running in a straight line,

the crown wheel, differential cage, planet pinion and

the sun gear all turns as a unit without any relative

motion.

When the car takes a turn, the planet pinions

rotates on their shaft to permit the outer rear

wheel to turn more rapidly than the inner wheel.

CHAPTER NO. – 5

FRONT AXLE

FRONT AXLE

INTRODUCTION : • Front axle is used to carry the weight of the front part of the vehicle .• It facilitates the stearing mechanism. • It absorb shocks due to the road surface variations.• It must be right and robust in construction.• It is made of "I" section in the centre portion , while the ends are made either circular or elliptical.• Different components of the front axle are the axle beam , stab axle , king pin , tie rod.

Types of Front Axles

Usually there are two main types of front axles1) Live axle 2) Dead front axle 1) - Front axles are usually dead axles because they do not rotate

Types of Front Axles

- A live front axle receives additional power from the gear box transfer case - Live axle receives the power of the engine

2) Dead axle do not receive the power of engine but moves with the help of the driving force of rear axles . The wheels are mounted on the stub axles which are often pivoted.

STUB AXLE

- The stub axle turns on the king pin

which is a light drive fit in the axle

beam eye located and locked by a taper

cotter pin.

STUB AXLE

-Bronze buses are fitted in to the forked

ends of the axle to the axle to provide

a bearing surface for the king pin.

- Vertical load are taken by thrust bearing`

located either on the top fork of the stub

axle are between the lower fork and the

underside of the beam.

There are four types of stub axles 1. Elliot2. Reverse Elliot3. Lamoine4. Reverse Lamoine

Types of Stub Axles

ELLIOT TYPEIn elliot stub axle is attached to the front axle by placing it in the yoke end with a king pin and cotter pin to poin two together

REVERSE ELLIOT In reverse Elliot type stub axle the arrangement is reversed. It is widely used in current auto mobiles used in trucksLEMOINE

In lemoine type stub axle instead of yoke type hinge a L- shaped spindle is used as shown in fig used in tractors

REVERSE LEMOINE It is the reverse position of lemoine but not used in modern automobiles.

CHAPTER NO. – 6

SUSPENSION SYSTEM

SUSPENSION SYSTEM

INTRODUCTION :INTRODUCTION :

#The suspension is a system of devices that effect an elastic

connection between the under carriage and the wheels.

# Its purpose is to absorb any road shocks that results

from the wheels hitting holes or bumps.

# Suspension system includes springs, shock absorbers

and their mountings.

# Suspension system of a vehicle is divided into the rear

and suspension and front suspension.

PRINCIPAL OF SUSPENSION SYSTEM :# These system works on two principals 1. Tensile Strength 2. Compression Strength

1. To prevent the road shocks from transmitted to the vehicle frame.2. To preserve the stability of the vehicle in pitching or rolling, while in motion.3. To safeguard the occupants from road shocks.4. To provide good road holding while driving, cornering and breaking.5. To maintain proper steering geometry.

FUNCTION OF SUSPENSION SYSTEM

REQUIREMENTS OF SUSPENSION SYSTEM :

1. Minimum deflection consistent with required stability.

2. Comparability with other vehicle components- types

frame, wheel base, steering linkage.

3. Low maintenance and operating costs.

4. Low initial cost.

5. Minimum weight.

6. Minimum Tyre wear

# The front suspension is more complicated than the rear end suspension.# The front wheel not only moves up and down but also swing at various angles during stearing

FRONT END SUSPENSION & TYPES :

# The front end suspension may be of Two types 1) Rigid suspension 2) Independent suspension.

INDEPENDENT SUSPENSION :

# Each front wheel is independently

supported by a coil spring, torsion bar.

# This type of suspension is able to cushion

road shochs by causing the lower arm to

twist the torson bar.

# A shock absorber is the supportive member

for the independent suspension.

# Almost all the passenger cars now use the

independent suspension.

* Provides mere space for engine accommodation.

* Provides softer suspension.

* Effect on the stearing geometry is over come with

Independent front suspension.

* Weight is low.

* Reduces the tendency of causing wheel wobble

or shimmy.

*Reduces the tendency of tilting the vehicle to one side

when the wheel is lifted or drop due to road variations.

ADVANTAGES OF INDEPENDENT SUSPENSION :

# Fig shows a typical rigid axle wheel suspension.# Universally used before the introduction of Independent suspension.# Two longitudinal leaf spring or transverse spring in conjunction with shock absorber is used.

RIGID AXLE SUSPENSION :

TYPES OF INDEPENDENT SUSPENSION SYSTEM :

1. Vertical Slide Method

2. Divided Axle Method

3. Swing arm Method

4. Parallel link Method

Shock Absorber

Coil Spring

Stabilizer

Ball Joints

Upper Control Arm

TYPES OF INDEPENDENT SUSPENSION SYSTEM :

TYPES OF SUSPENSION SPRING :

1. Leaf spring

2. Coil spring

3. Torsion spring

4. Air Bags

5. Rubber spring

Rear Shakle

Shock Absorber

Leaf Spring

Front Hanger

LEAF SPRING :

Leaf springs are of the following types

1) Semi-elliptical spring

2) Quarter elliptical spring

3) Three quarter elliptical spring

4) Transverse spring

5) Full elliptical spring

6) Platform type spring

# Semi-elliptical spring are usually used in all the vehicles.

Quarter Elliptical

Semi Elliptical

Three Quarter Elliptical

Transverse Spring

Axle

PARTS OF RIGID AXLE SUSPENSION :

1. Main Leaf2. Helper Leaf3. Shackle4. Bracket5. Centre bolt6. 'C' clamp7. 'U' bolt8. Shackle pin

Helper Spring

Rubber Bush Frame Bracket

Spring Bollt

Rubber Bush

Shackle Lings

Shackle pin

Rubber Packing

Metal Plate

Lower Clamp plate

Mrtal Housing

Rollers

Rubber Bumper

Rubber Packing

PARTS OF INDIPENDENT SUSPENSION

1. Upper Arm2. Lower Arm3. Ball Joints 4. Coil Spring5. Shock Absorber6. Torson bar/ Stabilizer bar