Manual Transmissions

A vehicles transmission allows for torque multiplication (which helps acceleration) and a wider range of vehicle speeds than would be possible if the engine were connected directly to the drive axle.

A Manual Transmission has toothed gears that must be selected by the vehicle operator with a lever and connected to the output shaft of the transmission.

Manual Trans input shaft and counter gear power flow.

Input shaft and counter gear

Manual Trans power flow: Neutral

Counter gear

Input shaft

Power Flow: First gear

Five Speed Transmission: Neutral

Shifting rails & forks can be seen in this photo:

Shift rails

Shifting forks

Shifter / Rail movements for each gear.

View from front of trans

Synconizers are needed to help gears rotating at different speeds mesh together without grinding.

Synchronizer assembly

Syncro collar or hub

Sliding sleeve

Synchronizer ring and gear

Synchronizer assembly

Another small gear is needed to reverse the direction of the output shaft.

Typical parts layout

Input , counter and 1st,2nd, 3erd gears. Very expensive to replace!

Special tools

Tools required to work on Manual transmissions:

Snap ring pliers Pullers Feeler gauges Dial indicator caliper

Good luck with unit test!