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Item Description
1 Engine
5 Input shaft B - 2nd gear, 4th gear, 6th gear and reverse gear
6 Output shaft A - 1st gear, 2nd gear, 5th gear and 6th gear
In principle, the transmission comprises two independent gear trains.
Each of the two input shafts is connected via outer splines to a clutch disc.
Each of the two output shafts provide a final drive gear ratio to the differential ring gear.
Input shaft A is the core shaft and drives the odd numbered gears (1st, 3rd, and 5th gear).
Input shaft B is the hollow shaft and drives the even numbered gears (2nd, 4th, and 6th gear) as well as
the reverse gear (via an intermediate gear).
Output shaft A contains the driven gears and synchronizers for 1st, 2nd, 5th, and 6th gear as well as the
intermediate gear for reverse.
Output shaft B contains the driven gears and synchronizers for 3rd, 4th, and reverse gears.
During driving, one gear train is always positively connected and the next gear is already engaged in the
other gear train (although the clutch for this gear is still open).
Synchronizers
Single and double synchronization are both used on this transmission.
Single synchronization is used on gears 1, 3, 4, 5, 6 and reverse gear.
Double synchronization is used for the 2nd gear.
Torque Path
NOTE: In the descriptions below, the shafts are shown outside their actual position for greater clarity.
Item Description
1 Differential
2 Reverse gear
3 4th gear
4 3rd gear
5 1st gear
6 5th gear
7 6th gear
8 2nd gear
9 Input shaft B - 2nd gear, 4th gear, 6th gear and reverse gear
In first gear, engine torque flows from the flex plate to the flywheel and pressure plate A. Pressure plate
A is engaged and torque is transferred to clutch disc A, which is on the engine side of the dual clutch
assembly. From clutch disc A, torque flows to input shaft A (the inner, solid shaft). The small gear on the
end of input shaft A transmits the torque to the first gear of output shaft A. In first gear, the 1-5
synchronizer on output shaft A engages first gear and allows torque to flow from the first gear to the
output shaft. Torque is transmitted to the differential via the output shaft A pinion.
Second gear
In second gear, engine torque flows from the flex plate to the flywheel and pressure plate B. Pressure
plate B is engaged and torque is transferred to clutch disc B, which is on the transmission side of the
dual clutch assembly. From clutch disc B, torque flows to input shaft B (the outer, hollow shaft). The
small gear near the middle of input shaft B transmits the torque to the second gear of output shaft A. In
second gear, the 2-6 synchronizer on output shaft A engages second gear and allows torque to flow
from the second gear to the output shaft. Torque is transmitted to the differential via the output shaft A
pinion.
Third gear
In third gear, engine torque flows from the flex plate to the flywheel and pressure plate A. Pressure
plate A is engaged and torque is transferred to clutch disc A. From clutch disc A, torque flows to input
shaft A. The gear nearest the clutch on input shaft A transmits the torque to the third gear of output
shaft B. In third gear, the third gear synchronizer on output shaft B engages third gear and allows torque
to flow from the third gear to the output shaft. Torque is transmitted to the differential via the output
shaft B pinion.
Fourth gear
In fourth gear, engine torque flows from the flex plate to the flywheel and pressure plate B. Pressure
plate B is engaged and torque is transferred to clutch disc B. From clutch disc B, torque flows to input
shaft B. The large gear on the end of input shaft B transmits the torque to the fourth gear of output
shaft B. In fourth gear, the 4-R synchronizer on output shaft B engages fourth gear and allows torque to
flow from the fourth gear to the output shaft. Torque is transmitted to the differential via the output
shaft B pinion.
Fifth gear
In fifth gear, engine torque flows from the flex plate to the flywheel and pressure plate A. Pressure plate
A is engaged and torque is transferred to clutch disc A. From clutch disc A, torque flows to input shaft A.
The large gear on the end of input shaft A transmits the torque to the fifth gear of output shaft A. In fifth
gear, the 1-5 synchronizer on output shaft A engages fifth gear and allows torque to flow from the fifth
gear to the output shaft. Torque is transmitted to the differential via the output shaft A pinion.
Sixth gear
In sixth gear, engine torque flows from the flex plate to the flywheel and pressure plate B. Pressure plate
B is engaged and torque is transferred to clutch disc B. From clutch disc B, torque flows to input shaft B.
The large gear on the end of input shaft B transmits the torque to the sixth gear of output shaft A. In
sixth gear, the 2-6 synchronizer on output shaft A engages sixth gear and allows torque to flow from the
sixth gear to the output shaft. Torque is transmitted to the differential via the output shaft A pinion.
Reverse gear
In reverse gear, engine torque flows from the flex plate to the flywheel and pressure plate B. Pressure
plate B is engaged and torque is transferred to clutch disc B. From clutch disc B, torque flows to input
shaft B. The small gear in the middle of input shaft B transmits the torque to the second gear of output
shaft A. The second gear has a fixed connection to the intermediate gear. The intermediate gear is in
mesh with the reverse gear on output shaft B. In reverse gear, the 4-R synchronizer on output shaft B
engages reverse gear and allows torque to flow from the reverse gear to the output shaft. Torque is
transmitted to the differential via the output shaft B pinion.
Parking lock
Item Description
1 Shift lever
2 Actuating shaft
3 Torsion spring
5 Park pawl
A park pawl needs to be installed since both clutches are opened after the engine is switched off.
Internal gearshift mechanism
Layout of the internal gearshift mechanism
Item Description
The gears are shifted by means of two brushless DC motors, which each actuate a gear selector drum via
a two-stage transmission ratio. The gear selector drums each have one shift slot for moving the selector
forks. As a result of using the gear selector drum principle, no additional mechanical lock is required in
order to prevent more than one gear being engaged at the same time in the same sub-transmission in
the event of a fault.
Layout of the gearshift system (schematic diagram)
Item Description
6 Shift slot
7 Lower cam
9 Sliding block
10 Upper cam
The shift slot in the gear selector drum has two counter-running cams on its circumference, which are
offset by 180°. A slider which is connected to the selector fork is moved via the shift slot. If the slider
moves up or down on the cam then the selector fork is moved accordingly in an axial direction, and as a
result either a gear is engaged or the synchronizer assembly is moved to the neutral position.
Function of the gear selector drum
Item Description
2 Lower cam
4 Upper cam
5 Selector fork for 1st/5th gear with slider
3 Upper cam
4 Lower cam
1 Clutch unit
3 Guide sleeve
5 Engagement bearing
6 Snap ring
The clutch system consists of:
the clutch unit
the engaging unit
the two lever actuators, each of which is actuated by a brushless DC clutch actuator motor.
The clutch unit is connected to the two input shafts of the transmission and attached to the drive plate
with nuts. The nuts need to be removed from the drive plate if the transmission is removed.
Clutch unit
Sectional view
Item Description
1 Drive plate
3 Driving disc
4 Clutch discs
5 Pressure Plate B - 2nd gear, 4th gear, 6th gear and reverse gear.
6 Torsion damper
B Clutch A closed
1 Pressure plate B
2 Clutch disc B
3 Driving disc
4 Pressure plate A
5 Clutch disc A
6 Input shaft A
7 Input shaft B
8 Lever spring B
9 Lever spring A
The two lever springs open the clutches in the rest state. They are closed through actuation of the
relevant engaging bearing, which acts on the corresponding lever spring. By pressing the lever springs,
the relevant pressure plate is pressed against the clutch disc and the driving disc.
Engaging unit
Sectional view
Item Description
1 Engaging bearing B
Comments:
Actuates the lever spring B of clutch
2 Engaging bearing A
Comments:
Actuates the lever spring A of clutch
3 Compensating element
4 Guide sleeve
The two engaging bearings are accommodated by the guide sleeve in such a way that they can be
moved independently of each other. The sliding sleeves are slotted for this purpose and engage in
segments in each other. The compensating element is used to compensate for any offset to the
actuating levers.
The two engaging bearings are each equipped with a hardened engaging disc. This lies loose on the
engaging bearing and transmits the axial forces.
Electromechanical lever actuator
Item Description
2 Pressure spring
4 Rollers
5 Engagement lever
The force required to close the clutches is largely generated by a compression spring via the mechanical
system of the lever actuator. This force acts on the outer end of the engaging lever. This has the form of
a rocker. The rollers form the central point of contact of the engagement lever.
The brushless DC clutch actuator motors are bolted directly onto the transmission clutch housing. The
DC clutch actuator motor drives the threaded bar of the ball screw via gear teeth. Through rotation of
the threaded rod, the recirculating ball nuts and thus the rollers are moved in an axial direction.
Function of the electromechanical lever actuator
Item Description
A Clutches open
Comments:
Brushless DC clutch actuator motor de-energized
B Clutch B closed
Comments:
Brushless DC clutch actuator motor energized
2 Pressure spring
4 Rollers
5 Engagement lever
When the DC clutch actuator motor is de-energized the clutch is open. In order to close the clutch, the
DC clutch actuator motor is actuated by the TCM. As a result of the rotation of the ball screw, the roller
is moved downwards via the recirculating ball nut. Due to this axial movement of the rollers, the central
support point of the engaging lever is displaced, as a result of which the leverage is altered. The change
in leverage in turn causes the force which acts via the engaging lever and the engaging bearing on the
lever spring of the clutch to be increased. The engaging bearing presses against the lever spring and the
clutch is pressed into the closed position.
Inserted from
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&callfrom=proc&bookcode=SC8&market=WD&language=EN&VIN=&selected_year=2012&selected_model=Focus - D3>