Chapter 8 Gears and Shafts

Upon completion and review of this chapter, the student should be able to:

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Classroom Manual Objectives

Shop Manual Objectives

Identify the components in a basic planetary gearset and describe their operation. Describe how different gear ratios are obtained from a single planetary gearset. Describe the construction and operation of typical Simpson gear-based transmissions. Describe the construction and operation of Ravigneaux gear-based transmissions. Describe the construction and operation of transmissions that use planetary gearsets in tandem. Describe the purpose of a differential. Identify the major components of a differential and explain their purpose. Describe the various gears in a differential assembly and state their purpose. Explain the operation of a FWD differential and its drive axles. Describe the different designs of four-wheel-drive systems and their applications. Discuss the purpose of the various shafts found in todays automatic transmissions and transaxles.

Inspect, measure, and replace thrust washers and bearings. Inspect and replace bushings. Inspect and measure a planetary gear assembly, and replace parts as necessary. Inspect and replace shafts. Remove and install the various types of shaft seals. Inspect, repair, or replace transaxle drive chains, sprockets, gears, bearings, and bushings. Inspect and replace parking pawl, shaft, spring, and retainer. Inspect, measure, repair, adjust, or replace transaxle final drive components.

Overview
This chapter in both manuals covers planetary gears and shafts, their design variations, applications, and service.

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Reading Assignments
Classroom Manual, pages 249-276 Shop Manual, pages 325-353

Terms to Know Annulus gear Etching Interaxle differential Internal gear Pinion gear Reaction member Selective thrust washers Thrust load

Lecture Outline and Notes

I. Objectives
Review the chapters objectives.

II. Simple Planetary Gearsets

A. Review of Gear Theory 1. Discuss the use of levers and gears. 2. Introduce automatic transmission gears. B. Planetary Gears 1. Discuss the possible gear ratios available with planetary gearsets. 2. Discuss gear reduction with planetary gearsets. 3. Describe direct drive in a planetary gear system. 4. Describe overdrive using planetary gear systems. 5. Describe reverse with a planetary gearset. 6. Discuss neutral with planetary gearsets. 7. Discuss compound planetary gearsets.

III. Planetary Gear Assemblies

A. Simpson Gearset 1. Describe the members of this type of gear train. 2. Explain how ratios and rotations are obtained. 3. Discuss basics of gearset power flow. B. Ravigneaux Gearset 1. Describe the members of this type of gear train. 2. Explain how ratios and rotations are obtained. 3. Discuss basics of gearset power flow. C. Planetary Gearsets in Tandem 1. Describe the members of this type of gear train. 2. Explain how ratios and rotations are obtained.

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3. Discuss basics of gearset power flow. D. Non-Planetary Based Transmissions Describe the operation of Hondas non-planetary transmission.

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E.Planetary Gear Service 1. Discuss the need for careful inspection. 2. Explain measuring procedures. 3. Discuss the need for setting clearances to specifications.

IV. Final Drives and Differentials

A. Differential Units 1. Review differential operation and purpose. 2. Describe the maintenance of final drive assemblies used in transaxles. B. Final Drive Components Explain the operation of final drives.

V. 4WD Design Variations

A. Discuss the control variations of 4WD gears. B. Describe how a transfer case works. C. Describe how a viscous clutch works.

VI. Shafts
A. Types and Location of Shafts Discuss the location, and the reason for this location, of the various shafts found in todays transmissions and transaxles. B. Shaft Service 1. Describe inspecting the shafts for scores and wear. 2. Discuss how to determine if the shafts can be reused.

VII. Thrust Washers, Bushings, and Bearings

A. Location and Purpose of Bearings, Bushings, and Thrust Washers 1. Discuss the different types of bearings and thrust washers. 2. Discuss transmission bushings and where they are typically used. B. Thrust Washer, Bushing, and Bearing Service 1. Discuss the maintenance of thrust washers, bushings, and bearings. 2. Explain how to select the correct thrust washer or bearing. C. Snap Rings 1. Discuss the various types of snap rings used in todays transmissions. 2. Explain what a selective snap ring is.

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VIII. Parking Pawl

A. Theory Explain the purpose of a parking pawl and how it is activated. B. Service Describe parking pawl inspection and service.

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IX. Drive Chains

A. Theory Explain the purpose of drive chains and when they are used. B. Service Describe how to inspect and test a drive chain.

X. Transfer Gears
A. Theory Explain the purpose of transfer gears and why they are used. B. Service Discuss the typical procedures for inspecting and checking the transfer gears in a transaxle.

XI. Summary
Review the material covered, emphasizing the main points and key words.

Chapter 8 Answers to Review Questions

CLASSROOM MANUAL, PAGES 277-279

Short Answer Essays

1. If any two of the planetary gearset members receive power in the same direction and at the same speed, the third member is forced to move with the other two and direct drive results. 2. The input shaft connects the output of the torque converter to the driving members inside the transmission. The output shaft connects the driven member of the gearsets to the final drive gearset. 3. There are two common designs of compound gearsets: the Simpson gearset, in which two planetary gearsets share a common sun gear, and the Ravigneaux gearset, which has two sun gears, two sets of planet gears, and a common ring gear. 4. If the planet carrier is held and the sun gear is rotated in a clockwise rotation, the ring gear will rotate in a counterclockwise direction. The planet gears cannot travel around the teeth of an enmeshed gear; rather, the carrier is held in place and the planet gears spin on their shafts. The sun gear spins the planet gears, which drive the ring gear in the opposite direction but at a slower speed. Therefore the gearset is providing reverse gear with reduction. 5. Gear reduction is accomplished in a planetary gearset by holding the sun gear. If power is applied to the ring gear, the planet gears will spin on their shafts in the planet carrier. Because the sun gear is

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being held, the spinning planet gears will walk around the sun gear and carry the planet carrier with them; this causes a gear reduction. Gear reduction can also occur if the ring gear is held and the sun gear is the input gear. The planet carrier rotates around the sun gear, but turns more slowly than it did when the ring gear drove the planet carrier. 6. As the vehicle goes around a corner, the inside wheel travels a shorter distance than the outside wheel. The inside wheel must therefore rotate more slowly than the outside wheel. An equal percentage of speed is removed from one axle and given to the other; however, an equal amount of torque is applied to each wheel. 7. A transfer case divides transmission output to the two different drive axles to provide for four-wheel drive. 8. These transaxles have a main shaft and countershaft on which the gears ride. The two shafts run parallel to each other, and some later models have a third parallel shaft. To provide the forward gears and one reverse gear, different pairs of gears are locked to the shafts by hydraulically controlled clutches. Reverse gear is obtained, on some models, through the use of a shift fork that slides the reverse gear into position. The power flow through these transaxles is also similar to that of a manual transaxle. 9. When there is input into a planetary gearset but a member is not held, neutral results. 10. When two gearsets are in tandem, the front ring gear is normally connected to the rear carrier and the rear ring gear is connected to the front carrier.

Fill-in-the-Blanks
1. External, internal 2. Sun, ring 3. Direction, speed, direct 4. Sun gear, planetary carrier, ring gear 5. Annulus, internal 6. Increased, decreased 7. Planet carrier 8. Interaxle 9. Planet, ring, sun 10. Sun, planet, ring

Multiple Choice
1. B 2. B

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3. D 4. D 5. C 6. A 7. C 8. C 9. C 10. C

SHOP MANUAL, PAGES 353-354

ASE-Style Review Questions

1. A 2. C 3. C 4. B 5. C 6. B 7. C 8. C 9. B 10. D

ASE Challenge Questions

1. B 2. D 3. C 4. C 5. A

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