In this section, removal and installation are described using a manual gearbox as an example. Other gearboxes are removed and installed in a similar manner.
Manual transmission is made according to a two-shaft scheme with five synchronized forward gears. The gearbox and the main gear with the differential have a common housing 2
(Fig. 6.3). Clutch housing 5 is attached to the front part of the gearbox housing. A stamped steel cover 1 is installed on the rear part of the gearbox housing.
Fig. 6.3. Schematic diagram of a mechanical five-speed gearbox: 1 – rear cover of the gearbox housing; 2 – gearbox housing; 3 – breather; 4 – clutch release hydraulic drive slave cylinder; 5 – clutch housing; 6 – clutch release bearing; 7 – primary shaft; 8 – secondary shaft; 9 – main gear and differential
On the primary shaft 7, there is a gear of the 5th gear with a synchronizer fixed on the shaft splines, and the driving gears of the 1st, 2nd, 3rd and 4th gears are made as a single unit with the primary shaft.
The secondary shaft 8 is manufactured together with the driving gear of the main transmission 9. In addition, the driven gears of the I, II, III, IV and V gears are mounted on the shaft and rotate freely on plain bearings.
Forward gears are engaged by axial movement of the clutches of two synchronizers of I-II and III-IV gears and the clutch of the synchronizer of V gear, installed on the secondary shaft. The gear shift mechanism is located inside the gearbox housing on its left side.
The manual transmission control drive consists of a gear shift lever linkage with a ball joint mounted on the body base, two gear shift and selection cables, and a mechanism installed in the gearbox housing. To ensure precise gear engagement, the gear shift lever of the gear shift mechanism is made in one piece with a massive counterweight. The gear selection and shift cables are structurally different from each other and are not interchangeable.
The main transmission is made in the form of a pair of cylindrical gears, selected for noise. Torque is transmitted from the driven gear of the main transmission to the differential and then to the front wheel drives.
The differential is conical, with two satellites. The tightness of the connection of the internal joints of the front wheel drives with the differential gears is ensured by seals.
The automatic transmission with adaptive control system provides the choice of the optimal gear shift mode for almost any driving style and road conditions.
Automatic transmission is arranged according to the traditional planetary scheme with friction braking and is connected to the engine crankshaft via a torque converter. A special feature of the Ford Fusion gearbox compared to the automatic gearboxes of previous generations is the ability to switch from a fully automatic control mode to a manual mode (the so-called sequential gearbox), in which the driver independently selects the moment of switching to an upshift during acceleration of the car. This allows, if desired, to achieve more intense acceleration compared to the automatic mode, artificially delaying the switching to an upshift, which allows bringing the engine crankshaft speed to the range of the highest torque. At the same time, the electronic control system constantly monitors the car speed and engine load, eliminates driver errors, not allowing him to engage a higher gear at low speed in order to avoid engine overload, and not allowing him to engage a downshift at too high a speed, which eliminates the possibility of exceeding the maximum permissible engine crankshaft speed. When the car speed decreases, the gears are automatically switched to lower ones without driver intervention. When the car comes to a complete stop, the first gear is automatically engaged.
The automatic transmission control drive is cable-operated and is constructed on the same principle as the manual transmission control drive, but differs from it in the number and design of parts. The automatic transmission selector is installed in the same place on the floor tunnel as the manual transmission control lever, and is connected to the control unit on the transmission by a control cable.
The design of the differential of an automatic transmission is completely similar to that of a manual transmission.
To repair a gearbox, especially an automatic gearbox, a large set of special tools and appropriate training of the performer are required, therefore this section only covers the removal and installation of the gearbox, replacement of its seals, and repair of the drive. If necessary, perform gearbox repairs in a specialized car service.
[This article is a copy from the website: FORDBOOK.RU]