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1.

INTRODUCTION

1.1

Transmission Transmission as an assembly of parts including the speed-changing gears and the propeller shaft by which the power is transmitted from an engine to a live axle. Often transmission refers simply to the gearbox that uses gears and gear trains to provide speed and torque conversions from a rotating power source to another device. Gearbox is any device that converts speed and torque, whereas a transmission is a type of gearbox that can be "shifted" to dynamically change the speed-torque ratio such as in a vehicle. The most common use is in motor vehicles, where the transmission adapts the output of the internal combustion engine to the drive wheels. Such engines need to operate at a relatively high rotational speed, which is inappropriate for starting, stopping, and slower travel. The transmission reduces the higher engine speed to the slower wheel speed, increasing torque in the process. Transmissions are also used on pedal bicycles, fixed machines, and anywhere rotational speed and torque must be adapted. Often, a transmission has multiple gear ratios, with the ability to switch between them as speed varies. This switching may be done manually, or automatically. Directional (forward and reverse) control may also be provided. Single-ratio transmissions also exist, which simply change the speed and torque (and sometimes direction) of motor output. In motor vehicles, the transmission generally is connected to the engine crankshaft via a flywheel and/or clutch and/or fluid coupling, partly because internal combustion

engines cannot run below a particular speed. The output of the transmission is transmitted via driveshaft to one or more differentials, which in turn, drive the wheels. While a differential may also provide gear reduction, its primary purpose is to permit the wheels at either end of an axle to rotate at different speeds (essential to avoid wheel slippage on turns) as it changes the direction of rotation.

1.2

Manual transmission A manual transmission, also known as a manual gearbox, stick shift, or standard transmission is a type of transmission used in motor vehicle applications. It uses a driver-operated clutch engaged and disengaged by a foot pedal (automobile) or hand lever (motorcycle), for regulating torque transfer from the engine to the transmission; and a gear stick operated by foot (motorcycle) or by hand (automobile). A conventional, 5-speed manual transmission is often the standard equipment in a basemodel car; other options include automated transmissions such as an automatic transmission (often a manumatic), a semi-automatic transmission, or a continuously variable transmission (CVT).

2.0

OBJECTIVE

I. To study how to assemble and dissemble a transmission.

II. To study working principle of transmission.

III. To conduct repair of damage part for the transmission.

IV. To conduct replacement of items such as seals, and bearings.

V. To study how to overhaul a transmission.

3.0

APPARATUS

The following apparatus are needed for the overhaul of a transmission: 1. Set of spanner

2. Ratchet and ratchet socket

3. WD 40

4. Screwdriver

5. Hammer

6. High temperature silicon gasket maker

7. Brush and diesel

4.0

SAFETY PRECAUTION

1. Careful when handling the diesel that used to clean the transmission.

2. Avoid to exposing the diesel to heat source.

3. Caution when using the WD 40, do not spray it to other or eye.

4. Careful with the hands when tightening the bolt and nut.

5. Always have a fire extinguisher handy, just in case.

6. Become familiar with the transmission by reading the manual before overhaul operation.

5.0

PROCEDURE

5.1

ASSAMBLE

1. Open the bolt for casing using WD 40 and ratchet or spanner.

Opening the bolt using ratchet

Opening the bolt using WD 40


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2. Dissemble all part using hammer and screwdriver. 3. Do the inspection to identify the problem of the transmission. 4. Dismantle the bevel gear that used the tapered roller bearing.

The tapered roller bearing

Oil Seal damage

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5. Remove the old oil seal.

Old Oil seal 6. Clean all part with diesel and brush.

Cleaning process

Part that have been cleaned


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5.2

ASSEMBLE 1. Replace the oil seal with the new one.

Oil seal replaced

New oil seal 2. Replace the gasket on the casing

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Gasket is replaced

3. Install the bevel gear.

Bevel gear installed

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Installed O ring 4. Assemble all part and tighten the bolt using ratchet or spanner.

Tightening process

Tightening the bolt


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5. Overhaul is done.

Transmission that has been overhauled

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6.0

DISCUSSION

1. Shaft cannot be dissembled due to modification where the key should be inserted.

2. The bolt was hard to be open or loosen due to rusting on it, therefore WD 40 is used to loosen the bolt.

3. Oil seal was broken and replaced.

4. Gasket was installed.

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7.0

CONCLUSION

Overall, this study case of overhaul manual transmission of Honda civic has achieved its objective. The first objective is to study how to assemble and dissemble a transmission. When the dissembled is conducted, many problems are detected during the process. Through the problem, there are several actions that have been taken and the problem was solved immediately. Second objective is to study working principle of transmission has been achieved. Research are done to know the working principle of the transmission in order to complete the case study. The fourth is to conduct repair. During the overhaul, the breakdown can be identified. All parts that need the replacement must be change to new one to restore the situation to normal. The fifth objective also has been achieved with replacement the broken and damage item such as seal. The last objective of this study case is about the maintenance also has been achieved. Overhaul is one of maintenance process that is to examine or go over carefully for needed repairs or to dismantle in order to make repairs.

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8.0

REFERENCE

1. http://www.metrotransmission.com/transmission-overhaul-leucadia-ca/

2. http://www.ehow.com/how_7869527_overhaul-transmission.html

3. http://en.wikipedia.org/wiki/Manual_transmission

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