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If
you drive a stick-shift car, then you may have
several questions floating in your head.
How does the funny "H" pattern that I am moving this
shift knob through have any relation to the gears
inside the transmission? What is moving inside the
transmission when I move the shifter?
When I mess up and hear that horrible grinding
sound, what is actually grinding? What would happen
if I were to accidentally shift into reverse while I
am speeding down the freeway? Would the entire
transmission explode?
Cars need
transmissions because of the physics of the gasoline
engine. First, any engine has a redline -- a maximum
rpm value above which the engine cannot go without
exploding. Second, if you have read How Horsepower
Works, then you know that engines have narrow rpm
ranges where horsepower and torque are at their
maximum. For example, an engine might produce its
maximum horsepower at 5,500 rpm. The transmission
allows the gear ratio between the engine and the
drive wheels to change as the car speeds up and
slows down. You shift gears so the engine can stay
below the redline and near the rpm band of its best
performance.

Mercedes-Benz Actros, manual transmission
Ideally,
the transmission would be so flexible in its ratios
that the engine could always run at its single,
best-performance rpm value. That is the idea behind
the continuously variable transmission (CVT).
A CVT has a nearly infinite range of gear ratios. In
the past, CVTs could not compete with four-speed and
five-speed transmissions in terms of cost, size and
reliability, so you didn't see them in production
automobiles. These days, improvements in design have
made CVTs more common. The Toyota Prius is a hybrid
car that uses a CVT.

The
transmission is connected to the engine through the
clutch. The input shaft of the transmission
therefore turns at the same rpm as the engine. A
five-speed transmission applies one of five
different gear ratios to the input shaft to produce
a different rpm value at the output shaft. Here are
some typical gear ratios:
|
Gear
|
Ratio
|
RPM at Transmission
Output Shaft
with Engine at 3,000
rpm
|
| 1st |
2.315:1 |
1,295
|
| 2nd |
1.568:1 |
1,913
|
| 3rd |
1.195:1 |
2,510
|
| 4th |
1.000:1 |
3,000
|
| 5th |
0.915:1 |
3,278
|
The
five-speed manual transmission is fairly standard on
cars today. Internally, it looks something like
this:


Keep in
mind that the shift lever has a rotation point in
the middle. When you push the knob forward to engage
first gear, you are actually pulling the rod and
fork for first gear back.
You can see that as you move the shifter left and
right you are engaging different forks (and
therefore different collars). Moving the knob
forward and backward moves the collar to engage one
of the gears.

Reverse
gear is handled by a small idler gear (purple). At
all times, the blue reverse gear in this diagram is
turning in a direction opposite to all of the other
blue gears. Therefore, it would be impossible to
throw the transmission into reverse while the car is
moving forward -- the dog teeth would never engage.
However, they will make a lot of noise!
Synchronizers
Manual transmissions in modern passenger cars use
synchronizers to eliminate the need for
double-clutching. A synchro's purpose is to allow
the collar and the gear to make frictional contact
before the dog teeth make contact. This lets the
collar and the gear synchronize their speeds before
the teeth need to engage, like this:

The cone
on the blue gear fits into the cone-shaped area in
the collar, and friction between the cone and the
collar synchronize the collar and the gear. The
outer portion of the collar then slides so that the
dog teeth can engage the gear.
Every manufacturer implements transmissions and
synchros in different ways, but this is the general
idea.
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