3239208 - Introduction - GEARBOX

GENERAL CHARACTERISTICS

F40 Gearbox

The F40 gearbox assembly with three transmission shafts is illustrated in the diagram. 1. Gear engagement assembly 2. Layshaft C 3. Main shaft A 4. Layshaft B The gearbox configuration is transverse with three shafts: one main shaft (A) and two layshafts (B and C).There are five fixed gears on the main shaft A which transmit power to the gears for 1st, 2nd, 3rd, 4th, 5th, 6th and Reverse speeds on the two layshafts (B and C) which are permanently meshed.The two layshafts (B and C) both have a pinion which is permanently meshed with the differential ring gear.The layshaft (B) contains 1st and 2nd gears and 5th and 6th gears, whilst layshaft (C) has 3rd and 4th speeds and reverse gear.The gears and drive chains inside the gearbox are lubricated dynamically by channeling oil flows through holes in the casings and on the mainshaft and layshaft and also through additional plastic channels; all this allows improved torque transmission efficiency and more effective wear prevention.The clutch control is hydraulic with a coaxial CSC system coaxial on the mainshaft inside the gearbox.

This system has the following advantages:

• a clutch plate wear recovery device that allows the force on the clutch pedal to be kept constant during the working life of the vehicle.
• improved acoustic comfort
• reduced shift effort
• no vibrations / lever shuddering

Gearbox in neutral

The diagram below illustrates the gearbox when no gear is engaged. 1. 1st speed gear 2. 1st and 2nd speed synchronizer 3. 2nd speed gear 4. 3rd speed gear 5. 3rd and 4th speed synchronizer 6. 4th speed gear 7. 5th speed gear 8. 5th and 6th speed synchronizer 9. 6th speed gear 10. Reverse gear 11. Reverse gear synchronizer 12. Differential A. Main shaft B. Layshaft C. Layshaft

TRANSMISSION OF DRIVE IN DIFFERENT GEARS

First speed

The power enters the gearbox via the main shaft (A) and is transmitted, via the drive gear, to the driven gear for 1st speed on the layshaft (B).When 1st speed is engaged, the synchronizer (2) joins the driven gear (1) with the layshaft (B) and the power is transmitted to the differential (12) thereby completing the kinematic chain. A. Main shaft B. Layshaft 1. 1st speed gear 2. Synchronizer 12. Differential

Second speed

The power enters the gearbox via the main shaft (A) and is transmitted, via the drive gear, to the driven gear (3) for 2nd speed on the layshaft (B). When 2nd speed is engaged, the synchronizer (2) joins the driven gear (3) to the layshaft (B) and the power is transmitted to the differential (12) thereby completing the kinematic chain. A. Main shaft B. Layshaft 2. Synchronizer 3. 2nd speed gear 12. Differential

Third speed

The power enters the gearbox via the main shaft (A) and is transmitted, via the fixed drive gear, to the driven gear (4) for 3rd speed on the layshaft (C). When 3rd speed is engaged, the synchronizer (5) joins the driven gear (4) to the layshaft (C) and the power is transmitted to the differential (12) thereby completing the kinematic chain. A. Main shaft C. Layshaft 4 3rd speed gear 5. Synchronizer 12. Differential

Fourth speed

The power enters the gearbox via the main shaft (A) and is transmitted, via the fixed drive gear, to the driven gear (6) for 4th speed on the layshaft (C). When 4th speed is engaged, the synchronizer (5) joins the driven gear (6) to the layshaft (C) and the power is transmitted to the differential (12) thereby completing the kinematic chain. A. Main shaft C. Layshaft 5. Synchronizer 6. 4th speed gear 12. Differential

Fifth speed

The power enters the gearbox via the main shaft (A) and is transmitted, via the fixed drive gear, to the driven gear (6) for 5th speed on the layshaft (B). When 5th speed is engaged, the synchronizer (8) joins the driven gear (7) to the layshaft (B) and the power is transmitted to the differential (12) thereby completing the kinematic chain. A. Main shaft B. Layshaft 7. 5th speed gear 8. Synchronizer 12. Differential

Sixth speed

The power enters the gearbox via the main shaft (A) and is transmitted, via the fixed drive gear, to the driven gear (9) for 6th speed on the layshaft (B). When 6th speed is engaged, the synchronizer (8) joins the driven gear (9) to the layshaft (B) and the power is transmitted to the differential (12) thereby completing the kinematic chain. A. Main shaft B. Layshaft 8. Synchronizer 9. 6th speed gear 12. Differential

Reverse

The power enters the gearbox via the main shaft (A) and is transmitted to the gear (1) for 1st speed on the layshaft (B).This gear remains free on the shaft and is only designed as an idler for the power between the main shaft (A) and the driven gear (10) for reverse fitted on the layshaft (C).When reverse is engaged, the synchronizer (11) joins reverse gear (10) with the layshaft (C) and the power is transmitted to the differential (12) thereby completing the kinematic chain. A. Main shaft C. Layshaft 1. 1st speed gear (neutral on the shaft) 10. Reverse gear 11. Reverse gear synchronizer 12. Differential

MANUAL GEARBOX EXTERNAL CONTROLS

The external linkage ensures slick, noiseless manoeuvres. 1. Transmission control lever 2. Gear engagement cable 3. Gear selector cable 4. Support for gear selector and engagement cable 5. Gear engagement lever 6. Gear selector lever

CLUTCH CONTROL

COAXIAL HYDRAULIC OPERATION (CSC)

The (CSC) control system consists of an anular actuator cylinder located in the bell housing which controls the clutch, operating coaxially to the main shaft. 1. Air bleed plug 2. Pressurized oil inlet 3. Coaxial hydraulic operation assembly