3022463 - 2110B manual gearbox with differential gears and synchronisers

COMPONENT DESCRIPTIONS

main shaft

The main shaft consists of:

• 1st, Reverse and 2nd speed gears
• 3rd, 4th, 5th speed gears, fitted on needle bearings with the synchronizers

3rd, 4th and 5th speed gears fitted on the shaft make it possible to:

• reduce shift loads during synchronisation
• reduce gearbox noise while in neutral.

The main shaft is supported by means of two ball bearings.The co-axial clutch device is fitted to the end of the main shaft [ Characteristic of working principle 1820  CLUTCH RELEASE CONTROLS].

Layshaft

The layshaft consists of:

• 1st and 2nd speed gears, fitted on needle bearings with synchronizers
• 3rd, 4th and 5th speed gears fitted on the shaft.

The layshaft is supported on:

• a roller bearing at the pinion end
• a ball bearing at the cover end.

Reverse idler gear

This gear is designed to reverse the direction of rotation of the layshaft.

Gears

The gears are the following type:

• helical toothed for the forward speeds
• straight toothed for Reverse.

synchronisers

The synchronizers for all the gears are brass, baulk ring 'Borg-Warner' of the type:

• double cone for 1st and 2nd speeds;
• single cone for 3rd, 4th and 5th speeds.

Multiple cone synchronizers make it possible to:

• distribute the lever engagement load over several cones;
• facilitate the engagement of the gears.

1 - Sleeve 2 - Single-cone synchronizer 3 - Pre-synchronizer mounting 4 - Hub-1 - Sleeve 2 - Double-cone synchronizer 3 - Pre-synchronizer mounting 4 - Hub

Pre-synchronizer mounting

To facilitate the operations of dismantling and reassembly pre-synchronizer mountings have been fitted between the hub and the sleeve and each synchronizer unit.

Gear shift/selection system

The gear shift/selection system consists of:

• a swinging control (1) connected to selector dog (2)
• selector dog (2) which operates sliding rods (4) fitted with synchronisation sleeve control forks (3, 5, 6, 7).

1 - Fluctuating control 2 - Selector dog 3 - 1st and 2nd engagement/selector fork 4 - Sliding rods 5 - 5th engagement/selector fork 6 - 3rd and 4th engagement/selector fork 7 - Reverse engagement/selector fork

Safety devices

The safety devices consist of:

• three dowels (1) that prevent two speeds being engaged at the same time
• dowel (3), pin (4) and spring (5), which maintain reversing dog (2) in a safe position to prevent dangerous movements of reversing fork (9) with the attendant possibility of engaging reverse.
• Lever (10) and spring (11), which prevent involuntary engagement of reverse while changing from 5th to 4th speed.

1 - Safety dowels 2 - Reverse dog 3 - Dowel 4 - Pin 5 - Spring 6 - 5th and Reverse rod 7 - 3rd and 4th rod 8 - 1st and 2nd rod 9 - Reverse selector fork 10 - Lever 11- Spring