By Alec Stokes
Essential e-book for somebody designing handbook gearboxes, in accordance with forty years of commercial event.
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Additional info for Manual Gearbox Design
On surfaces with loose gravel, potholes or thick mud, the road wheels will have a tendency to bounce and skid. This tendency will be increased due to the low internal resistance of the differential. With such movement occurring on one wheel, the end result is wheel-spin, which creates an unbalanced drive which makes the vehicle difficult to control and could result in violent skidding. The bevel or pinion type of 28 Manual Gearbox Design differential consists of either a spider with two trunnions carrying two differential pinions, or with four trunnions carrying four differential pinions, each pinion being backed by a thrust washer.
However, the roller-type bearing has its inner track complete with rollers clamped on the intermediate shaft and its outer track positively located into the gearbox rear cover. This bearing arrangement permits the internal gears to be assembled onto the intermediate shaft along with the shaft bearings, so that the assembly can be fully checked prior to the gearbox rear cover being fitted. An alternative arrangement used in some gearbox designs has the bearing positions reversed, the roller bearing being at the forward end and the location ball bearing being at the rear end of the intermediate shaft, but this does lead to complications during the centralizing of the internal ratios on assembly, especially when checking the neutral position and fully engaged position of the face dogs.
Using the point where the vertical line crosses the maximum torque line, and joining this with the point on the engine maximum revolution horizontal line coinciding with the maximum road speed required, will provide a guide-line for the bottom points of other intermediate ratios. The ratio nearest to but above the minimum engine revolution torque band-line must be used as the first approximation for second gear, unless second gear has to be fixed to meet some specific target, such as zero to a given miles per hour where only one gear change is allowable.
Manual Gearbox Design by Alec Stokes