TRANSMISSION ASSEMBLY

Summary

This video provides a step-by-step guide for assembling a transmission system, specifically focusing on the installation of gears, synchronizers, and clutch components. Key procedures include aligning synchronizer keys, inserting synchronizer rings, and securing components with precision. The video emphasizes proper lubrication with transmission oil (ATF or gear oil) and highlights the importance of correct positioning to avoid assembly errors. Practical tips such as using a flathead screwdriver for precise assembly and ensuring parts stay in place during the process are also shared. The detailed instructions make the process clear for both beginners and experienced mechanics.

Takeaways

• 😀 Begin by inserting the second gear into place, ensuring it is properly aligned.
• 😀 After inserting the second gear, assemble the clutch for the first and second gears, including the synchronizer ring and synchronizer sleeve.
• 😀 The synchronizer key should be positioned with the raised edges aligned near the circular holes of the hub.
• 😀 Always use a flat screwdriver to help guide the synchronizer ring into place, ensuring it locks securely.
• 😀 After inserting the first and second synchronizer rings, check that the hub remains centered and rotate it to lock everything in place.
• 😀 For the output shaft, verify the synchronizer sleeve is positioned correctly before inserting the first gear.
• 😀 Ensure the correct orientation of the roller bearing and bearing bushings when installing the first gear.
• 😀 Use ATF (Automatic Transmission Fluid) or gear oil, never engine oil, to lubricate the components during the assembly process.
• 😀 When securing the locknut, make sure it is positioned properly to facilitate future disassembly.
• 😀 Flip the assembly over to insert the third gear and repeat the synchronizer key and snap ring installation process.
• 😀 Always perform a final check to confirm the proper alignment of all components and ensure smooth movement of the assembly.

Q & A

What is the first step in assembling the gear system?

The first step is to insert the second gear and assemble the clutch components, including the synchronizer rings for the first and second gears.

How do you insert the synchronizer key correctly?

The synchronizer key must be positioned with its bumps aligned with the corresponding holes on the synchronizer ring. It should be inserted with precision to ensure proper engagement.

What tool is used to assist with the insertion of synchronizer rings?

A flathead screwdriver is used to help push the synchronizer rings into their correct positions within the hub.

Why is lubrication important during the assembly process?

Lubrication is important to ensure smooth operation and to prevent parts from becoming stuck or damaged. Transmission oil (ATF or gear oil) should be used to lubricate bearings and gears.

What is the purpose of the synchronizer in the gear assembly?

The synchronizer ensures smooth engagement between the gears by aligning their speeds and preventing grinding when shifting between gears.

What should you do if the synchronizer components do not fit correctly?

If the synchronizer components do not fit correctly, check that the keys and rings are aligned properly. Adjust the positioning and make sure there are no obstructions before reassembling.

What is the correct position for the main drive bearing during installation?

The main drive bearing should be installed with the small end facing down, ensuring that it fits snugly into its designated slot.

What happens if the snap rings are not inserted properly?

If the snap rings are not inserted properly, the components they are holding in place could become dislodged, leading to potential failure during operation.

Why is it important to check the final assembly by rotating the gears?

Rotating the gears allows you to check for smooth operation and ensures that all components are aligned and functioning as they should. It helps detect any issues before completing the assembly.

What oil should be used for lubricating the transmission parts, and why can't engine oil be used?

Transmission oil, either ATF or gear oil, should be used because it is thicker and designed for the specific requirements of the transmission system. Engine oil is too thin and won't provide the necessary lubrication for the gears.