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Internal-combustion engines run at high speeds, so a reduction in gearing is necessary to transmit power to the drive wheels, which turn much more slowly.
Driving a car with a DSG gearbox isn’t really any different to driving most other automatics - you’ll need to put your foot on the brake to switch between neutral, park, reverse or drive. We would like to show you a description here but the site won’t allow us.
The gearbox provides a selection of gears for different driving conditions: standing start, climbing a hill, or cruising on level surfaces. The lower the gear, the slower the road wheels turn in relation to the engine speed.
The gearbox is the second stage in the transmission system, after the clutch. It is usually bolted to the rear of the engine, with the clutch between them.
Modern cars with manual transmissions have four or five forward speeds and one reverse, as well as a neutral position.
The gear lever, operated by the driver, is connected to a series of selector rods in the top or side of the gearbox. The selector rods lie parallel with shafts carrying the gears.
The most popular design is the constant-mesh gearbox. It has three shafts: the input shaft, the layshaft and the mainshaft, which run in bearings in the gearbox casing.
There is also a shaft on which the reverse-gear idler pinion rotates.
The engine drives the input shaft, which drives the layshaft. The layshaft rotates the gears on the mainshaft, but these rotate freely until they are locked by means of the synchromesh device, which is splined to the shaft.
It is the synchromesh device which is actually operated by the driver, through a selector rod with a fork on it which moves the synchromesh to engage the gear.
The baulk ring, a delaying device in the synchromesh, is the final refinement in the modern gearbox. It prevents engagement of a gear until the shaft speeds are synchronised.
On some cars an additional gear, called overdrive, is fitted. It is higher than top gear and so gives economic driving at cruising speeds.
Synchronising the gears
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The synchromesh device is a ring with teeth on the inside that is mounted on a toothed hub which is splined to the shaft.
When the driver selects a gear, matching cone-shaped friction surfaces on the hub and the gear transmit drive, from the turning gear through the hub to the shaft, synchronising the speeds of the two shafts.
With further movement of the gear lever, the ring moves along the hub for a short distance, until its teeth mesh with bevelled dog teeth on the side of the gear, so that splined hub and gear are locked together.
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Modern designs also include a baulk ring, interposed between the friction surfaces. The baulk ring also has dog teeth; it is made of softer metal and is a looser fit on the shaft than the hub.
The baulk ring must be located precisely on the side of the hub, by means of lugs or 'fingers', before its teeth will line up with those on the ring.
In the time it takes to locate itself, the speeds of the shafts have been synchronised, so that the driver cannot make any teeth clash, and the synchromesh is said to be 'unbeatable'.
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Thank you for visiting SCS Gearbox, your number one source for quality manufactured quick change gears, 4×4 transfer cases, custom machining, high performance transmissions and so much more. For answers to questions about ordering, give us a call at 419-483-7278 or by emailing us at sales@scsgearbox.com. In the meantime, browse through the rest of our website to learn more about our products.
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SCS Gearbox Inc, manufactures specialized gearing for high performance racing applications in tractors, trucks, and much more. When you take the time to see all that we have to offer, you will find a company with a track record of exceptional products with outstanding customer service. SCS Gearbox Inc. is a company that never settles for being less than the best it can be. Here is a sample of what we have to offer. You will find that we have just what you’re looking for.
We are a company that grows with its clientele. We have expanded to provide the wide range of items that we sell today and we will continue to grow with our clientele into the future. If you need Quick Change Gears and Custom Machining or a 4×4 Transfer Case, Transmissions, and Truck Gears. We will do our very best to give you what you need.
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Please remember when giving our company a call that each customer means as much to us as the next. Our phone calls tend to last around 20 minutes per customer. We strive to give each customer the time and respect that they deserve. Your wait time could be extended as we are assisting others. We appreciate customers who are willing to hold. Your call will be taken in order as received. We understand your time is as valuable as ours. We can take a message and give you a call back at our earliest convenience. Please remember that we tend to be very busy and when you cannot hold for a chance to talk to a Tech or Sales Associate you may have a longer wait to get a return call from us. Thank you for your understanding.