Frelander 2. Manual — part 349
16
-
Ball limiter for gear selector
The transmission is operated by two shift cables which are attached to the selector lever. Movement of the selector lever
is passed via the cables to two lever mechanisms on the top of the transmission. The levers operate a shift control
mechanism within the transmission to select the requested gear ratio.
The shift control mechanism is located at the front of the transmission and transfers the shift cable movement into gear
selections.
The shift control mechanism is a one-piece assembly which is retained in the transmission housing with 4 bolts. The shift
control mechanism moves the upper and lower gear selector forks via the lateral and longitudinal levers on the top of the
shift control mechanism. There are 2 upper selector forks and 2 lower selector forks as follows:
The 2 upper gear selector forks are used to engage reverse, 1st or 2nd gears
The 2 lower gear selector forks are used to engage 3rd, 4th, 5th and 6th gears.
The 4 selector forks transfer movement from the shift control mechanism to the relevant shift coupling sleeve. The shift
forks are mounted in bearings in the transmission case.
Two carrier plates transfer torque from the longitudinal lever to the sliding gear selectors. The carriers are located and run
in a groove in the gear selector plate.
The carrier plates can move vertically between 4 positions. The different gears are selected from one of the 4 positions as
follows:
Uppermost position - gear selector selects reverse gear
Second uppermost position - gear selector selects 1st and 2nd gears
Second lowest position - gear selector selects 5th and 6th gears
Lowest position - gear selector selects 3rd and 4th gears.
The shift control mechanism has two springs that return the selector lever to the neutral position.
Transmission Shift Selector Shafts
The above illustration shows the coupling sleeves for each gear cluster. Movement of these sleeves as selected by the
shift control mechanism, connect the required gear trains together to produce the required output ratio.
The coupling sleeve is part of the synchronizing hub assembly which also consists of a flange and the hub. Each
synchronizing hub is joined to its shaft by splines and rotates with it. Idler wheels are fitted on both sides of each
synchronizing hub. The idler wheels rotate freely on the shaft (with the exception of reverse gear). Each idler wheel is
constantly engaged in its pinion. The synchronizing set is positioned between the synchronizing hub and the idler wheel.
The synchronizing units are positioned on the shafts in the transmission as follows:
The synchronizing unit for 1st - 2nd gear is on the intermediate shaft 1st - 2nd, 5th - 6th
The synchronizing unit for 3rd - 4th gear is on the intermediate shaft 3rd - 4th
The synchronizing unit for 5th-6th gear is on the input shaft
The synchronizing unit for reverse gear is on the reverse shaft.
The synchronizing rings expand when heated by the same amount as the components they are in contact with. As a result
no safety margin is required to counter expansion. The idler wheels for single and double synchronization have no cones.
An inner ring on the synchronizer unit performs this function instead.
Transmission Gear Cluster
Item
Part Number
Description
A
-
Input shaft
B
-
Intermediate shaft 1st to 2nd, 5th to 6th
C
-
Intermediate shaft 3rd to 4th
D
-
Reverse shaft
1
-
Reverse final gear
2
-
Reverse idler gear
3
-
Reverse gear coupling sleeve
4
-
Final gear - Differential
5
-
2nd gear - idle gear
6
-
5th gear
7
-
6th gear
8
-
6th gear - idle gear
9
-
5th to 6th gear coupling sleeve
10
-
4th gear - idle gear
11
-
5th gear - idle gear
12
-
3rd to 4th gear coupling sleeve
13
-
4th gear
14
-
2nd gear path
15
-
1st gear path
16
-
3rd gear - idle gear
17
-
3rd to 4th final gear pinion
18
-
3rd gear
19
-
1st to 2nd gear coupling sleeve
20
-
1st to 2nd and 5th to 6th final gear pinion
21
-
1st gear - idle gear
The gear wheels are located on four shafts, as follows:
Input shaft
Intermediate shaft 1-2, 5-6
Intermediate shaft 3-4
Reverse shaft.
In order to keep the shafts short, the clutch gears are welded directly to the idler wheel and needle bearings with inner
rings are used instead of snap rings. The inner rings sit on the shaft inside the idler gears and extend lengthwise outside
each idler gear. W hen the components on the shafts are pulled together the inner rings counterhold, so that the idler
wheels have the clearance that they require to rotate. The components of the input shafts are pulled together with a bolt
located in the end of the shaft. Components of intermediate shaft 3rd -4th are held together with a press joint and a bolt
located in the end of the shaft. The components of intermediate shaft 1st -2nd, 5th -6th are held together with the press
joint of the 5th and 6th gear pinion.
1st Gear Power Flow
Item
Part Number
Description
A
-
Input shaft
B
-
Intermediate shaft 1st - 2nd and 5th - 6th
4
-
Ring gear
15
-
1st gear
19
-
1st - 2nd gear coupling sleeve
20
-
Final drive 1st - 2nd and 5th - 6th
21
-
1st gear idler gear
When 1st gear is selected, the coupling sleeve for 1st - 2nd gear is moved by a gear selector fork along the synchronizing
hub towards the 1st gear idler gear. The coupling sleeve and the synchronizing hub lock the 1st gear idler gear at the
intermediate shaft 1st - 2nd and 5th - 6th.
Engine torque is transferred to the input shaft via the clutch. The 1st gear rack on the input shaft transfers the power to
the 1st gear idler gear. From there the power is transferred to the intermediate shaft 1st - 2nd and 5th - 6th and to the
final drive, which in turn transfers power to the ring gear. The ring gear is connected to the drive shafts through the
differential.
2nd Gear Power Flow
Item
Part Number
Description
A
-
Input shaft
B
-
Intermediate shaft 1st - 2nd and 5th - 6th
4
-
Ring gear
5
-
2nd gear idler gear
14
-
2nd gear
19
-
1st - 2nd gear coupling sleeve
20
-
Final drive 1st - 2nd and 5th - 6th
When 2nd gear is selected, the coupling sleeve for 1st - 2nd gear is moved by a gear selector fork along the synchronizing
hub towards the 2nd gear idler gear. The coupling sleeve and the synchronizing hub lock the 2nd gear idler gear at the
intermediate shaft 1st - 2nd and 5th - 6th.
Engine torque is transferred to the input shaft via the clutch. The 2nd gear rack on the input shaft transfers the power to
the 2nd gear idler gear. From there the power is transferred to the intermediate shaft 1st - 2nd and 5th - 6th and to the
final drive, which in turn transfers power to the ring gear. The ring gear is connected to the drive shafts through the
differential.
3rd Gear Power Flow
Item
Part Number
Description
A
-
Input shaft
C
-
Intermediate shaft 3rd - 4th
4
-
Ring gear
12
-
3rd - 4th gear coupling sleeve
16
-
3rd gear idler gear
17
-
Final drive 3rd - 4th
18
-
3rd gear
When 3rd gear is selected, the coupling sleeve for 3rd - 4th gear is moved by a gear selector fork along the synchronizing
hub towards the 3rd gear idler gear. The coupling sleeve and the synchronizing hub lock the 3rd gear idler gear at the
intermediate shaft 3rd - 4th.
Engine torque is transferred to the input shaft via the clutch. The 3rd gear rack on the input shaft transfers the power to
the 3rd gear idler gear. From there the power is transferred to the intermediate shaft 3rd - 4th and to the final drive, which
in turn transfers power to the ring gear. The ring gear is connected to the drive shafts through the differential.
4th Gear Power Flow
Item
Part Number
Description
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