The FWD Gearbox transfers the torque and power of the engine to the wheels. It has a number of gears that mesh in order to provide higher and lower gear ratios. Higher gear ratios mean car can take off and drive up steep gradients. The lower ratios mean higher speeds are available at lower RPM to achieve better efficiency.
The Disassembling Was relatively easy, Although The gearboxes we used had not been apart many times so the 5th gear was relatively tight on the shaft. We didnt have the correct service tool to remove the gear but as a last measure used a puller that acted on the gear itself. This was done very carefully to ensure no damage to teeth occurred.
When inspecting the gears i looked for any pitting, chips or grooves. All the gears were in surprisingly good condition. Although as expected the reverse sliding gears had a little more wear than the rest but it would have been fine to return into service.
During the time the gearbox was apart i learned about the detent mechanisms and the interlock mechanisms. The detent balls and springs hold the gear shafts in place so the gearbox wont slip out of gear. The interlock stops the driver from selecting 2 gears at the same time. It is a very important part and is highly efficient yet is only comprised of two ball bearings.
Reassembling took longer than planned. The shafts are a bit tricky to put in correctly however with a bit of unplanned practice i soon got quicker. Due to me forgetting to turn the reverse gear idler shaft to the correct point to ensure it lines up with the casing. A Mistake i will not make again is it was very time consuming.
Once reassembled the gearbox went through all the gears properly and didnt have any issues. Great success.
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