Power Flow - Forward Gears
The power flow through the AR5 transmission speed gears is a basic transmission design. During 1st gear (110), 2nd gear (120) or 3rd gear (130), the input shaft (100) delivers the power from the engine to the transmission. The external teeth on the input shaft (100) engage with the front gear on the counter shaft (400). Depending on the selected gear position, the power flows from a countershaft gear to a speed gear and then through the speed gear selector teeth. The gear selector teeth engage with the synchronizer sleeve. The synchronizer sleeve is slip splined on the synchronizer hub. The synchronizer hubs are press fit on the output shaft, therefore delivering the engine power to the output shaft (195).
- 1st gear
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Moving the 1st/2nd shift fork (210) rearward, moves the 1st/2nd synchronizer sleeve (170). The inner teeth on the synchronizer sleeve push against the blocking ring teeth, causing the synchronizer rings to contact, and the speed gear and the output shaft to match speeds. The synchronizer sleeve (170) then engages the selector teeth on 1st gear (110). Power flow is now from the input shaft (100) to the countershaft (400) to the 1st gear (110), through the synchronizer and to the output shaft (195).
- 2nd gear
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Moving the 1st/2nd shift fork (210) forward, moves the 1st/2nd synchronizer sleeve (170). The inner teeth on the synchronizer sleeve push against the blocking ring teeth, causing the synchronizer rings to contact, and the speed gear and the output shaft to match speeds. The synchronizer sleeve (170) then engages the selector teeth on 2nd gear (120). Power flow is now from the input shaft (100) to the countershaft (400) to the 2nd gear (120) through the synchronizer and to the output shaft (195).
- 3rd gear
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Moving the 3rd/4th shift fork (230) rearward, moves the 3rd/4th synchronizer sleeve (234). The inner teeth on the synchronizer sleeve push against the blocking ring teeth, causing the synchronizer rings to contact, and the speed gear and the output shaft to match speeds. The synchronizer sleeve (234) then engages the selector teeth on 3rd gear (130). Power flow is now from the input gear (100) to the countershaft (400) to the 3rd gear (130) through the synchronizer and to the output shaft (195).
- 4th gear
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In 4th gear, the power flow goes directly from the input shaft (100) to the output shaft (195) through the 3rd/4th synchronizer. This happens because 4th gear is the same ratio as the engine speed. When moving the 3rd/4th shift fork (230), the 3rd/4th synchronizer sleeve (234) inner teeth push against the single blocking ring teeth for 4th gear. Matching the input shaft (100) to the output shaft (195) allows the synchronizer sleeve to engage to the selector teeth on the input shaft (100).
- 5th gear
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5th gear is an overdrive ratio. Because 5th gear is overdrive, the 5th gear (150) is splined on the rear of the output shaft (195). The 5th countershaft gear (450) is located on the rear of the countershaft (400) and rotates on needle bearings. The 5th countershaft gear (450) is larger diameter, with more teeth than 5th gear (150). The power flow for 5th gear is from the input shaft (100) to the countershaft (400). Moving the 5th shift fork (250) rearward, the 5th/reverse synchronizer sleeve (254) pushes against the teeth on the blocking ring, forcing the blocking ring against the middle ring. The middle ring has tabs in the 5th synchronizer gear (255). The blocking rings match the speed of the 5th synchronizer gear (255) and the 5th countershaft gear (250), which is rotating by the 5th gear (150). Matching the speeds, the synchronizer sleeve slides onto the 5th synchronizer gear. Power flows from the countershaft (400) to the 5th synchronizer gear (255), through the synchronizer sleeve. With the synchronizer sleeve also engaged with the 5th countershaft gear (450), power flows from the 5th countershaft gear (450) to the 5th gear (150) and to the output shaft (195), which now turns faster than the speed of the input shaft (100).