Method of manufacturing and assembling transmission components

Claim 1

A method of manufacturing a drive train, including: forming an input shaft with an input gear mounted thereon, a bearing, an output shaft including a front pilot bearing having a pilot taper for axially aligning with said input shaft, output gearing and clutching mechanism for selectively connecting each output gear to the output shaft and an input gear to the output shaft, and assembling the output gearing and clutching mechanism on the output shaft in operative position to selectively clutch each output gear and the input gear to the output shaft to selectively establish a plurality of ratio drives, and the bearing being fixed on the rear portion of the output shaft; forming a countershaft having a support portion with a pilot taper at each end and a countershaft cluster gear having an input gear and a plurality of ratio gears and each having bearing means, and assembling the cluster gear with the bearing means rotatably supporting the cluster gear on the countershaft; forming an idler gear on an idler shaft; casting a cup-shaped clutch housing having a smooth draftable interior cup-shaped surface and a cupshaped external surface generally smooth eXcept for a draftable securing flange at the lip of the cup-shaped housing and forming in the bottom end wall of the cup-shaped clutch housing an input shaft aperture and a countershaft aperture; and positioning the output shaft in the gear assembly, positioning said cluster gear and countershaft adjacent said gear assembly with said ratio gears of said cluster gear in mesh with said output gears, positioning one end of each of said countershaft and said input shaft into said countershaft aperture and said input shaft aperture, respectively, of said cup-shaped clutch housing, casting a cup-shaped transmission housing having a smooth draftable interior cup-shaped surface and a cup-shaped external surface generally smooth except for a draftable securing flange at the lip of the cup-shaped transmission housing and an annular flange around an opening for the control linkage entry and forming in the bottom end wall of the cup-shaped transmission housing an output shaft aperture, an idler shaft aperture and a countershaft aperture; positioning said idler gear and idler shaft assembly with said idler shaft mounted in said idler shaft aperture of said transmission housing for mesh with a countershaft gear; placing said transmission housing over said assembled output gears, countershaft cluster gear and input gear and against said end wall of said clutch housing, meshing said idler gear with a countershaft gear, and securing and sealing said securing flange to said end wall of said clutch housing.

Claim 2

A method of manufacturing a drive train, including: forming an input shaft with an input gear mounted thereon, a bearing, an output shaft including a front pilot bearing having a pilot taper for axially aligning with said input shaft, output gearing and clutching mechanism for selectively connecting each output gear to the output shaft and an input gear to the output shaft, and assembling the output gearing and clutching mechanism on the output shaft in operative position to selectively clutch each output gear and the input gear to the output shaft to selectively establish a plurality of ratio drives, and the bearing being fixed on the rear portion of the output shaft; forming a countershaft having a support portion with a pilot taper at each end and a countershaft cluster gear having an input gear and a plurality of ratio gears and each having bearing means, and assembling the cluster gear with the bearing means rotatably supporting the cluster gear on the countershaft; forming an idler gear on an idler shaft; casting a cup-shaped clutch housing having a smooth draftable interior cup-shaped surface and a cupshaped external surface generally smooth eXcept for a draftable securing flange at the lip of the cup-shaped housing and forming in the bottom end wall of the cup-shaped clutch housing an input shaft aperture and a countershaft aperture; and positioning the output shaft in the gear assembly, positioning said cluster gear and countershaft adjacent said gear assembly with said ratio gears of said cluster gear in mesh with said output gears, positioning one end of each of said countershaft and said input shaft into said countershaft aperture and said input shaft aperture, respectively, of said cup-shaped clutch housing, casting a cup-shaped transmission housing having a smooth draftable interior cup-shaped surface and a cup-shaped external surface generally smooth except for a draftable securing flange at the lip of the cup-shaped transmission housing and an annular flange around an opening for the control linkage entry and forming in the bottom end wall of the cup-shaped transmission housing an output shaft aperture, an idler shaft aperture and a countershaft aperture; positioning said idler gear and idler shaft assembly with said idler shaft mounted in said idler shaft aperture of said transmission housing for mesh with a countershaft gear; placing said transmission housing over said assembled output gears, countershaft cluster gear and input gear and against said end wall of said clutch housing, meshing said idler gear with a countershaft gear, and securing and sealing said securing flange to said end wall of said clutch housing.

Claim 3

A method of manufacturing a drive train, including: forming an input shaft with an input gear mounted thereon, a bearing, an output shaft including a front pilot bearing having a pilot taper for axially aligning with said input shaft, output gearing and clutching mechanism for selectively connecting each output gear to the output shaft and an input gear to the output shaft, and assembling the output gearing and clutching mechanism on the output shaft in operative position to selectively clutch each output gear and the input gear to the output shaft to selectively establish a plurality of ratio drives, and the bearing being fixed on the rear portion of the output shaft; forming a countershaft having a support portion with a pilot taper at each end and a countershaft cluster gear having an input gear and a plurality of ratio gears and each having bearing means, and assembling the cluster gear with the bearing means rotatably supporting the cluster gear on the countershaft; forming an idler gear on an idler shaft; casting a cup-shaped clutch housing having a smooth draftable interior cup-shaped surface and a cup-shaped external surface generally smooth eXcept for a draftable securing flange at the lip of the cup-shaped housing and forming in the bottom end wall of the cup-shaped clutch housing an input shaft aperture and a countershaft aperture; and positioning the output shaft in the gear assembly, positioning said cluster gear and countershaft adjacent said gear assembly with said ratio gears of said cluster gear in mesh with said output gears, positioning one end of each of said countershaft and said input shaft into said countershaft aperture and said input shaft aperture, respectively, of said cup-shaped clutch housing, casting a cup-shaped transmission housing having a smooth draftable interior cup-shaped surface and a cup-shaped external surface generally smooth except for a draftable securing flange at the lip of the cup-shaped transmission housing and an annular flange around an opening for the control linkage entry and forming in the bottom end wall of the cup-shaped transmission housing an output shaft aperture, an idler shaft aperture and a countershaft aperture; positioning said idler gear and idler shaft assembly with said idler shaft mounted in said idler shaft aperture of said transmission housing for mesh with a countershaft gear; placing said transmission housing over said assembled output gears, countershaft cluster gear and input gear and against said end wall of said clutch housing, meshing said idler gear with a countershaft gear, and securing and sealing said securing flange to said end wall of said clutch housing.

Claim 4

A method of manufacturing a drive train, including: forming an input shaft with an input gear mounted thereon, a bearing, an output shaft including a front pilot bearing having a pilot taper for axially aligning with said input shaft, output gearing and clutching mechanism for selectively connecting each output gear to the output shaft and an input gear to the output shaft, and assembling the output gearing and clutching mechanism on the output shaft in operative position to selectively clutch each output gear and the input gear to the output shaft to selectively establish a plurality of ratio drives, and the bearing being fixed on the rear portion of the output shaft; forming a countershaft having a support portion with a pilot taper at each end and a countershaft cluster gear having an input gear and a plurality of ratio gears and each having bearing means, and assembling the cluster gear with the bearing means rotatably supporting the cluster gear on the countershaft; forming an idler gear on an idler shaft; casting a cup-shaped clutch housing having a smooth draftable interior cup-shaped surface and a cup-shaped external surface generally smooth eXcept for a draftable securing flange at the lip of the cup-shaped housing and forming in the bottom end wall of the cup-shaped clutch housing an input shaft aperture and a countershaft aperture; and positioning the output shaft in the gear assembly, positioning said cluster gear and countershaft adjacent said gear assembly with said ratio gears of said cluster gear in mesh with said output gears, positioning one end of each of said countershaft and said input shaft into said countershaft aperture and said input shaft aperture, respectively, of said cup-shaped clutch housing, casting a cup-shaped transmission housing having a smooth draftable interior cup-shaped surface and a cup-shaped external surface generally smooth except for a draftable securing flange at the lip of the cup-shaped transmission housing and an annular flange around an opening for the control linkage entry and forming in the bottom end wall of the cup-shaped transmission housing an output shaft aperture, an idler shaft aperture and a countershaft aperture; positioning said idler gear and idler shaft assembly with said idler shaft mounted in said idler shaft aperture of said transmission housing for mesh with a countershaft gear; placing said transmission housing over said assembled output gears, countershaft cluster gear and input gear and against said end wall of said clutch housing, meshing said idler gear with a countershaft gear, and securing and sealing said securing flange to said end wall of said clutch housing.

Claim 6

A method of manufacturing a multispeed ratio transmission casing, suitable for variable speed ratios, the method including the following steps: a. forming a clutch housing, a transmission case, and an extension housing by die casting, said clutch housing serving as the forward wall of the transmission case and having first and second openings formed therein for mounting one end of each of a main shaft and countershaft, said transmission case serving as the front wall of the extension housing and having first and second openings formed therein and aligned with said first and second openings, respectively, in said clutch housing for mounting the other end of each of the mainshaft and countershaft, and a third opening formed therein for mounting a reverse idler gear, and said extension housing having first and second bosses formed on an inner surface thereof; and b. forming an opening in the first boss axially aligned with said transmission case third opening, said formed opening and said third opening serving as means for mounting a reverse idler and input gear shaft therein.

Claim 7

A method of manufacturing a multispeed ratio transmission casing, suitable for variable speed ratios, the method including the following steps: a. forming a clutch housing, a transmission case, and an extension housing by die casting, said clutch housing serving as the forward wall of the transmission case and having first and second openings formed therein for mounting one end of each of a main shaft and countershaft, said transmission case serving as the front wall of the extension housing and having first and second openings formed therein and aligned with said first and second openings, respectively, in said clutch housing for mounting the other end of each of the mainshaft and countershaft, and a third opening formed therein for mounting a reverse idler gear, and said extension housing having first and second bosses formed on an inner surface thereof; and b. forming an opening in the first boss axially aligned with said transmission case third opening, said formed opening and said third opening serving as means for mounting a reverse idler and input gear shaft therein.

Claim 8

A method of manufacturing a multispeed ratio transmission casing, suitable for variable speed ratios, the method including the following steps: a. forming a clutch housing, a transmission case, and an extension housing by die casting, said clutch housing serving as the forward wall of the transmission case and having first and second openings formed therein for mounting one of each of a mainshaft and countershaft, said transmission case serving as the front wall of the extension housing and having first and second openings formed therein aligned with said first and second openings, respectively, in said clutch housing for mounting the other end of each of the mainshaft and countershaft, and a third opening formed therein for mounting a reverse idler gear, and said extension housing having first and second bosses formed on an inner surface thereof; b. forming an opening in the first boss axially aligned with said transmission case third opening, said formed opening and said thiRd opening serving as means for mounting a reverse idler and input gear shaft therein; c. forming an opening in the second boss axially aligned with said clutch housing and transmission case second openings suitable for mounting one end of an extension shaft therein; and d. forming said second opening in the transmission case larger, suitable for mounting bearings therein to support an end of the countershaft to which the other end of the extension shaft is splined.

Claim 9

A method of manufacturing a multispeed ratio transmission casing, suitable for variable speed ratios, the method including the following steps: a. forming a clutch housing, a transmission case, and an extension housing by die casting, said clutch housing serving as the forward wall of the transmission case and having first and second openings formed therein for mounting one of each of a mainshaft and countershaft, said transmission case serving as the front wall of the extension housing and having first and second openings formed therein aligned with said first and second openings, respectively, in said clutch housing for mounting the other end of each of the mainshaft and countershaft, and a third opening formed therein for mounting a reverse idler gear, and said extension housing having first and second bosses formed on an inner surface thereof; b. forming an opening in the first boss axially aligned with said transmission case third opening, said formed opening and said thiRd opening serving as means for mounting a reverse idler and input gear shaft therein; c. forming an opening in the second boss axially aligned with said clutch housing and transmission case second openings suitable for mounting one end of an extension shaft therein; and d. forming said second opening in the transmission case larger, suitable for mounting bearings therein to support an end of the countershaft to which the other end of the extension shaft is splined.

Claim 10

A method of assembling a four-speed transmission on a motor vehicle, the method including the following steps: a. mounting the mainshaft assembly including input gear, first, second and third ratio output gears and countershaft assembly including drive gear, first, second and third ratio input gears on the rear wall of the clutch housing, said mainshaft of said assembly extending through an opening therein into the clutch housing; b. mounting the transmission case on the mainshaft and countershaft, the mainshaft extending through an opening formed in the rear wall of the transmission case; c. mounting the reverse output gear on the extension of the mainshaft; d. mounting the speedometer drive gear on the extension of the mainshaft; e. mounting the extension housing including a shifter fork on the mainshaft and against the rear wall of the transmission housing; and f. mounting the side cover assembly including first-second and third-fourth shifter forks on the transmission housing.

Claim 11

A method of assembling a four-speed transmission on a motor vehicle, the method including the following steps: a. mounting the mainshaft assembly including input gear, first, second and third ratio output gears and countershaft assembly including drive gear, first, second and third ratio input gears on the rear wall of the clutch housing, said mainshaft of said assembly extending through an opening therein into the clutch housing; b. mounting the transmission case on the mainshaft and countershaft, the mainshaft extending through an opening formed in the rear wall of the transmission case; c. mounting the reverse output gear on the extension of the mainshaft; d. mounting the speedometer drive gear on the extension of the mainshaft; e. mounting the extension housing including a shifter fork on the mainshaft and against the rear wall of the transmission housing; and f. mounting the side cover assembly including first-second and third-fourth shifter forks on the transmission housing.