Abstract
Manual transmissions dominate the Indian market for their obvious benefit of low cost and higher mechanical efficiency resulting in higher fuel economy. Development of new Transmission starts much before the actual concept of vehicle and development is done keeping in mind the future vehicle applications, Government (emission & FE) norms and market trends. The same Transmission may have to cater to range of applications in that vehicle segment. During conceptualization of new vehicle, existing transmission is examined for requirements of new application. One of important check is response of driveline (transmission) to abuse loads due to the change of application. Current small transmission was not satisfying the minimum strength criteria for abuse loads based on initial design calculation for the new application due to increase in GVW and Tire size. This paper describes the work that was carried for limiting the magnitude of abuse loads. Actual tests were performed in prototype vehicle for measurement of abuse loads with different type of clutch release system. Finally with the change of Clutch release system, the abuse loads were resulted within the acceptable limit for small size transmission. This approach has helped us meet the cost and weight targets for new application.