MR2 Manual Gearbox

 A car need a transmission so that it is easier on the engine to move the car because if it was direct the engine must have a lot of low end torque to move a 1000kg car from stand still and lots of horsepower for speed. 
The gear ratios of the gears is the most important thing to get a good start and a top speed.



To work out gear ratios
gear ratio=input driven/input driver X output driven/output driver


This gear box ratio 
1st 3.29
2nd 1.96
3rd1.32
4th 1.03
5th 0.82
reverse 3.15
                                                                                                                                                            

1.Remove the selector

2.Undo all the bolt on top of the cap.

3.Using a pry bar or a screwdriver, place it against a leverage and impact it with a hammer until  the silicon give way.

4.The cover should come off like this.

 5. Remove all the c clip at the top of all the gears.       6.the reverse gear should slip right out or else use a gear puller

7. Remove the bolts for the plate and the c clips on the shaft.











8. remove all the bolts for the second case and hit all the leverage places to crack the silicon.

 9. here is all the gears 1, 2 ,3 ,4, and 5

and heres the synchros  

10.The gears and shaft should slip out from the bottom casing 

11. Whats left of the casing. the final drive and bearings

Puting it back together

1. Make sure the reverse gear is the right way up(notic how the square in the middle of the slit is higher) or else the gears and the synchros wont be compact enough for the shaft so the c clip wont go on.

Perfect fit

This is the gears the wrong way up notice how its taller 

2. When putting the selector in make sure it is in neutral. as you can see all the square slit lines up.

3. Should slip right in.

Capacitor

Capacitors are used to store charge Q and this charge is usefull it acts like a battery after the power supply have been removed it is also used to smooth out voltage. Capacitance is measured in fared (1 Fared is 1,000,000, mF microfared). Capacitors takes less than a second to fully charge.

Time constant
T=5RC
(R)resistor=ohms
(C)capacitance=farad
(T)time=sec

Measure charge
C=Q/V
(C)capacitance=farad
(Q)charge=coulombs
(V)voltage=V

To measure capacitance in
Series :  1/Ct=1/C1+1/C2
Parallel : Ct=C1+C2

ignition system

Mechanically timed ignition

Ignition systems are use in a car to deliver spark  to ignite the air fuel mixture in the cylinder.it has to be at the right time and the spark has to last long enough  for it to be able to burn all the fuel before the exhaust valve is open this maximise the power and lowers emission.


This type of Ignition system consist of the following battery/alternator, low tension cable,ignition coil, high tension cable , distributor , spark plug cable and the spark plug


The system has two circuit the primary low tension circuit and the secondary which goes from the secondary  coil in the ignition to the distributor which then rotates and  distribute to all four leads 

Clutch

A clutch is a mechanical device that is use to limit the amount of torque being sent from driving to driven,  that is why it is so important to upgrade the clutch to prevent slipping when the engine is upgrade to more power.
In cars clutched are used to free up the transmission from the motor so that the motor keep revving when the gear is being changed.


How it works

http://autorepair.about.com/library/a/1i/bl201i.htm
The flywheel is bolt on to the crank, clutch disk is bolt on to the flywheel and the pressure plate is bolt on to the flywheel aswell. Through it all is the drive shaft (from the crank out put) which is where the clutch paddle thrust bearing is ( infront of the the pressure plate). When the clutch paddle is press the clutch thrust bearing depresses the inner pressure plate which in turn leavers up the outer pressure plate lifting it off the clutch disk.

Driveshaft/line

A drive shaft/propeller shaft  is a mechanical component that is use to  transfer the torque and rotation that the engine has made from one end to the other end.


Drive shafts have to be strong enough to withstand a huge amounts of stress and torsion and also be as light as possibly so that they can respond quickly (known as inertia), each drive shaft is usually balanced before assemble to minimize vibration for a smoother ride.


Drive shafts usually have one or more universal joints (Constant velocity joint, Cardan joint and Thompson Couplingl) to allow unexpected changes in the structure when under stress.


CV type drive shaft

CV Joint

Constant velocity joints (known as  CV joints) allow a drive/axle shaft to transmit power through different angles with out a noticeable increase in friction or vibration and  contains a constant rotational speed.

In automotive CV joints are use on the axle shaft to transmit the power from the gearbox/differential to the hub.

on some 4WD their even used on the end of the drive shaft (propeller shaft) for a smoother transmit of torque from the front to the back differential.

Constant-velocity joints are packed with grease and protected by a rubber boot a split boot will alow contaminant from the road and will result in quicker wear. 

How to replace a worn CV joint

CV joint kit : New boot , 2 clamp ,C clip, Grease and CV

Step 1. Remove CV/ Hub nut 32mm in my case

Step 2.  Remove all link to the hub (eg tie rod) 

Step 3. Remove boot clamp.

Step 4. Lift the hub off the CV

Step 5. hit back of CV to remove from axle shaft






















Step 6. As seen here CV is removed so now replace the C clip.

Step 7. Assemble CV.

4841 Voltage regulator

A voltage regulator is a electrical component that can regulate a higher voltage (input) into a specific voltage (out put) and maintain a constant voltage level even though the input voltage fluctuate.But the input voltage must not drop below 2v of the specify voltage of the out put eg 5v out put, the input must not drop below 7v or else the out put will start to go lower.

As seen in the above picture , this is my circuit from my AC to DC blog. I use a 7805 regulator 05 stands for the voltage its going to out put. From the bridge rectifier it has a raw voltage of 16v which is then pass through the voltage regulator and out put a steady 5V.