Advanced Vehicle Technology To my long-suffering wife, who has provided sup- port and understanding throughout the preparation of this book. Advanced Vehicle Technology Second edition Heinz Heisler MSc., BSc., F.I.M.I., M.S.O.E., M.I.R.T.E., M.C.I.T., M.I.L.T. Formerly Principal Lecturer and Head of Transport Studies, College of North West London, Willesden Centre, London, UK OXFORD AMSTERDAM BOSTON LONDON NEW YORK PARIS SAN DIEGO SAN FRANCISCO SINGAPORE SYDNEY TOKYO Butterworth-Heinemann An imprint of Elsevier Science Linacre House, Jordan Hill, Oxford OX2 8DP 225 Wildwood Avenue, Woburn, MA 01801-2041 First published by Edward Arnold 1989 Reprinted by Reed Educational and Professional Publishing Ltd 2001 Second edition 2002 Copyright # 1989, 2002 Heinz Heisler. All rights reserved The right of Heinz Heisler to be identified as the author of this work has been asserted in accordance with the Copyright, Designs and Patents Act 1988 No part of this publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means and whether or not transiently or incidentally to some other use of this publication) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act 1988 or under the terms of a license issued by the Copyright Licensing Agency Ltd, 90 Tottenham Court Road, London, England W1T 4LP. Applications for the copyright holder's written permission to reproduce any part of this publication should be addressed to the publishers Whilst the advice and information in this book are believed to be true and accurate at the date of going to press, neither the authors nor the publisher can accept any legal responsibility or liability for any errors or omissions that may be made. Library of Congress Cataloguing in Publication Data A catalogue record for this book is available from the Library of Congress ISBN 0 7506 5131 8 For information on all Butterworth-Heinemann publications visit our website at www.bh.com Typeset by Integra Software Services Pvt. Ltd, Pondicherry, India www.integra-india.com Printed and bound in Great Britain ..........................................................................................1 Vehicle structure ................................................................................1.1 Integral body construction 1.2....................................................... Engine, transmission and body structures .........................................................................1.3 Fifth wheel coupling assembly ............................................................1.4 Trailer and caravan drawbar couplings ..................................................................................1.5 Semi-trailer landing gear ..............................................................1.6 Automatic chassis lubrication system ..............................................................................................2 Friction clutch ........................................................................................2.1 Clutch fundamentals 2.2 Angular driven plate cushioning.................................. and torsional damping ....................................................................................2.3 Clutch friction materials 2.4 Clutch..................................................... drive and driven member inspection .........................................................................................2.5 Clutch misalignment ...............................................................................2.6 Pull type diaphragm clutch .....................................................................2.7 Multiplate diaphragm type clutch .................................................................2.8 Lipe rollway twin driven plate clutch 2.9 Spicer twin driven plate...................................... angle spring pull type clutch .....................................................................................2.10 Clutch (upshift) brake 2.11 Multiplate hydraulically operated automatic transmission................ clutches ....................................................................................2.12 Semicentrifugal clutch ...................................................................2.13 Fully automatic centrifugal clutch ..............................................................2.14 Clutch pedal actuating mechanisms 2.15 Composite flywheel and integral single plate.................... diaphragm clutch .............................................................3 Manual gearboxes and overdrives .............................................................................3.1 The necessity for a gearbox 3.2 Five speed and........................................... reverse synchromesh gearboxes ...........................................................3.3 Gear synchronization and engagement 3.4 Remote controlled gear.................................... selection and engagement m ..............................................................3.5 Splitter and range change gearboxes .............................................................................3.6 Transfer box power take-off .................................................................................3.7 Overdrive considerations ............................................................................................3.8 Setting gear ratios 4 Hydrokinetic fluid couplings............................... and torque converters .............................................................................4.1 Hydrokinetic fluid couplings 4.2 Hydrokinetic fluid coupling efficiency............................... and torque capacity .......................................................................................4.3 Fluid friction coupling 4.4 Hydrokinetic................................................... three element torque converter 4.5 Torque..................................................... converter performance terminology ..............................................................................................4.6 Overrun clutches ..................................................................4.7 Three stage hydrokinetic converter 4.8......................................................... Polyphase hydrokinetic torque converter 4.9 Torque converter with lock-up and gear change.................... friction clutches 5 Semi-.................................................... and fully automatic transmission .............................................................5.1 Automatic transmission consideration 5.2 Four speed and reverse longitudinally mounted automatic transmission ...........................................................................................mechanical power flow 5.3 The fundamentals.............................................. of a hydraulic control system 5.4 Basic principle of a .......................................hydraulically controlled gearshift 5.5....................................................... Basic four speed hydraulic control system 5.6 Three speed and reverse transaxle automatic transmission mechanical ..............................................................................................................power flow 5.7 Hydraulic.................................................. gear selection control components 5.8....................................................... Hydraulic gear selection control operation 5.9 The continuously variable................................... belt and pulley transmission 5.10 Five speed automatic transmission with electronic-hydraulic............ control 5.11 Semi-automatic (manual gear change two pedal control) transmission .................................................................................................................... system 6 Transmission bearings and............................... constant velocity joints ...................................................................................6.1 Rolling contact bearings ................................................................6.2 The need for constant velocity joints .............................................................................7 Final drive transmission 7.1........................................................ Crownwheel and pinion axle adjustments ...............................................................................................7.2 Differential locks ................................................................................7.3 Skid reducing differentials ....................................................................................7.4 Double reduction axles ..............................................................................................7.5 Two speed axles ...........................................................................7.6 The third (central) differential .......................................................................7.7 Four wheel drive arrangements .............................................................7.8 Electro-hydralic limited slip differential 7.9 Tyre grip when braking and accelerating with good and poor road .................................................................................................................surfaces ..................................................................................7.10 Traction control system .............................................................................................................8