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Drivetrain System (Power Transmission)

Automobile Maintenance · 自動車整備分野 · Written by Tokutei Pass based on the official study texts; not copied verbatim.

Drivetrain Layout (FR and FF Vehicles) and Gear Ratio Calculation

The drivetrain (power transmission system) changes speed and increases the rotational torque generated by the engine according to driving conditions and transmits it to the drive wheels.

In an FR (front-engine, rear-wheel-drive) vehicle, power flows in the order: Engine → Clutch → Transmission → Propeller shaft → Final gear (Differential) → Axle shafts (Drive shafts) → Rear wheels.

In contrast, an FF (front-engine, front-wheel-drive) vehicle uses a transaxle that integrates the transmission and final gear (differential) into a single unit.

Because left and right drive shafts directly drive the front wheels from the transaxle, an FF vehicle has no propeller shaft.

When two gears mesh, the gear ratio is calculated by: Gear ratio = Number of teeth on driven gear ÷ Number of teeth on drive gear. Driving a large gear with a small gear reduces rotational speed to 1 ÷ gear ratio and multiplies torque by the gear ratio.

Furthermore, the product of the transmission gear ratio and the final gear reduction ratio is called the total reduction ratio (overall gear ratio = transmission gear ratio × final reduction ratio). When starting off or climbing a hill, a large gear ratio such as 1st gear is selected to obtain high driving force.

Drivetrain Layout (FR and FF Vehicles) and Gear Ratio Calculation

Key points


  • FR vehicles use a propeller shaft to send power to the rear axle, whereas FF vehicles drive the front wheels directly from the transaxle via drive shafts and have no propeller shaft

  • Gear ratio = Driven gear teeth ÷ Drive gear teeth; speed reduction lowers rotational speed and increases torque in proportion to the gear ratio

  • Total reduction ratio = Transmission gear ratio × Final gear reduction ratio

  • Example: When the drive gear has 15 teeth and the driven gear has 45 teeth, gear ratio = 45 ÷ 15 = 3.0, rotational speed becomes 1/3, and torque becomes 3 times greater

  • Example: When the transmission gear ratio is 2.5 and the final gear reduction ratio is 4.0, the total reduction ratio = 2.5 × 4.0 = 10.0
WordMeaning
Propeller shaft
Drive shaft
Transaxle
Gear ratio (transmission ratio)

Clutch Structure, Operation, and Pedal Free Play

The clutch is located between the engine and transmission to connect and disconnect power. It smoothly engages power via friction when starting off and cleanly interrupts power when shifting gears or stopping.

Manual transmission (MT) vehicles widely use a dry single-plate clutch with a disc-shaped diaphragm spring. Friction facings are riveted to both sides of the clutch disc, which is pressed tightly between the flywheel and pressure plate to transmit power.

Coil springs (torsion springs) are built into the hub of the clutch disc to absorb rotational shock during engagement and dampen engine torque fluctuations.

In a hydraulic clutch release mechanism, pressing the pedal sends hydraulic pressure from the clutch master cylinder to the release cylinder, pushing the center of the diaphragm spring via the release fork and release bearing to disengage the clutch.

The clutch pedal requires a specified amount of free play—the distance the pedal moves when pressed lightly by finger until resistance is felt.

As the clutch disc facing wears down, the pressure plate moves closer to the flywheel, causing clutch pedal free play to decrease (become smaller). If free play reaches zero, the clutch slips; conversely, excessive free play causes poor disengagement (gear grinding during shifts).

Clutch Structure, Operation, and Pedal Free Play

Key points


  • Torsion springs in the clutch disc absorb engagement shock and rotational fluctuations for smooth power transmission

  • As the clutch disc (facing) wears, clutch pedal free play decreases (becomes smaller—note that it does not increase)

  • Insufficient (zero) clutch pedal free play causes clutch slipping, whereas excessive free play causes poor clutch disengagement
WordMeaning
Diaphragm spring
Clutch disc
Torsion spring
Release bearing

Transmission Structure and Function (MT, AT, and CVT)

A manual transmission (MT) is equipped with a synchromesh mechanism that uses friction on the conical surface of a synchronizer ring to match (synchronize) the rotational speeds of meshing gears during shifting.

This prevents gear clash (grinding) and allows smooth shifting with light effort. An interlock mechanism is also provided to prevent two gears from engaging simultaneously.

The torque converter of an automatic transmission (AT) is a hydrodynamic coupling that transmits power through ATF (automatic transmission fluid). It consists of three elements: a pump impeller driven by the engine, a turbine runner connected to the output shaft, and a stator supported on a one-way clutch between them.

The stator redirects ATF returning from the turbine runner so that it assists pump impeller rotation, thereby multiplying torque. During high-speed cruising, a lock-up mechanism mechanically connects the input and output sides to eliminate fluid slip loss and improve fuel economy.

The gear unit of an AT uses planetary gear sets, whereas a CVT (Continuously Variable Transmission) uses hydraulic pressure to vary the groove widths of primary and secondary pulleys, continuously changing the running radius of a steel belt or chain for stepless, smooth shifting.

Key points


  • The MT synchromesh mechanism uses synchronizer ring friction to synchronize gear speeds and prevent gear noise during shifting

  • A torque converter consists of a pump impeller (input), turbine runner (output), and stator (torque multiplication), while the lock-up clutch eliminates fluid slip loss

  • A CVT varies the groove width of two pulleys to change the steel belt or chain wrap radius steplessly
WordMeaning
Synchromesh mechanism
Torque converter
Planetary gear
Lock-up mechanism

Propeller Shafts and Drive Shafts (Universal Joints)

In FR and 4WD vehicles, the propeller shaft connects the transmission (fixed to the body) with the differential/final gear (which moves up and down continuously with road bumps).

Therefore, it is equipped with universal joints to accommodate changes in joint angle and a sleeve yoke (splined slip joint) to absorb axial length changes.

A single Hooke joint (cross-type universal joint) used on a propeller shaft produces rotational speed fluctuations twice per revolution when operating at an angle. Therefore, two Hooke joints are arranged at both ends of the shaft to cancel out speed fluctuations and transmit rotation at constant velocity.

In contrast, drive shafts that drive the front wheels of FF vehicles or independent-suspension drive wheels use constant velocity joints (CVJs) that transmit power smoothly without rotational fluctuations even at large steering angles.

Barfield (Rzeppa) CV joints capable of large steering angles are used on the wheel (outboard) side of the drive shaft, while tripod or double-offset CV joints capable of both angular change and axial sliding (plunge) are used on the differential (inboard) side.

Each joint is sealed by a rubber drive shaft boot filled with special grease.

Propeller Shafts and Drive Shafts (Universal Joints)

Key points


  • The sleeve yoke (spline) of a propeller shaft absorbs axial length changes caused by up-and-down suspension movement

  • Because a Hooke joint causes speed fluctuations at an angle, two or more joints are combined to cancel out non-constant velocity

  • FF drive shafts use constant velocity joints (CVJs: Barfield type on the wheel side and sliding tripod/double-offset type on the differential side)
WordMeaning
Universal joint
Sleeve yoke
Hooke joint (cross joint)
Constant velocity joint (CVJ)

Final Gear (Final Reduction) and Differential

The final gear performs the final speed reduction and torque multiplication through the meshing of the drive pinion and ring gear. In FR vehicles, hypoid gears or spiral bevel gears are used to turn the direction of power transmission by 90° toward the left and right axle shafts.

A hypoid gear is a bevel gear set in which the drive pinion axis is offset below the center line of the ring gear. This lowers the propeller shaft and cabin floor and provides quiet operation with a high contact ratio, but high tooth sliding speed requires extreme-pressure hypoid gear oil.

When a vehicle turns a corner, the outer wheel travels a longer distance than the inner wheel, creating a rotational speed difference between the left and right drive wheels. The differential automatically absorbs this speed difference to prevent tire scrubbing and allow smooth cornering.

The differential consists of a differential case rotating integrally with the ring gear, differential pinions supported on a pinion shaft inside the case, and left and right side gears connected to the axles. When driving straight ahead, the differential pinions do not spin on their own axis but revolve together with the case, rotating both side gears at the same speed.

Key points


  • FR final gears use hypoid gears to perform final speed reduction and change the direction of rotation by 90°

  • The differential automatically absorbs the rotational speed difference between left and right drive wheels (outer wheel > inner wheel) during cornering

  • When driving straight, road resistance on both wheels is equal, so the differential pinions do not spin on their own shaft and both side gears rotate at the same speed
WordMeaning
Final gear (final reduction unit)
Hypoid gear
Differential
Differential pinion and side gear

Differential Rotational Characteristics and LSD (Limited Slip Differential)

The differential obeys the key relationship: Left side gear speed + Right side gear speed = Ring gear (differential case) speed × 2. That is, whatever speed one wheel loses, the opposite wheel gains by the exact same amount.

For example, when the ring gear rotates at 100 rpm while driving straight ahead, both the left and right wheels rotate at 100 rpm.

If the inner wheel slows to 80 rpm during a turn, the outer wheel rotates at 200 - 80 = 120 rpm. Furthermore, if the vehicle is jacked up and one wheel is held stationary (0 rpm), the opposite wheel rotates at twice the ring gear speed, or 200 rpm.

Because of this property, with a standard open differential, if one drive wheel slips on mud or ice, only the slipping wheel spins rapidly while no driving force is transmitted to the opposite wheel on firm ground, making it impossible to get unstuck.

To prevent this, sports cars and off-road vehicles use an LSD (Limited Slip Differential) that restricts differential action when a large speed difference occurs, distributing driving torque to the non-slipping wheel as well.

Key points


  • The average speed of the left and right side gears (drive wheels) always equals the ring gear speed (Left + Right = Ring gear × 2)

  • If one wheel spins on mud or ice, the other wheel loses drive torque too; an LSD (Limited Slip Differential) restricts differential action to maintain traction

  • Example: When the ring gear rotates at 150 rpm and one wheel is stopped at 0 rpm, the opposite wheel rotates at twice that speed: 300 rpm

  • Example: When the ring gear rotates at 100 rpm and the inner wheel slows to 70 rpm in a turn, the outer wheel rotates at (100 × 2) - 70 = 130 rpm
WordMeaning
Differential action
Wheel spin (slip)
LSD (Limited Slip Differential)

Drivetrain Inspection and Maintenance Precautions

During routine and periodic clutch inspections, check that the fluid level in the clutch reservoir tank is between MAX and MIN, measure clutch pedal free play and pedal-to-floor clearance when fully depressed, and verify smooth gear shifting without abnormal noise with the engine running.

To inspect manual transmission (MT) oil or differential gear oil, park the vehicle level, remove the filler plug, and check that the oil level reaches near the bottom edge of the plug hole and that there are no leaks around the drain plug or oil seals.

Because automatic transmission fluid (ATF) expands with temperature, warm up the engine to normal operating temperature, let it idle, shift the selector lever slowly through all ranges and back to P (or N), and check that the fluid level is within the HOT range on the dipstick.

On FF and 4WD vehicles, always visually inspect the rubber drive shaft boots protecting the CV joints for tears, cracks, or grease leakage. Driving with a torn boot lets water and sand enter the joint, causing rapid wear and clicking or popping noises when turning.

Key points


  • Clutch inspection includes checking pedal free play, floor clearance when fully depressed, and reservoir fluid level

  • Check AT fluid (ATF) level with the engine warmed up and idling, after shifting through all ranges and returning the lever to P (or N)

  • A torn drive shaft boot leaks grease and allows water and dirt into the CV joint, causing abnormal noise and failure during cornering
WordMeaning
ATF (Automatic Transmission Fluid)
Filler plug and drain plug
Drive shaft boot

Frequently Tested Points and Memory Tips

The most common trap question on clutches is: What happens to clutch pedal free play when the clutch disc wears?

Unlike brake pads, as the clutch disc wears, the pressure plate moves closer to the flywheel, so clutch pedal free play decreases (becomes smaller). Zero free play causes clutch slipping, while excessive free play causes poor disengagement.

For transmissions, memorize as a set: MT synchromesh = synchronizes gear speeds by friction to prevent gear clash; AT torque converter = Pump impeller (input), Turbine runner (output), and Stator (torque multiplication); Lock-up mechanism = direct mechanical coupling to eliminate fluid slip and improve fuel economy.

For shafts and joints, contrast FR vs. FF: FR vehicles have a propeller shaft (Hooke joints + sliding sleeve yoke), whereas FF vehicles have no propeller shaft and drive the front wheels directly with drive shafts (CV joints).

For differentials and gear ratios, lock in three rules: Gear ratio = Driven teeth ÷ Drive teeth; Differential pinions do not spin on their own axis when driving straight; Stopping one wheel makes the opposite wheel spin at twice the ring gear speed.

Key points


  • Clutch disc wear causes pedal free play to decrease / Too little free play = slipping; too much free play = poor disengagement

  • Synchromesh = speed synchronization / Torque converter stator = torque multiplication / Lock-up clutch = direct connection to prevent slip loss

  • FF vehicles have no propeller shaft and drive the front wheels using drive shafts equipped with constant velocity joints (CVJs)

  • The differential absorbs left-right wheel speed differences in turns; when driving straight, diff pinions revolve with the case without spinning on their own axis

  • Gear ratio = Driven teeth ÷ Drive teeth / Total reduction ratio = Transmission gear ratio × Final gear reduction ratio
WordMeaning
Pedal free play
Poor disengagement
Spinning on own axis (rotation) and revolving (revolution)

Official references

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