TRANSAXLE - TA65 Star 2 3. GENERAL INFORMATION TA65 star is similar transmission as current TA65 as regards the architecture of input shaft, lay shaft and differential final drive, bearings and oil seals. The transmission TA65* provides five forward speeds and one reverse speed by means of three synchronizers and input shaft, lay shaft and reverse idler shaft and differential. All forward gears are in constant mesh engaged through synchronizers and reverse gear uses a sliding idler gear arrangement. All the synchronizers are mounted on lay shaft and engaged with gears on lay shaft. The lay shaft turns the final drive gear and differential assembly, thereby turning the front drive shafts which are attached to the front wheels. Movement of gear shift lever / knob is transmitted through gear shift cables and shift /select levers on transmission to the selector shifting finger. This is further transmitted through shifter dogs and shifter forks to the shifter sleeves and synchronizers. Interlock piece is provided to prevent double engagement of gears. Inhibitor is provided to block direct shift from 5th gear to Reverse gear which guides the shift lever towards 4th gear. Central detent is provided for distinct position of gears about neutral position. The major areas of change and benefits over TA65 are: 1. The internal and external gear shifting mechanism and arrangement. TA65 star employees cable shift in place of current rod shift for TA65. The advantages of cable shift over rod shift are: Better end stop feel. No gear shift lever vibrations. No gear lever rocking Ease of routing / packaging, better serviceability. 2. Twin cone carbon lined synchronizers for first and second gears to replace single cone brass synchronizers. Benefits are improved shift smoothness, reduction in shift efforts and enhanced life of synchro cones. 3. Deletion of intermediate plate and its integration into housing front half. This has improved the housing rigidity and accuracy of gear train positioning thus helping reduction in noise level. 4. The selection / shifting bracket in TA65 is replaced by integrating it in to one single unit called ‘Assembly Top cover’ which is placed at top of transmission. 5. Features of top cover are: The shifting components can be serviced by removing the top cover alone. The selector shifter shaft seal is located on top against at bottom in TA65. The top cover is provided with central detent to replace individual detents of shifter shafts. A well optimized cam profile on shifter finger, gives good shift feel and precision. 6. TA65 star front half housing is 10mm wider than of TA65 to accommodate increased inertia flywheel to reduce marching noise. Housings are strengthened as compared to TA65 by additional ribs. 7. Rear cover rubber seal is replaced by liquid gasket. 8 No’s of bolts are used to mount the rear cover in place of 3 bolts in TA65. 8. The reverse light switch is shifted to top side of transmission, to reduce failures of oil dipped switch in TA65. 9. Mechanical Speedo (pinion and gear arrangement) is replaced by contact less Speedo (A sensor and a toothed wheel). This is to improve reliability of Speedo mechanism and to reduce complexity in assembling transaxles.
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