Abstract: A transmission having an integral lubrication (stem for delivering lubrication fluid to transmission components is provided. The lubrication system has a housing with a sump portion for holding the fluid. The lubrication system also includes a pump assembly with inlet and outlet chambers wherein the pump assembly moves the fluid from the inlet chamber to the outlet chamber. The housing has a collection system with an inlet passageway which interconnects the inlet chamber and the sump to provide fluid communication between them. The housing has a distribution system with a plurality of fluid distribution ports for delivering the fluid to the transmission components. The distribution system interconnects said distribution ports and said outlet chamber to provide fluid communication between them. First, second, and third passageways are integrally formed within various portions of the housing and deliver the fluid to bearing portions of the shafts and to the transmission gears.

Abstract: A manual transmission has a main gear box and an auxiliary box with an input shaft extending along an axis from a first end that extends into the auxiliary box for transmitting power to the auxiliary box. The auxiliary box has an output shaft having a second end adjacent the input shaft and coaxial with the axis for transmitting power out of the auxiliary box. A first gear is supported by the input shaft at the first end, and a second and third gear are supported by the output shaft. At least one countershaft having fourth, fifth, and sixth gears affixed to a shaft engages the first, second, and third gears, respectively. A synchronizer and a clutch collar are supported by the output shaft for engaging one of the first, second, and third gears. The arrangement eliminates an intermediate shaft that was required in the prior art.

Abstract: A shift by wire vehicle transmission system includes control methods that are especially useful for controlling the transmission under start-from-stop conditions. Since the master clutch must be manually operated under such conditions, the invention includes a method of determining whether the clutch is open or closed. The rotational speed of the engine output shaft is compared to the rotational speed of the transmission input shaft and if the difference between those speeds is greater than a preselected value, the clutch is determined to be open. Another use of the disclosed method is to provide an indication to the driver whether a desired gear has been engaged. A visual or audible signal indicates to the driver that the desired gear is not yet engaged. Once engagement is confirmed, the signal is turned off and the driver knows that the desired shift has been accomplished.

Abstract: Clutches are provided with electrically controlled actuation elements for selectively moving a sleeve between engaged and non-engaged positions. The electrically controlled elements may include rotary motors driving a sleeve through a ball screw connection. An actuator having a distance amplification element for driving the sleeve is also disclosed.

Abstract: A shift by wire vehicle transmission includes control methods for engaging gears after the vehicle has been at rest or coasting. When the vehicle is started from a stop or rest, a default starting gear is automatically selected. The driver can override the default gear and choose to start driving the vehicle in one gear above or below the default starting gear by manipulating a shift lever. Similarly, the driver can override the default starting gear to begin driving the vehicle in reverse. When the vehicle has been coasting, the transmission control unit chooses the next gear based upon a signal that is provided when the driver manipulates the shift lever. Depending on the indicated desire of the driver, the system controller automatically selects a gear depending upon vehicle speed and torque conditions.

Abstract: A vehicle transmission system includes an automated clutch operator. An electronic controller determines when the transmission is in a neutral condition and controls the automated clutch operator to move the clutch into a non-engaged condition. The electronic controller also determines when the vehicle engine is operating at an idle speed and causes the automated clutch operator to move the clutch into a non-engaged condition only when the engine is idling and the transmission is in a neutral condition, which eliminates neutral idle gear rattle.

Abstract: A method of engaging and disengaging transmission gears in a vehicle is provided. A controller processes an initial torque representing an engine torque and an estimated zero torque representing an estimate of a transmission output shaft torque. The controller also sets a high and low band torque about the estimated zero torque. Once the above torques have been determined, the controller compares the initial torque to the high band torque. If the initial torque is below the high band torque, the controller increases the engine torque to the high band torque. If the initial torque is greater than the high band torque, then no preliminary adjustments to the engine torque need be made. At least one shift valve is energized when the engine torque is equal to or greater than the high band torque. The engine torque is decayed by the controller to the low band torque to facilitate engaging and disengaging transmission gears.

Abstract: A vehicle transmission assembly includes a main gear box that supports an auxiliary gear box assembly, such as a range gear box. The main gear box has a shaft that is coupled to a shaft of the range gear box assembly. The range gear box assembly includes selectively engageable range gears, a shifting assembly, and a range piston assembly. The range piston assembly includes a single piece housing, an air filter regulator, and a range position sensor. The sensor monitors range selection of the range gears and produces a range position signal that is sent to an electronic control unit. The air regulator is threadably attached to the single piece housing and provides air to a pneumatic piston that resides in the housing. The pneumatic piston is used to control the positioning of the range gears.

Abstract: A top cover assembly for a manual transmission having a plurality of gears and a reverse gear is provided. The top cover assembly comprises a shift rail assembly, a reverse biasing assembly, and a shift housing assembly. The shift rail assembly includes a sensing device that interacts with a contoured surface for producing a first electronic signal in response to the shift rail being in a neutral position for range shifting. Another contoured surface acts to center the shift rail and an operatively connected shift lever. For reverse biasing, the shift lever has a first lower shift force when moved to shift at least one of the forward gears. An interlock supported by the shift rail and shift sleeve rotates with the shift rail and acts to lock out other gears during a gear shift. In one aspect of the invention, the interlock is also used for reverse biasing. A detent engages the interlock for creating a higher shift force than the first lower shift force when the shift lever is moved to shift the reverse gear.

Abstract: An improved shift input module may be moved to a stowed position where it is out of the way of a vehicle operator. This allows the operator to move easily about the cab of the vehicle. The module also carries the cruise control buttons, such that they are easily accessible.

Abstract: A multi-speed transmission has a main transmission section and a splitter section. The electronic control for this transmission is operable to either provide the actuation of the splitter system or not allow that actuation. Thus, the operator of the vehicle is able to request either a smaller number of available speed ratios or a larger number of available speed ratios by selecting the appropriate electronic control. The vehicle manufacturer is able to tailor the vehicles to have a transmission which is appropriate to the needs of its customer without having to change the transmission. Moreover, upon resale, a transmission that was initially provided with only a smaller number of speeds may be easily upgraded to provide additional speeds. The control is further reprogrammable to either provide or not provide actuation of the splitter gear. The control may be actuated remotely, such as by a satellite, to provide the additional speed ratios based upon expected driving conditions.