1. 1 Power Transmission System Presentation IKCO Samand

2. 2 Table of Contents... Clutch System BE3/5 Manual Gearbox MA5 Manual Gearbox AL4 Automatic Gearbox Drive Shaft

3. 3 Samand Power is transmitted from the engine to the gearbox via a clutch. This clutch consists of a dry plate and a pressure plate of diaphragm spring type. The release mechanism is mechanical, being operated by a cable. Power is transmitted from the flywheel on the engine to the input shaft in the gearbox via a driven plate. This power is transmitted by the pressure plate, which is bolted to the flywheel, forcing the friction surface of the driven plate against the flywheel. Clutch System… 1. System overview:

4. 4 Samand Type: Diaphragm spring type. Diameter: 200mm. Clutch System… 2. Pressure plate:

5. 5 Samand Type: Single dry plate with diaphragm spring. Clutch System… 3. Driven plate:

6. 6 Samand The gearbox is designed for front wheel drive and forms a unit with the engine. The drive unit is transversely mounted in the car, which gives good cooling and the shortest possible route for the transfer of power to the drive wheels. This location also contributes to a compact engine compartment. The gearbox has five forward gears, all of which have synchromesh. BE3/5 Manual Gearbox… Characteristics - identification

7. 7 Samand engine codeLFZ – N6A special features185/65 R 15 H type of gearboxBE3/5 gearbox ratios : 1st11 X 38 gearbox ratios : 2nd23 X 43 gearbox ratios : 3rd25 X 32 gearbox ratios : 4th39 X 41 gearbox ratios : 5th47 X 35 gearbox ratios : reverse12 X 40 final drive ratio(s)17 X 61 speedometer drive gear19 X 17 BE3/5 Manual Gearbox… Characteristics - identification

8. 8 Performance Manual Gearbox – BE3/5 Basic design Samand

9. 9 Performance Manual Gearbox – BE3/5 Basic design Samand

10. 10 Samand ( 1 ) Location of gearbox reference. ( 2 ) Self adhesive label fitted for factory assembly use. BE3/5 Manual Gearbox… Characteristics - identification 2 1

11. 11 Samand ( 1 ) Protector. ( 2 ) Obturator. ( 3 ) Lower opening obturator. ( 4 ) Rear gearbox obturator. 4 3 2 1 BE3/5 Manual Gearbox… 1. Obturators:

12. 12 Samand ( 1 ) Heavy duty ribbed casing. ( 2 ) Heavy duty sun and planet wheels. ( 3 ) Single pin differential cross shaft pin in blind hole. 3 2 1 BE3/5 Manual Gearbox… 2. Special feature:

13. 13 Samand ( 1 ) Gearbox casing. ( 2 ) Level plug. ( 3 ) Bolt. 3 2 1 BE3/5 Manual Gearbox… 3. Gearbox casing:

14. 14 Samand ( 1 ) Retaining pin. ( 2 ) Nut from the input shaft. ( 3 ) Circlip from the 1st/2nd, 3rd/4th fork shaft. 3 2 1 BE3/5 Manual Gearbox… 4. 5th gear:

15. 15 Samand 1 7 6 7 4 3 5 ( 1 ) One-piece engagement shaft and lever. A: Cassette. assembly comprising: ( 2 ) Sleeve. ( 3 ) Reverse engagement finger. ( 4 ) 1st-2nd, 3rd-4th and 5th engagement finger. ( 5 ) Interlock key. ( 6 ) Spring. ( 7 ) Cups. BE3/5 Manual Gearbox… 5. Gear controls:

16. 16 Samand ( 1 ) Input shaft. ( 2 ) Output shaft. 1 2 BE3/5 Manual Gearbox… 6. Shafts:

17. 17 Samand ( 2 ) 4th speed driving gear. ( 3 ) Bush ( 4 ) Synchroniser and hub. ( 5 ) 3rd speed driving gear. 3 2 4 5 BE3/5 Manual Gearbox… 7. Gears:

18. 18 Samand 1 4 5 2 3 ( 1 ) 5th speed driven wheel. ( 2 ) Bearing. ( 3 ) 4th and 3rd speed driven gear. ( 4 ) 2nd speed driven gear. ( 5 ) 2nd speed gear bush. BE3/5 Manual Gearbox… 7. Gears :

19. 19 Samand ( 1 ) Crown wheel bolts. ( 2 ) Crown wheel ( 3 ) Differential cross pin tension pin. ( 4 ) Differential cross pin. ( 5 ) Two planet wheels. ( 6 ) Two thrust washers 1 2 3 4 6 6 5 5 BE3/5 Manual Gearbox… 8. Differential:

20. 20 Samand ( a ) 18 shims from 0.7 to 2.4mm - in 0.1mm steps. ( b ) 12 shims from 1.1 to 2.1mm - in 0.1mm steps. b a BE3/5 Manual Gearbox… 9. Adjustment:

21. 21 Samand ( 1 ) Bolt. ( 2 ) Bearing guide. ( 3 ) Shim. ( 4 ) The bearing outer race. ( 5 ) Bearing guide oil seal. 5 1 4 3 2 BE3/5 Manual Gearbox… 9. Adjustment:

22. 22 Samand 1 2 5 4 3 2 ( 1 ) Screw, washer and speedometer drive. ( 2 ) Bolt and drive housing. ( 3 ) O. ring. ( 4 ) Speedometer gear. ( 5 ) Shim. BE3/5 Manual Gearbox… 9. Adjustment:

23. 23 Samand 2 5 6 3 4 1 ( 1 ) Gear lever. ( 2 ) Gear lever housing. ( 3 ) Gear lever ball. ( 4 ) Ball race. ( 5 ) Selector rod. ( 6 ) Gear linkage. Transfer of force from the gear lever to the gearbox is via a linkage which transmits both torsional and shear forces with the least possible friction to achieve low shifting force. BE3/5 Manual Gearbox… 10. Gear change linkage:

24. 24 Samand Gate positions are as shown on the gear lever knob. In order to engage reverse the gearlever must be depressed whilst selecting reverse. In the neutral position, the spring- loading inside the gearbox causes the gear lever to attempt to maintain an equilibrium position between 3rd and 4th gears. This is so it is easy for the driver to find his way around the gear layout and avoid engaging the wrong gear. BE3/5 Manual Gearbox… 11. Gearchange lever:

25. 25 Samand 2 1 ( 1 ) Drain plug. ( 2 ) Gearbox and final drive filler and level plug. The gearbox is equipped with two plugs, these are used for work on the gearbox which requires the oil to be drained. When checking level or topping up, the filler/level plug is removed and oil is topped up until it flows out of the level plug. A dry gearbox has a capacity of 1.9 litres of oil. BE3/5 Manual Gearbox… 12. Lubrication:

26. 26 Samand Oil Type: ESSO GEAR OIL BV [ Parts Ref. 9736.41 ] Oil Viscosity: 75 W 80 Oil Capacity: 1.9 Liters Service Interval: Every 60,000 km BE3/5 Manual Gearbox… 13. Maintenance:

27. 27 Samand BE3/5 Manual Gearbox…Special Tools

28. 28 Samand MA5 Manual Gearbox… Characteristics - identification The MA5 gearbox has 5 forward gears and reverse gear.

29. 29 Samand engine codeN6A special features185/65 R 15 H type of gearboxMA/5 gearbox ratios : 1st12 X 41 gearbox ratios : 2nd20 X 39 gearbox ratios : 3rd30 X 41 gearbox ratios : 4th37 X 39 gearbox ratios : 5th41 X 35 gearbox ratios : reverse12 X 43 final drive ratio(s)17 X 64 speedometer drive gear21 X 18 MA5 Manual Gearbox… Characteristics - identification

30. 30 Samand Area of marking (A) - (B From 02/2000): The component reference. Serial number. MA5 Manual Gearbox… Characteristics - identification

31. 31 Samand MA5 N Gearbox fitted to TU5JP4 engine MA5 Manual Gearbox… Characteristics - identification

32. 32 Samand (20) the steel casing. WARNING: do not oil the seal (19) of the metal casing (20). MA5 Manual Gearbox… 1. Gearbox casing:

33. 33 Samand (13) The fork: 5th. (14) The 5th synchroniser. (15) The thrust washer. (16) The stop washer. (17) The notched nut. MA5 Manual Gearbox… 2. 5th speed drive:

34. 34 Samand (11) The stop ring. (12) The spring washer. (13) The needle roller bearing. (14) The spacer ring. (15) The spacer washer distance piece. MA5 Manual Gearbox… 2. 5th speed drive:

35. 35 Samand (10) The 3 speed driven gear. (11) The stop ring. (12) The 2 speed driven gear. (13) The synchroniser ring (2nd). (14) The 1st/2nd synchroniser. (15) The synchroniser ring (1st). (16) The stop ring. (17) The 1st speed driven gear. (18) The stop ring. (19) The lubrication nipple. MA5 Manual Gearbox… 3. Output shaft:

36. 36 Samand ( 4 ) The washer. ( 5 ) The 4 speed driven gear. ( 6 ) The synchroniser ring (4th). ( 7 ) The 3rd/4th synchroniser. ( 8 ) The synchroniser ring (3th). MA5 Manual Gearbox… 3. Output shaft:

37. 37 Samand ( 1 ) The reverse idler shaft. ( 2 ) The plastic bush. ( 3 ) The reverse sliding gear. MA5 Manual Gearbox… 4. Reverse gear shaft:

38. 38 Samand ( 1 ) Fork: 1st/2nd. ( 2 ) Fork: 3rd/4th. ( 3 ) Fork: 5th. ( 4 ) Reverse fork. ( 5 ) Reverse fork control relay. ( 6 ) 3rd/4th fork shaft. ( 7 ) 5th speed fork and reverse relay shaft. ( 8 ) Reverse gear brake spring. ( 9 ) Reverse gear brake spring retaining circlip. ( A ) 1st/2nd fork control lug. ( B ) Reverse fork drive pin. ( C ) 5th speed fork and reverse relay control lug. MA5 Manual Gearbox… 5. Forks:

39. 39 Samand ( 7 ) The engagement shaft. ( 8 ) The engagement shaft seal. ( 9 ) The spring. (10) Two thrust cups (depending on the type of gearbox assembly). MA5 Manual Gearbox… 6. Gear engagement shaft:

40. 40 Samand (11) Interlock key. MA5 Manual Gearbox… 6. Gear engagement shaft:

41. 41 Samand ( 1 ) Sleeve. ( 2 ) Hub. ( 3 ) Ball. ( 4 ) Spring. ( 5 ) Finger. MA5 Manual Gearbox… 7. Conventional synchroniser 1st/2nd:

42. 42 Samand ( 6 ) Sleeve. ( 7 ) Hub. ( 8 ) Ball. ( 9 ) Finger. (10) Ball seat. (11) Spring. MA5 Manual Gearbox… 8. Improved 1st/2nd synchroniser:

43. 43 Samand (12) Sleeve. (13) Hub. (14) Ball. (15) Spring. (16) Finger. MA5 Manual Gearbox… 9. Conventional synchroniser 3rd/4th/5th:

44. 44 Samand ( 6 ) The differential pinion shaft circlip. ( 7 ) The differential pinion shaft. ( 8 ) The planet wheels, turning the sun wheels. ( 9 ) The friction housing. (10) The sun wheels. (11) The sun gear centraliser, opposite the crown wheel. MA5 Manual Gearbox… 10. Differential:

45. 45 Samand (12) Use ESSO NORVA 275 grease to coat the hinges. (13) Use ESSO 3106 grease to coat the hinge. ( 7 ) Use LOCTITE FRENETANCH to coat the thread of bolt. MA5 Manual Gearbox… 11. Gear change linkage:

46. 46 Samand (1) Drain plug. (2) Filler and level plug. Drain the gearbox when warm. Always replace the drain and top-up plug seal. Shake the new can of oil before use to make the mixture uniform (the additives settle at the bottom of the can). MA5 Manual Gearbox… 12. Lubrication:

47. 47 Samand Oil Type: ESSO GEAR OIL BV or TOTAL Transmission BV Oil Viscosity: 75 W 80 Oil Capacity: 2.0 Liters Service Interval: Every 60,000 km MA5 Manual Gearbox… 13. Maintenance:

48. 48 Samand MA5 Manual Gearbox… Special Tools

49. 49 An Automatic Gearbox Option will be made available for the SAMAND LX TU5 engine range: - the [ AL4 ] Auto-Adaptive 4-speed Automatic Gearbox, fitted to the TU5 engine only * AL4 Automatic Gearbox * : under design Samand AL4 Automatic Gearbox…

50. 50 The AL4 Automatic Gearbox is designed to be lubricated for life. However, periodic oil quality and oil level checks MUST be carried out The AL4 incorporates a Oil quality diagnosis function ( Oil Temperature Sensor + ECU program ) Samand AL4 Automatic Gearbox… Service Maintenance:

51. 51 ONLY ESSO LT 71141 Transmission Fluid should be used when replacing the fluid in the AL4 gearbox Excerpt taken from the SAMAND LX Owner’s Handbook Samand AL4 Automatic Gearbox… Service Maintenance:

52. 52 Samand Power is transmitted from the gearbox to the wheels by means of two solid-steel driveshafts of unequal length. Constant velocity joints are fitted to each end of the driveshafts, to ensure a smooth and efficient transfer of power at all suspension and steering angles. Drive Shaft… 1. System overview :

53. 53 Samand Both driveshafts are splined at their outer ends to accept the wheel hubs, and are threaded so that each hub can be fastened by a large nut. The inner end of each driveshaft is splined, to accept the differential sun gear. A very rigid intermediate shaft runs from the right side of the differential and is mounted in an extra support bearing attached to the engine block. Drive Shaft… 2. Drive shafts:

54. 54 Samand The inner constant velocity (CV) joint is of tripod type and consists of housing and tripod. The tripod has three rollers mounted in needle bearings and can be moved axially in the tripod housing. The outer CV joint transmits engine torque from the drive shaft to hub and wheel. The drive shaft is linked to the outer CV joint with splines and is secured with a circlip. The joint is shaped like a bell with spherical grooves where ball bearings transfer the drive from the drive shaft to the hub. The CV joint is permanently greased and protected by a gaiter. the joint is only lubricated when the gaiter is changed or when the joint is dismantled for some other reason. Drive Shaft… 3. Constant velocity joints:

55. 55 … The End Questions ? IKCO Samand