6.2.1. Features of a design

The Ford Fusion cars in a basic equipment equip with the mechanical Durashift five-speed transmission. By request the advanced mechanical five-step robotic Durashift EST transmission with the mode of consecutive manual switching which is not demanding pressing of a pedal of coupling can be installed on cars with the petrol engine with a working volume of 1,4 l. Also with the 1,6 l engine install automatic four-speed transmissions on cars.
In this section removal and installation are described on the example of the mechanical transmission. Other transmissions are removed and established almost similarly.
The mechanical transmission is executed according to the two-shaft scheme with five synchronized transfers of the forward course. The transmission and the main transfer with differential have the general case of 2 (fig. 6.3). The case of the 5th coupling is attached to a forward part of a case of the transmission. On a back part of a case of the transmission the steel stamped cover 1 is established.

Fig. 6.3. Schematic diagram of the mechanical five-speed transmission: 1 – back cover of a case of the transmission; 2 – transmission case; 3 – сапун; 4 – working cylinder of a hydraulic actuator of switching off of coupling; 5 – coupling case; 6 – coupling switching off bearing; 7 – main shaft; 8 – secondary shaft; 9 – main transfer and differential

On primary to a shaft 7 the gear wheel of the V transfer recorded on shaft vents with the synchronizer is located, and the leading gear wheels I, II, III and IV transfers are made for a single whole with a main shaft.
The secondary shaft 8 is made together with the leading gear wheel of the main transfer 9. Besides on a shaft the slidings which are freely rotating on bearings the conducted gear wheels I, II, III, IV and V transfers are established.
Transfers of the forward course join axial movement of couplings of two synchronizers I-II and III-IV of transfers and the couplings of the synchronizer V of transfer installed on secondary to a shaft. The mechanism of gear shifting is located in a transmission case from its left side.
The drive of control of the mechanical transmission consists of the coulisse of the lever of gear shifting with the spherical support established on the basis of a body, two cables of switching and the choice of transfers, and also the mechanism installed in a transmission case. For ensuring accurate inclusion of transfers the lever of gear shifting of the mechanism of switching is manufactured for a single whole with a massive counterbalance. Cables of the choice and gear shifting structurally differ from each other and are not interchanged.
The main transfer is executed in the form of couple of cylindrical gear wheels which are picked up for noise. The torque is transferred from the conducted gear wheel of the main transfer to differential and further to drives of forward wheels.
The differential is conic, two-satellite. Tightness of connection of internal hinges of drives of forward wheels with gear wheels of differential is provided with epiploons.
The automatic transmission with an adaptive control system provides the choice of the optimum mode of gear shifting practically for any styles of driving and road conditions.
The automatic transmission is grouped according to the traditional planetary scheme with braking by friction clutches and connected to a bent shaft of the engine via the hydrotransformer. Feature of a box of the Ford Fusion cars in comparison with automatic transmissions of the previous generations is the possibility of transition from completely automatic control mode to the manual mode (the so-called sekventalny transmission) at which the driver during dispersal of the car independently chooses a moment of switching to the raising transfer. It allows at desire to achieve more intensive dispersal in comparison with the automatic mode, artificially detaining switching to the raising transfer that allows to bring the frequency of rotation of a bent shaft of the engine to the range of the greatest torque. At the same time the electronic control system constantly controls the speed of the car and loading of the engine, excludes the driver's mistakes, without allowing it to include higher transfer at a small speed of the movement to avoid an engine overload, and also without allowing to include the lowering transfer on too high speed that excludes a possibility of excess of the most admissible frequency of rotation of a bent shaft of the engine. At reduction of speed of the car of transfer automatically switch to lower without participation of the driver. At the time of a full stop of the car the I transfer automatically joins.
The drive of control of the automatic transmission hummock, is designed by the same principle, as the drive of management of a mechanical box, but differs from it in quantity and a design of details. The selector of the automatic transmission is installed on the same place on a floor tunnel, as a control lever by a mechanical box, and connected to the control unit on the transmission of a cable of management.
The differential of the automatic transmission on a design is completely similar to differential of the mechanical transmission.
Repair of the transmission, especially automatic box, requires a big set of special tools and the corresponding training of the performer therefore in this section only removal and installation of the transmission, replacement of its consolidations, repair of the drive are considered. In case of need carry out repair of the transmission in specialized car service.