SERVICING INSTRUCTIONS AND ILLUSTRATED PARTS ...Max engine torque: STD: 540Nm (400 lbft) WIDE: 610Nm...

© Copyright Hewland Engineering Limited

SERVICING INSTRUCTIONS AND ILLUSTRATED PARTS LIST FOR HEWLAND SGT GEARBOX

HEWLAND ENGINEERING LTD

WALTHAM ROAD, WHITE WALTHAM,

Issue 3 19 January 2006.

MAIDENHEAD, BERKSHIRE, SL6 3LR, ENGLAND


CONTENTS Page Page Technical specification 4 General notes 5 Sequential fork setting 6-7 H-Gate fork setting 8 Gearbox Assembly 9 Changing gear ratios 10 Illustrated Parts List Illustrated Parts List (Sequential shift) 12-15 (H-gate shift) 16-19 Illustrated Parts List Illustrated Parts List Wide Ratios (Sequential shift) 20-23 Wide Ratios (H-gate shift) 24-27 Installation Drawing Installation Drawing (Sequential shift) 28 (H-gate shift) 29 Installation Drawing Wide Ratios Installation Drawing Wide Ratios (Sequential shift) 30 (H-gate shift) 31


ILLUSTRATIONS

Page

Fig 1 Sequential Fork Setting 7

Fig 2 H-gate Fork Setting 8

Fig 3 Assembly Drawing (Sequential Shift) 12-13

Fig 4 Assembly Drawing (H-gate Shift) 16-17

Fig.5 Assembly Drawing Wide Ratios (SGTRS Sequential Shift) 20-21

Fig.6 Assembly Drawing Wide Ratios (SGTR H-gate Shift) 24-25

Fig.7 Installation Drawing (Sequential Shift) 28

Fig.8 Installation Drawing (H-gate Shift) 29

Fig.9 Installation Drawing Wide Ratios (SGTRS Sequential Shift) 30

Fig.10 Installation Drawing Wide Ratios (SGTR H-gate Shift) 31


TECHNICAL SPECIFICATION The SGT gearbox is designed for front engine, rear wheel drive GT cars. The unit is produced with six forward gears and reverse. The drive is taken from the engine via the clutch shaft and transfer gears, through the ratios and on to the output drive flange. The gear selection mechanism is either “sequential”, or “H-gate”. Both versions have a mechanically Interlocked reverse engagement mechanism. In the sequential version the gear change sequence is 1-2-3-4-5-6 with neutral as a half position between 1st and 2nd. Reverse, in the sequential version, can only be engaged whilst in neutral. Heat treated nickel chrome steel (to Hewland specification) is used to manufacture all gears and shafts. The selector forks are also steel. The unit is lubricated by way of an internal pump and an extensive distribution circuit, with oil being retained by lipped oil seals. In general configuration, the SGT is a high tech racing unit, which achieves the maximum effective use of the sup-plied power. Dry weight: 36.5 kg (Gearbox) Recommended Torque Settings: Oil type: SAE 80 or 90 Input Transfer gear nuts ~ 340Nm(250lbft) Oil quantity: 1.10 to 1.60 L (excluding ext. cooler & pipe work) Layshaft Front Nut ~ 340Nm(250lbft) Max engine torque: STD: 540Nm (400 lbft) WIDE: 610Nm (450 lbft) Layshaft Rear Nut ~ 200Nm(150lbft) Clutch shaft Made to customer requirements Mainshaft Rear Nut ~ 340Nm(250lbft) M8 Casing Nuts ~ 20Nm (15lbft) Selector Rod Nuts ~ 34Nm (25lbft)


GENERAL NOTES a/ Read these instructions carefully and with reference to the illustrations. b/ Before dismantling the gearbox, see that a clean tray is available, in which to place the parts. c/ Thoroughly clean and inspect all parts before reassembly. Discard any worn or damaged components and replace with new

ones. d/ Use only genuine Hewland parts as replacements. These are manufactured in our workshops to the fine tolerances

necessary and are rigorously inspected. e/ Always ensure that locknuts, and oil seals are in good condition when reassembling. f/ All studs and screws must be Loctited or wirelocked in position, unless stated otherwise g/ Bearing Replacement :- Bearings can only be removed or renewed if the casings have been warmed in an oven, or with a blowlamp. In the latter

case, keep the blowlamp moving while heating the casing. Note: Do not overheat. Test with a spot of water which will bounce off at the correct temperature. Once a casing is heated, all bearings should be pressed into their respective seatings without delay, thus eliminating the

need to reheat. At the correct temperature, fitting the bearings should present no difficulty. During cooling, or when the casings have cooled, it is advisable to once more lightly press the bearings to ensure that they

are correctly seated. h/ Oil: Fill the gearbox through the plug hole on top of the maincase. The oil will find it's own level within the gearbox. Note: Too much oil will not directly cause any harm, but is undesirable as it may induce power loss and overheating of

internals.


SEQUENTIAL FORK SETTING 1. Fit the selector head to the main selector rod using the roll pin. Heat the bearing carrier and fit the mainshaft and layshaft ball bearings, and the retaining circlips Stand the carrier up on the output end face, so enabling access to the gear chamber. Slide the main selector rod into its location bore in the bearing carrier, whilst stacking the pinion bearing spacers, pinion gears, hubs and relevant clutch rings over the output shaft bore, in the correct sequence. When the 3rd-4th and 5th-6th clutch rings are positioned, the corresponding selector fork must be fitted onto the selector rod so that the two components are combined. Build the stack, including the bearing support plate, that is secured in place onto the face of the bearing carrier. 2. Once the 1st-2nd fork is in position on the end of the selector rod the roll pin can be temporarily fitted to it, then the first gear and spacer can be 3. applied. The mainshaft, can now be carefully positioned through the centre of the stack ensuring all components are correctly aligned to allow them to

locate. Temporarily fit the mainshaft nuts. In order to tighten both nuts it will be necessary to move the selector forks so that 2 gears are simultaneously engaged. (On final fitting secure nuts, and locknuts with loctite.) 3. Fit the barrel support into the barrel housing and secure it with two countersunk head screws. Heat the housing and fit the selector arm bush. Press the needle roller bearing and the anti-rotation pin into the barrel, and slide it into the selector housing. Fit the keep plate to the inside face of the selector housing, and secure it using three cap head screws and loctite. Fit the spring post using loctite,. Feed the primary lever through the hole in the selector housing, and press the selector input shaft though the lever and locate with the dowel pin. (Care must be taken to ensure the correct orientation of the arms and levers.) The input shaft assembly can now be completed and the cap secured with cap head screws fitted using loctite. 4. Fit the drum stopper assembly into the relevant position in the selector housing (On final assembly, secure the screw with loctite). Pull the stopper back out of the way with a suitable tool and slide the fork setting adjustment spacer and the barrel support ball bearing into position, (housing will require heating) push the detent drum onto the end of the barrel locating the anti-rotation pin. Screw the shifter pin into position by locking the barrel. (On final fitting secure with loctite.) Let the stopper spring back so the roller presses onto the detent drum. Turn the barrel by hand until the stopper locates the barrel in the neutral position. (Half position between 1st and 2nd gear.) The guide plate, complete with springs and pawls, can now be fitted using three countersunk head screws. Note that one of the screws is longer and passed right through the assembly and has a k-nut fitted against the internal keep plate. The selector arm assembly, complete with return spring, secondary lever and lever link, can now be applied. 5. Fit the 2 location dowels into the mounting face of the selector housing, and move the clutch rings/selector forks into their approximate neutral positions within the maincase. Fit the selector housing to the maincase ensuring that the selector fork pins locate into the tracks of the barrel. Temporarily secure the selector housing to the maincase. The dog face clearance of each ratio can now be checked, use of a small mirror is recommended. Ideally the dog face clearance would be equal on all ratios, however this is not usually achievable, therefore the set-up target should be to achieve minimum variations in dog face clearances across all ratios. This is achieved by grinding the fork setting adjustment spacer, (as shown in Fig.1 on the following page.) As a guide, this thickness is usually approximately 0.120”. Note:- It is not possible (or necessary) to individually adjust each fork


SEQUENTIAL FORK SETTING

Fig 1

0.120” Approx


H-GATE FORK SETTING 1. Heat the bearing carrier, then fit the mainshaft and layshaft bearings, reverse spigot , reverse guide pin and reverse fork spigot Fit all relevant gear lever and gear selector finger components into the output housing. Fit the 3 selector rods, the locking pin, balls, springs and load the shuttle pin and plungers, into their correct positions in the bearing housing. Secure the mainshaft and layshaft bearings using the relevant circlips. Stand the maincase up on the output face ensuring all 3 selector rods are in the neutral position. The detent springs can be shortened to achieve the desired gear shift resistance. 2. Stack the pinion bearing spacers, pinion gears, hubs and relevant clutch rings over the output shaft bore, in the correct sequence,

when the 3rd-4th and 5th-6th clutch rings are positioned, the corresponding selector fork must be fitted onto the selector rod so that the two components are combined. Each selector rod must be fitted with a spacer (0.180” to start), and a hexagon nut lightly tightened. Continue to build the stack, with the 1st-2nd gears, hub, spacers, clutch ring and selector fork can now be fitted, and a selector fork spacer and hexagon nut, lightly secured to the remaining selector rod. The mainshaft can now be slid through the stack and secured in place with the nut and locknut. In order to tighten both the mainshaft and layshaft nuts, the shafts can be locked by engaging 2 gears at the same time. Loosen the 1st-2nd selector fork retaining nut and pull the fork towards 1st gear

until it engages, another gear can then be selected by moving the relevant selector rod.

3. Correct selection of 1st, 3rd & 5th gear can now be achieved via modification to the relevant selector rod spacers fitted between the selector rod and fork.

4. Correct selection of 4th & 6th gear, and the limitation of detent over-travel, is achieved by fitting shims

between the selector fork bosses and the bearing carrier. Similarly 2nd gear is set with the same shims placed between the selector rod spacer and the bearing carrier face. (NB. This spacer may need to be reduced in length.) 5. Once all fork positions are correctly set, and the mainshaft and layshaft lock nuts have been tightened to the correct torques, then all selector rod nuts can be tightened to their specified torque and fitted using loctite retainer. It is advisable to support the selector rod heads whilst tightening the selector fork retaining nuts. Re-alignment of the heads and the selector finger may be necessary to ensure smooth operation of the selection mechanism.

Selector rod spacers Selector rod shims

Fig 2


GEARBOX – ASSEMBLY a/ It is assumed that all casings have been thoroughly cleaned and all bearings, oil seals, studs and dowels are already fitted. (NB. Bearing retaining screws need to be machined to length on assembly.) b/ Fit the oil spray tube complete with ‘o-ring’ , into the bearing carrier, and wire lock screw in position. c/ Fit the reverse idler assembly into the bearing carrier, securing with anti rotation screw and bridge plate screws. d/ Heat the output housing and fit oil feed tubes using loctite. (NB. Does not apply to wide “R” ratio version) Assemble the oil pump and fit it into position in the output housing. Secure with screws, add the drive gear and the circlip. e/ Assemble the selector barrel parts, including the reverse selector rail for the sequential version, or the selector rod arrangement for the H-gate version. Secure selector mechanism into relevant casings. f/ Ensure fork setting procedure has been completed. (See previous pages for details.) Complete assembly of all ratios into bearing carrier and secure all fasteners. Locate reverse sliding gear onto mainshaft, and secure the reverse selector arrangement. Mainshaft locknuts, must be secured with loctite on final assembly. (Note, loctite is not required on the SGT2 or SGTR gearbox versions, where locking rings are fitted.) g/ Assemble the relevant components into the output housing, including the oil pump fitted with the oil pump drive gear, apply

sealing strip, and secure the housing to the bearing carrier. h/ Heat the input housing, and fit the input bearing arrangement and the layshaft needle roller bearing. Press the taper roller bearing inner race onto the input transfer gear and fit the remaining input assembly parts. The bearing assembly must be adjusted so a light pre-load is felt when turning the input shaft, this is achieved by modifying the length of the pre-load spacer

positioned between the taper roller bearing inner races. The input locknut can now be fitted using loctite, to hold the assembly whilst tightening the nut, select 2 gears simultaneously (as previously described), and temporarily bolt the input flange to the

bearing carrier with the clutch shaft bearing cover removed. The nut can then be fitted, the input flange removed from the bearing carrier and the selector fork retaining nut secured.

I/ Fit the input wheel onto the layshaft, and secure with the nut. It is advisable to ensure that the reaction generated by tightening this nut is pushing the transfer gears tight into mesh, and not separating them. This is important to ensure that the bearings, shafts and housings are not over stressed by the forces generated during tightening.


CHANGING GEAR RATIOS a/ Place a drip tray beneath the gearbox, remove the drain plug and drain the oil. b/ Remove the nuts securing the bearing carrier to the input and output housings and use a soft hammer to tap the knock off

lugs if the housings don’t release freely, never use a screwdriver to lever between the joint faces as this may damage the faces and the efficiency of the seals when reassembled.

c/ On an h-gate shift selection versions the 5th-6th finger stop plunger, and clevis pin will need to be removed from the output

housing to allow the selector finger to pass by the selector rod heads. On sequential shift selection versions, remove the selector housing.. d/ Remove the mainshaft and layshaft nuts and stand the gear assembly casing down towards the output. Slide the main-

shaft and layshaft out. Remove the gears, hubs, bearings, bearing support plate, clutch rings and spacers. e/ If only the transfer gears are to be changed then remove the clutch shaft bearing housing, engage 2 gears and remove the

input pinion locknut before removing the input flange. Once the flange is removed the input gear locknut can be removed and the transfer gear changed.

f/ Replace the gears with the required ratios. Gears are supplied in matched pairs, one for the main shaft and one for the layshaft. Each gear is marked with two sets of numbers, the first of these indicates the number of teeth on the input gear,

while the second indicates the number of teeth on the mainshaft gear. It is essential that the gears are correctly paired to these numbers

g/ Whilst changing ratios it is advisable, as a matter of course, to wash and inspect all components which are to be reused before refitting. Check for wear and cracks, particularly to the clutch rings. Also inspect the selector forks for heavy or uneven wear. h/ Reassembly is a reversal of disassembly.


ILLUSTRATED PARTS LIST


Fig 3

GEARBOX – ASSEMBLY (SEQUENTIAL SHIFT)



Fig 3

47

96



Item No. Stock Code Description No.Per 1 DG-234-2 CIRCLIP 1 2 DG-265-1 SOCKET HEAD CAP SCREW 3 3 DG-265-6 KEY 1 4 DG-265-8 CIRCLIP 1 5 DGB-239-0 EXTERNAL CIRCLIP 1 6 DGB-244-10 INTERNAL CIRCLIP 1 7 DGB-244-12 BALL BEARING 1 8 DGC-230 PINION NUT 1 9 DGC-230-L PINION SHAFT LOCK NUT 1 10 F3A-244-13 SOCKET CAP SCREW 6 11 F3D-236-1 WASHER 5/16",.625" X .330 X .040" 33 12 FGA6-265 OIL PUMP ASSY 1 13 FGB-201-8 BONDED SEAL 2 14 FT-202-8 SOCKET SET SCREW 1 15 FT-203-5 PLUG 1 16 FT-237-4 WASHER 1 17 FT-244-11 OIL SEAL 1 18 HC-201-3A NUT 21 19 HP-M-7008 REVERSE SELECTOR HEAD 1 20 HP-M-7012 BARREL SUPPORT 1 21 HP-M-7013 DETENT DRUM 1 22 HP-M-7014 SHIFTER PIN 1 23 HP-M-7015 DRUM SHIFTER 1 24 HP-M-7016 COLLAR SHIFTER 1 25 HP-M-7017 PAWL 2 26 HP-M-7018 PLUNGER 2 27 HP-M-7018-A COMPRESSION SPRING 2 28 HP-M-7019 DRUM STOPPER 1 29 HP-M-7020 SPECIAL SPRING 1 30 HP-M-7021 SPECIAL SPRING 1 31 HP-M-7022 DOWEL 1 32 HP-M-7031 SPRING POST 1 33 HP-M-7039 DRUM WASHER 1 34 HP-M-7040 THRUST WASHER 1 35 HP-M-7042 PIVOT DRUM STOPPER 1 36 HP-M-7056 BARREL SPACER 1 37 HP-M-7062 BLANKING PLATE 1 38 HP-M-7066 THRUST WASHER 1 39 HP-M-7105 GUIDE PLATE 1 40 HP-M-7122 KEEP PLATE 1 41 HP-M-8008 BALL BEARING 1

Item No. Stock Code Description No.Per 42 HP-M-8009 NEEDLE ROLLER BEARING 1 43 HP-M-8012 OIL SEAL 3 44 HP-M-8014 O-RING 1 45 HP-M-8016 SELECTOR ARM BUSH 2 46 HP-M-9003 PLUG 1 47 HP-M-9016 DOWEL 1 48 HP-M-9029 SKT BUTTON HEAD SCREW 2 49 HP-M-9030 SOCKET CSK SCREW 2 50 HP-M-9031 SOCKET CSK SCREW 2 51 HP-M-9036 SOCKET CAP SCREW 3 52 HP-M-9037 BANJO JOINT 1 53 HP-M-9038 SEALING WASHER 2 54 HP-M-9039 BANJO BOLT 1 55 HP-M-9042 DOWTY WASHER 1 56 HP-M-9052 CIRCLIP 1 57 HP-M-9054 SOCKET CAP SCREW 1 58 HP-M-9063 BARREL HOUSING DOWEL 5 59 LD-201-2 STUD 4 60 LD-201-5 DOWEL 3 61 LD-202-9 WASHER 6 62 LD-203-7 WASHER 1 63 LD-225-1 SOCKET CAP SCREW 5 64 LD-237-2 NEEDLE CAGE 1 65 NUT-004 KAYNUT 2 66 NUT-006 K-NUT 1 67 ORI-014 O-RING 1 68 SCR-104 SOCKET CSK SCREW 1 69 SGT-201-4 STUD 19 70 SGT-201-G FRONT CASING 1 71 SGT-202-10 OIL SPRAY TUBE 1 72 SGT-202-12 SOCKET CAPHEAD SCREW 5 73 SGT-202-3 SOCKET CAP SCREW 3 74 SCR-003 SOCKET SET SCREW 2 75 SGT-202-9A DOWEL PIN 1 76 SGT-202-AS BEARING SUPPORT PLATE 1 77 SGT-202-S BEARING CARRIER 1 78 SGT-204-1 OIL OUTLET TUBE 1 79 SGT-204-4A RETAINING SCREW 2 80 SGT-204-4B SOCKET CAP SCREW 1 81 SGT-204-S REAR OUTPUT HOUSING 1 82 SGT-208 BARREL HOUSING 1



Item No. Stock Code Description No.Per 83 SGT-208-1 BARREL HOUSING COVER 1 84 SGT-208-10 REVERSE ACTUATOR ROD 1 85 SGT-208-11 BUSH - INPUT LEVER 2 86 SGT-208-12 SPRING SUPPORT 1 87 SGT-208-13 SOCKET CAP SCREW 3 88 SCR-150 SOCKET CAP SCREW 1 89 SGT-208-15 SOCKET CAP SCREW 1 90 SGT-208-16 SOCKET CAP SCREW 4 91 SGT-208-2 CAP-BARREL HOUSING 1 92 SGT-208-3 PRIMARY LEVER 1 93 SGT-208-4 SECONDARY LEVER 1 94 SGT-208-5 SELECTOR ARM 1 95 SGT-208-6 INPUT SELECTOR SHAFT 1 96 SGT-208-7 INPUT LEVER 1 97 SGT-208-8 LINK 1 98 SGT-208-9A BARREL 1 99 SGT-218-2 CIRCLIP 1

100 SGT-218-CUST DRIVE FLANGE 1 101 SGT-221 MAINSHAFT 1 102 SGT-221-1 THRUST WASHER 1 103 SGT-221-10 NEEDLE CAGE 1 104 SGT-221-1A THRUST WASHER 1 105 SGT-221-2 INNER TRACK 1 106 SGT-221-3 THRUST WASHER 1 107 SGT-221-4 BEARING 1 108 SGT-228 REVERSE GEAR HUB 1 109 SGT-229-1 NEEDLE ROLLER BEARING 3 110 SGT-230 MAINSHAFT NUT 1 111 SGT-230-L LAYSHAFT LOCKNUT 1 112 SGT-231 REVERSE SLIDING GEAR 1 113 SGT-234 LAYSHAFT 1 114 SGT-234-3 BEARING 1 115 SGT-234-4 CIRCLIP 2 116 SGT-234-5 THRUST WASHER 1 117 SGT-234-7 INNER TRACK LAYSHAFT 1 118 SGT-236 NUT 1 119 SGT-236-1 LAYSHAFT NUT 1 120 SGT-237-1 REVERSE IDLER GEAR 1 121 SGT-237-3 REV. IDLER SPIGOT 1 122 SGT-237-5 BRIDGE PLATE - REV. IDLER 1 123 SGT-237-6 RETAINING SCREW 2

Item No. Stock Code Description No.Per 124 SGT-237-6A RETAINING SCREW 1 125 SGT-237-7 BRIDGE PLATE SPACER 2 126 SGT-238 REVERSE LAYSHAFT GEAR 1 127 SGT-239-CUST CLUTCH SHAFT MASTER 1 128 TRANSFER-RATIO TRANSFER GEAR SET 1 130 SGT-242 BEARING HOUSING 1 131 SGT-242-1 BEARING SPACER 1 132 SGT-242-2 O-RING 1 133 SGT-242-5 TAPER ROLLER BEARING 1 134 SGT-244-13 SOCKET CAP SCREW 5 135 SGT-244-14 O-RING 1 136 SGT-246-AS SELECTOR ROD 1 137 SGT-249-1S SELECTOR HEAD 1 138 SGT-249-S 1ST & 2ND SELECTOR FORK 1 139 SGT-250-S SELECTOR FORK 1 140 SGT-251-S SELECTOR FORK 1 141 SGT-252-7 ROLL PIN 6 142 SGT-253-1S REVERSE SELECTOR SHAFT 1 143 SGT-253-S REVERSE SELECTOR FORK 1 144 SGT-265-7 DRIVE GEAR 1 145 SGT-265-9 OIL PUMP DRIVE GEAR 1 146 SGT-266-1 OIL PICK UP TUBE 1 147 SGT-266-3 OIL FILTER PLATE 1 148 SGTG-244-CUST CLUTCH SHAFT BRG HOUSING 1 149 ST-204-1 OIL SEAL 1 150 ST-204-3 NEEDLE ROLLER BEARING 1 151 ST-266-5A OIL FILTER OUTER 1 152 ST-266-5B OIL FILTER INNER 1 153 STA-242-4 TAPER ROLLER BEARING 1 154 TPT-226 HUB 2 155 TPT-226-1 NEEDLE ROLLER BEARING 6 156 TPT-227 HUB 1 157 TPT-232-S CLUTCH RING 3 158 TPT-233-SN PINION SHAFT GEARS 6 159 TPT-234-8 SPACER 3 160 TPT-235-SN INPUT SHAFT GEARS STD. 5 161 TPT-244-13R SOCKET HEAD SCREW 1 162 VG-201-9 SEALING STRIP 4 163 VG-204-4 OIL PLUG 2 164 VG-244-14 O-RING 1 165 VGC-266-6 FILTER ELEMENT 1


GEARBOX – ASSEMBLY (H-GATE SHIFT)

Fig 4



Item No. Stock Code Description No.Per 1 DG-234-2 CIRCLIP 1 2 DG-265-1 SOCKET HEAD CAP SCREW 3 3 DG-265-6 KEY 1 4 DG-265-8 CIRCLIP 1 5 DGB-239-0 EXTERNAL CIRCLIP 1 6 DGB-244-10 INTERNAL CIRCLIP 1 7 DGB-244-12 BALL BEARING 1 8 DGC-230 PINION NUT 1 9 DGC-230-L PINION SHAFT LOCK NUT 1 10 F3A-244-13 SOCKET CAP SCREW 6 11 F3D-236-1 WASHER 5/16",.625" X .330 X .040" 34 12 FGA6-203-4 COMPRESSION SPRING 1 13 FGA6-265 OIL PUMP ASSY 1 14 FGB-201-8 BONDED SEAL 4 15 FT-202-1 BALL BEARING 6 16 FT-202-2 COMPRESSION SPRING 6 17 FT-202-3 SOCKET SET SCREW 3 18 FT-202-4 PLUNGER 2 19 FT-202-8 SOCKET SET SCREW 3 20 FT-203-3 STEEL BALL 1 21 FT-203-5 PLUG 1 22 FT-203-6 PLAIN BEARING 2 23 FT-203-7S OIL SEAL 1 24 FT-237-4 WASHER 1 25 FT-244-11 OIL SEAL 1 26 FT-246-3 SELECTOR ROD SPACER 3 27 HC-201-3A NUT 21 28 LD-201-2 STUD 4 29 LD-201-5 DOWEL 3 30 LD-202-9 WASHER 6 31 LD-203-7 WASHER 1 32 LD-237-2 NEEDLE CAGE 1 33 LD-253-3 STOP WASHER 1 34 LD-253-4 SOCKET CSK SCREW 1 35 NUT-004 KAYNUT 2 36 ORI-014 O-RING 1 37 SGT-201-4 STUD 19 38 SGT-201-G FRONT CASING 1 39 SGT-202 BEARING CARRIER 1 40 SGT-202-10 OIL SPRAY TUBE 1 41 SGT-202-12 SOCKET CAPHEAD SCREW 5

Item No. Stock Code Description No.Per 42 SGT-202-13 GUIDE PIN 1 43 SGT-202-3 SOCKET CAP SCREW 3 44 SCR-003 SOCKET SET SCREW 2 45 SGT-202-9A DOWEL PIN 1 46 SGT-202-B BEARING SUPPORT PLATE 1 47 SGT-203-0 PLUNGER 2 48 SGT-203-0A SPRING GUIDE 2 49 SGT-203-1 RETAINING SLEEVE 1 50 SGT-203-1A RETAINING SLEEVE 1 51 SGT-203-5 CIRCLIP 2 52 SGT-204 OUTPUT HOUSING 1 53 SGT-204-1 OIL OUTLET TUBE 1 54 SGT-204-12 SOCKET HEAD CAP SCREW 2 55 SGT-204-4A RETAINING SCREW 2 56 SGT-204-4B SOCKET CAP SCREW 1 57 SGT-204-5 COMPRESSION SPRING 1 58 SGT-204-8 FULCRUM YOKE 1 59 SGT-204-9 FULCRUM PLATE 1 60 SGT-218-2 CIRCLIP 1 61 SGT-218-CUST DRIVE FLANGE 1 62 SGT-221 MAINSHAFT 1 63 SGT-221-1 THRUST WASHER 1 64 SGT-221-10 NEEDLE CAGE 1 65 SGT-221-1A THRUST WASHER 1 66 SGT-221-2 INNER TRACK 1 67 SGT-221-3 THRUST WASHER 1 68 SGT-221-4 BEARING 1 69 SGT-228 REVERSE GEAR HUB 1 70 SGT-229-1 NEEDLE ROLLER BEARING 3 71 SGT-230 MAINSHAFT NUT 1 72 SGT-230-L LAYSHAFT LOCKNUT 1 73 SGT-231 REVERSE SLIDING GEAR 1 74 SGT-234 LAYSHAFT 1 75 SGT-234-3 BEARING 1 76 SGT-234-4 CIRCLIP 2 77 SGT-234-5 THRUST WASHER 1 78 SGT-234-7 INNER TRACK LAYSHAFT 1 79 SGT-236 NUT 1 80 SGT-236-1 LAYSHAFT NUT 1 81 SGT-237-1 REVERSE IDLER GEAR 1 82 SGT-237-3 REV. IDLER SPIGOT 1



Item No. Stock Code Description No.Per 83 SGT-237-5 BRIDGE PLATE - REV. IDLER 1 84 SGT-237-6 RETAINING SCREW 2 85 SGT-237-6A RETAINING SCREW 1 86 SGT-237-7 BRIDGE PLATE SPACER 2 87 SGT-238 REVERSE LAYSHAFT GEAR 1 88 SGT-239-CUST CLUTCH SHAFT MASTER 1 89 TRANSFER-RATIO TRANSFER GEAR SET 1 91 SGT-242 BEARING HOUSING 1 92 SGT-242-1 BEARING SPACER 1 93 SGT-242-2 O-RING 1 94 SGT-242-5 TAPER ROLLER BEARING 1 95 SGT-244-13 SOCKET CAP SCREW 5 96 SGT-244-14 O-RING 1 97 SGT-246 SELECTOR ROD 1 98 SGT-246-4 STOP SPACER 1 99 SGT-247 SELECTOR ROD 1

100 SGT-247-1 SHUTTLE PIN 1 101 SGT-248 SELECTOR ROD 1 102 SGT-249 SELECTOR FORK 1 103 SGT-250 SELECTOR FORK 1 104 SGT-251 SELECTOR FORK 1 105 SGT-252 SELECTOR FINGER 1 106 SGT-252-1 GEAR LEVER LOWER 1 107 SGT-252-10 GUIDE BUSH 1 108 SGT-252-11 REVERSE LOCK CAM 1 109 SGT-252-12 SOLDERLESS NIPPLE 1 110 SGT-252-13 CABLE 1 111 SGT-252-14 SPRING 1 112 SGT-252-15A SPRING 1 114 SGT-252-17 SET SCREW 1 115 SGT-252-18 LOCK NUT 1 116 SGT-252-2 GEAR LEVER UPPER 1 117 SGT-252-3 CLEVIS 1 118 SGT-252-4 CLEVIS PIN 1 119 SGT-252-5 WASHER 1 120 SGT-252-6 CIRCLIP 1 121 SGT-252-7 ROLL PIN 1 122 SGT-252-8 GEAR KNOB 1 123 SGT-252-9 REVERSE LOCK BOBBIN 1 124 SGT-253 REVERSE SELECTOR FORK 1

Item No. Stock Code Description No.Per 125 SGT-253-1 SHAFT 1 126 SGT-265-7 DRIVE GEAR 1 127 SGT-265-9 OIL PUMP DRIVE GEAR 1 128 SGT-266-1 OIL PICK UP TUBE 1 129 SGT-266-3 OIL FILTER PLATE 1 130 SGTG-244-CUST CLUTCH SHAFT BRG HOUSING 1 131 ST-204-1 OIL SEAL 1 132 ST-204-3 NEEDLE ROLLER BEARING 1 133 ST-266-5A OIL FILTER OUTER 1 134 ST-266-5B OIL FILTER INNER 1 135 STA-242-4 TAPER ROLLER BEARING 1 136 TPT-226 HUB 2 137 TPT-226-1 NEEDLE ROLLER BEARING 6 138 TPT-227 HUB 1 139 TPT-232-S CLUTCH RING 3 140 TPT-233-SN PINION SHAFT GEARS 6 141 TPT-234-8 SPACER 3 142 TPT-235-SN INPUT SHAFT GEARS STD. 5 143 TPT-244-13R SOCKET HEAD SCREW 1 144 VG-201-9 SEALING STRIP 2 145 VG-204-4 OIL PLUG 2 146 VG-244-14 O-RING 1 147 VG-246-2 NUT 3 148 VGC-266-6 FILTER ELEMENT 1 149 VGC6-203-4 COMPRESSION SPRING 1


GEARBOX – ASSEMBLY WIDE RATIOS (SGTRS SEQUENTIAL SHIFT)

Fig 5



Item No. Stock Code Description No.Per 1 BEA-158 BEARING INNER TRACK 1 2 CIR-040 CIRCLIP 1 3 DG-234-2 CIRCLIP 1 4 DGB-239-0A SNAP RING 1 5 DGB-244-10 INTERNAL CIRCLIP 1 6 DGB-244-12 BALL BEARING 1 7 DGB-265-1A CAPSCREW 4 8 DGC-230 PINION NUT 1 9 DGC-230-L PINION SHAFT LOCK NUT 1 10 FGB-201-8 BONDED SEAL 2 11 FGB-265-5A CIRCLIP 1 12 F3D-236-1 WASHER 5/16",.625" X .330 X .040" 32 13 FT-202-8 SOCKET SET SCREW 1 14 FT-203-5 PLUG 1 15 FT-237-4 WASHER 1 16 FT-244-11 OIL SEAL 1 17 HC-201-3A NUT 21 18 HP-M-7008 REVERSE SELECTOR HEAD 1 19 HP-M-7012 BARREL SUPPORT 1 20 HP-M-7013 DETENT DRUM 1 21 HP-M-7014 SHIFTER PIN 1 22 HP-M-7015 DRUM SHIFTER 1 23 HP-M-7016 COLLAR SHIFTER 1 24 HP-M-7017 PAWL 2 25 HP-M-7018 PLUNGER 2 26 HP-M-7018-A COMPRESSION SPRING 2 27 HP-M-7019 DRUM STOPPER 1 28 HP-M-7020 SPECIAL SPRING 1 29 HP-M-7021 SPECIAL SPRING 1 30 HP-M-7022 DOWEL 1 31 HP-M-7031 SPRING POST 1 32 HP-M-7039 DRUM WASHER 1 33 HP-M-7040 THRUST WASHER 1 34 HP-M-7042 PIVOT DRUM STOPPER 1 35 HP-M-7056 BARREL SPACER 1 36 HP-M-7062 BLANKING PLATE 1 37 HP-M-7066 THRUST WASHER 1 38 HP-M-7105 GUIDE PLATE 1 39 HP-M-7122 KEEP PLATE 1 40 HP-M-8008 BALL BEARING 1 41 HP-M-8009 NEEDLE ROLLER BEARING 1

Item No. Stock Code Description No.Per 42 HP-M-8012 OIL SEAL 3 43 HP-M-8014 O-RING 1 44 HP-M-8016 SELECTOR ARM BUSH 2 45 HP-M-9003 PLUG 1 46 HP-M-9016 DOWEL 1 47 HP-M-9029 SKT BUTTON HEAD SCREW 2 48 HP-M-9030 SOCKET CSK SCREW 2 49 HP-M-9031 SOCKET CSK SCREW 2 50 HP-M-9036 SOCKET CAP SCREW 3 51 HP-M-9037 BANJO JOINT 1 52 HP-M-9038 SEALING WASHER 2 53 HP-M-9039 BANJO BOLT 1 54 HP-M-9042 DOWTY WASHER 2 55 HP-M-9052 CIRCLIP 1 56 HP-M-9054 SOCKET CAP SCREW 1 57 HP-M-9063 BARREL HOUSING DOWEL 5 58 LD-201-2 STUD 4 59 LD-201-5 DOWEL 3 60 LD-203-7 WASHER 1 61 LD-225-1 SOCKET CAP SCREW 5 62 LD-237-2 NEEDLE CAGE 1 63 NUT-004 KAYNUT 2 64 NUT-006 K-NUT 1 65 ORI-001 O-RING 1 66 ORI-014 O-RING 1 67 ORI-103 O-RING 1 68 SCR-003 SOCKET SET SCREW 1 69 SCR-104 SOCKET CSK SCREW 1 70 SCR-175 SOCKET CAP SCREW 3 71 SGT-201-4 STUD 19 72 SGT-201-G FRONT CASING 1 73 SGT-202-10 OIL SPRAY TUBE 1 74 SGT-202-12 SOCKET CAPHEAD SCREW 5 75 SGT-202-3 SOCKET CAP SCREW 3 76 SCR-003 SOCKET SET SCREW 2 77 SGT-202-9A DOWEL PIN 1 78 SGT-202-AS BEARING SUPPORT PLATE 1 79 SGT-204-4A RETAINING SCREW 2 80 SGT-204-4B SOCKET CAP SCREW 2 81 SGT-208 BARREL HOUSING 1 82 SGT-208-1 BARREL HOUSING COVER 1



Item No. Stock Code Description No.Per 83 SGT-208-10 REVERSE ACTUATOR ROD 1 84 SGT-208-11 BUSH - INPUT LEVER 2 85 SGT-208-12 SPRING SUPPORT 1 86 SGT-208-13 SOCKET CAP SCREW 3 87 SGT-208-14 SOCKET CAP SCREW 1 88 SGT-208-15 SOCKET CAP SCREW 1 89 SGT-208-16 SOCKET CAP SCREW 4 90 SGT-208-2 CAP-BARREL HOUSING 1 91 SGT-208-3 PRIMARY LEVER 1 92 SGT-208-4 SECONDARY LEVER 1 93 SGT-208-5 SELECTOR ARM 1 94 SGT-208-6 INPUT SELECTOR SHAFT 1 95 SGT-208-7 INPUT LEVER 1 96 SGT-208-8 LINK 1 97 SGT-208-9A BARREL 1 98 SGT-221-1 THRUST WASHER 1 99 SGT-221-10 NEEDLE CAGE 1

100 SGT-221-1A THRUST WASHER 1 101 SGT-221-2 INNER TRACK 1 102 SGT-221-3 THRUST WASHER 1 103 SGT-221-4 BEARING 1 104 SGT-228 REVERSE GEAR HUB 1 105 SGT-229-1 NEEDLE ROLLER BEARING 3 106 SGT-231 REVERSE SLIDING GEAR 1 107 SGT-234-3 BEARING 1 108 SGT-234-4 CIRCLIP 2 109 SGT-234-5 THRUST WASHER 1 110 SGT-236 NUT 1 111 SGT-236-1 LAYSHAFT NUT 1 112 SGT-237-1 REVERSE IDLER GEAR 1 113 SGT-237-3 REV. IDLER SPIGOT 1 114 SGT-237-5 BRIDGE PLATE - REV. IDLER 1 115 SGT-237-6 RETAINING SCREW 2 116 SGT-237-6A RETAINING SCREW 1 117 SGT-237-7 BRIDGE PLATE SPACER 2 118 SGT-238 REVERSE LAYSHAFT GEAR 1 119 TRANSFER-RATIO TRANSFER GEAR SET 1 120 SGT-242 BEARING HOUSING 1 121 SGT-242-1 BEARING SPACER 1 122 SGT-242-2 O-RING 1 123 SGT-242-5 TAPER ROLLER BEARING 1

Item No. Stock Code Description No.Per 124 SGT-244-13 SOCKET CAP SCREW 5 125 SGT-244-14 O-RING 1 126 SGT-246-AS SELECTOR ROD 1 127 SGT-249-1S SELECTOR HEAD 1 128 SGT-249-S 1ST & 2ND SELECTOR FORK 1 129 SGT-250-S SELECTOR FORK 1 130 SGT-251-S SELECTOR FORK 1 131 SGT-252-7 ROLL PIN 6 132 SGT-253-1S REVERSE SELECTOR SHAFT 1 133 SGT-253-S REVERSE SELECTOR FORK 1 134 SGT2-202-S BEARING CARRIER 1 135 SGT2-204-1 FILTER COVER PLATE 1 136 SGT2-204-S OUTPUT HOUSING 1 137 SGT2-221 MAINSHAFT 1 138 SGT2-230 MAINSHAFT NUT 1 139 SGT2-230-1 LOCKING RING 1 140 SGT2-265-7 OIL PUMP DRIVEN GEAR 1 141 SGT2-266 INLINE MAGNETIC FILTER 1 142 SGTG-244-CUST CLUTCH SHAFT BRG HOUSING 1 143 SGTW-218-1 PLUG 1 144 SGTW-218-CUST DRIVE FLANGE 1 145 SGTW-234 LAYSHAFT 1 146 SGTW-235-2 INPUT SHAFT GEARS 1 147 SGTW-239-CUST CLUTCH SHAFT MASTER 1 149 ST-204-1 OIL SEAL 1 150 ST-204-3 NEEDLE ROLLER BEARING 1 151 STA-242-4 TAPER ROLLER BEARING 1 152 STA-265 OIL PUMP ASSEMBLY 1 153 TE-266 OIL FILTER 1 154 TPT-226 HUB 2 155 TPT-226-1 NEEDLE ROLLER BEARING 6 156 TPT-227 HUB 1 157 TPT-232-S CLUTCH RING 3 158 TPT-233-SN PINION SHAFT GEARS 3 159 TPT-233-W PINION SHAFT GEARS 3 160 TPT-234-8 SPACER 1 161 TPT-235-2SN INPUT SHAFT GEARS HUB 3 162 TPT-244-13R SOCKET HEAD SCREW 1 163 VG-201-9 SEALING STRIP 4 164 VG-204-4 OIL PLUG 2 165 VG-239-0 CIRCLIP 1


GEARBOX – ASSEMBLY WIDE RATIOS (SGTR H-GATE SHIFT)

Fig 6



Item No. Stock Code Description No.Per 1 CIR-040 CIRCLIP 1 2 DG-234-2 CIRCLIP 1 3 DGB-239-0A SNAP RING 1 4 DGB-244-10 INTERNAL CIRCLIP 1 5 DGB-244-12 BALL BEARING 1 6 DGB-265-1A CAPSCREW 4 7 DGC-230 PINION NUT 1 8 DGC-230-L PINION SHAFT LOCK NUT 1 9 FGA6-203-4 COMPRESSION SPRING 1 10 FGB-201-8 BONDED SEAL 4 11 FGB-265-5A CIRCLIP 1 12 FT-202-1 BALL BEARING 6 13 FT-202-2 COMPRESSION SPRING 6 14 FT-202-3 SOCKET SET SCREW 3 15 FT-202-4 PLUNGER 2 16 F3D-236-1 WASHER 5/16",.625" X .330 X .040" 34 17 FT-202-8 SOCKET SET SCREW 3 18 FT-203-3 STEEL BALL 1 19 FT-203-5 PLUG 1 20 FT-203-6 PLAIN BEARING 2 21 FT-203-7S OIL SEAL 1 22 FT-237-4 WASHER 1 23 FT-244-11 OIL SEAL 1 24 FT-246-3 SELECTOR ROD SPACER 3 25 HC-201-3A NUT 21 26 HP-M-9037 BANJO JOINT 1 27 HP-M-9038 SEALING WASHER 2 28 HP-M-9039 BANJO BOLT 1 29 HP-M-9042 DOWTY WASHER 1 30 VG-239-0 CIRCLIP 1 31 LD-201-2 STUD 4 32 LD-201-5 DOWEL 3 33 LD-203-7 WASHER 1 34 LD-237-2 NEEDLE CAGE 1 35 LD-253-3 STOP WASHER 1 36 LD-253-4 SOCKET CSK SCREW 1 37 NUT-004 KAYNUT 2 38 ORI-014 O-RING 1 39 ORI-103 O-RING 1 40 SCR-175 SOCKET CAP SCREW 3 41 SGT-201-4 STUD 19

Item No. Stock Code Description No.Per 42 SGT-201-G FRONT CASING 1 43 SGT-202-10 OIL SPRAY TUBE 1 44 SGT-202-12 SOCKET CAPHEAD SCREW 5 45 SGT-202-13 GUIDE PIN 1 46 SGT-202-3 SOCKET CAP SCREW 3 47 SCR-003 SOCKET SET SCREW 2 48 DOW-040 DOWEL PIN 1 49 SGT-202-B BEARING SUPPORT PLATE 1 50 SGTW-202 BEARING CARRIER 1 51 SGT-203-0 PLUNGER 1 52 SGT-203-0A SPRING GUIDE 2 53 SGT-203-1A RETAINING SLEEVE 1 54 SGT-203-4 PLUNGER 1 55 SGT-203-5 CIRCLIP 2 56 SGT-203-6 RETAINING SLEEVE 1 57 SGT-204-12 SOCKET HEAD CAP SCREW 2 58 SGT-204-4A RETAINING SCREW 2 59 SGT-204-4B SOCKET CAP SCREW 1 60 SGT-204-5 COMPRESSION SPRING 1 61 SGT-204-8 FULCRUM YOKE 1 62 SGT-204-9 FULCRUM PLATE 1 63 SGT-221-1 THRUST WASHER 1 64 SGT-221-10 NEEDLE CAGE 1 65 SGT-221-1A THRUST WASHER 1 66 SGT-221-2 INNER TRACK 1 67 SGT-221-3 THRUST WASHER 1 68 SGT-221-4 BEARING 1 69 SGT-228 REVERSE GEAR HUB 1 70 SGT-229-1 NEEDLE ROLLER BEARING 3 71 SGT-231 REVERSE SLIDING GEAR 1 72 SGT-234-3 BEARING 1 73 SGT-234-4 CIRCLIP 2 74 SGT-234-5 THRUST WASHER 1 75 SGT-236 NUT 1 76 SGT-236-1 LAYSHAFT NUT 1 77 SGT-237-1 REVERSE IDLER GEAR 1 78 SGT-237-3 REV. IDLER SPIGOT 1 79 SGT-237-5 BRIDGE PLATE - REV. IDLER 1 80 SGT-237-6 RETAINING SCREW 2 81 SGT-237-6A RETAINING SCREW 1 82 SGT-237-7 BRIDGE PLATE SPACER 2



Item No. Stock Code Description No.Per 83 SGT-238 REVERSE LAYSHAFT GEAR 1 84 TRANSFER-RATIO TRANSFER GEAR SET 1 85 SGT-242 BEARING HOUSING 1 86 SGT-242-1 BEARING SPACER 1 87 SGT-242-2 O-RING 1 88 SGT-242-5 TAPER ROLLER BEARING 1 89 SGT-244-13 SOCKET CAP SCREW 5 90 SGT-244-14 O-RING 1 91 SGT-246 SELECTOR ROD 1 92 SGT-246-4 STOP SPACER 1 93 SGT-247 SELECTOR ROD 1 94 SGT-247-1 SHUTTLE PIN 1 95 SGT-248 SELECTOR ROD 1 96 SGT-249 SELECTOR FORK 1 97 SGT-250 SELECTOR FORK 1 98 SGT-251 SELECTOR FORK 1 99 SGT-252 SELECTOR FINGER 1

100 SGT-252-1 GEAR LEVER LOWER 1 101 SGT-252-10 GUIDE BUSH 1 102 SGT-252-11 REVERSE LOCK CAM 1 103 SGT-252-12 SOLDERLESS NIPPLE 1 104 SGT-252-13 CABLE 1 105 SGT-252-14 SPRING 1 106 SGT-252-15A SPRING 1 107 SGT-252-17 SET SCREW 3 108 SGT-252-18 LOCK NUT 1 109 SGT-252-2 GEAR LEVER UPPER 1 110 SGT-252-3 CLEVIS 1 111 SGT-252-4 CLEVIS PIN 1 112 SGT-252-5 WASHER 1 113 SGT-252-6 CIRCLIP 1 114 SGT-252-7 ROLL PIN 1 115 SGT-252-8 GEAR KNOB 1 116 SGT-252-9 REVERSE LOCK BOBBIN 1 117 SGT-253-1 SHAFT 1 118 SGT-265-9 OIL PUMP DRIVE GEAR 1 119 SGT2-204 OUTPUT HOUSING 1 120 SGT2-204-1 FILTER COVER PLATE 1 121 SGT2-221 MAINSHAFT 1 122 SGT2-230 MAINSHAFT NUT 1 123 SGT2-230-1 LOCKING RING 1

Item No. Stock Code Description No.Per 124 SGT2-265-7 OIL PUMP DRIVEN GEAR 1 125 SGT2-266 INLINE MAGNETIC FILTER 1 126 SGTG-244-CUST CLUTCH SHAFT BRG HOUSING 1 127 SGTW-218-1 PLUG 1 128 SGTW-218-CUST DRIVE FLANGE 1 129 SGTW-234 LAYSHAFT 1 130 SGTW-235-2 INPUT SHAFT GEARS 1 131 SGTW-239-CUST CLUTCH SHAFT MASTER 1 133 SGT-253 REVERSE SELECTOR FORK 1 134 SPR-063 COMPRESSION SPRING 1 135 ST-204-1 OIL SEAL 1 136 ST-204-3 NEEDLE ROLLER BEARING 1 137 STA-242-4 TAPER ROLLER BEARING 1 138 STA-265 OIL PUMP ASSEMBLY 1 139 TE-266 OIL FILTER 1 140 TPT-226 HUB 2 141 TPT-226-1 NEEDLE ROLLER BEARING 6 142 TPT-227 HUB 1 143 TPT-232-S CLUTCH RING 3 144 TPT-233-SN PINION SHAFT GEARS 3 145 TPT-233-W PINION SHAFT GEARS 3 146 TPT-234-8 SPACER 1 147 TPT-235-2SN INPUT SHAFT GEARS HUB 3 148 TPT-244-13R SOCKET HEAD SCREW 1 149 VG-201-9 SEALING STRIP 4 150 VG-204-4 OIL PLUG 2 151 VG-246-2 NUT 3

152 VGC6-203-4 COMPRESSION SPRING 1 153 ORI-001 O-RING 1 154 SCR-275 SOCKET CAP SCREW 1 155 WSH-025 PLAIN WASHER 1


GEARBOX – INSTALLATION (SEQUENTIAL)

GENERAL INFORMATION

Fig 7


Fig 8

GEARBOX – INSTALLATION (H-GATE SHIFT)

GENERAL INFORMATION


GEARBOX – INSTALLATION WIDE RATIOS (SGTRS SEQUENTIAL SHIFT)

GENERAL INFORMATION

Fig 9


Fig 10

GEARBOX – INSTALLATION WIDE RATIOS (SGTR H-GATE SHIFT)

GENERAL INFORMATION

SERVICING INSTRUCTIONS AND ILLUSTRATED PARTS ...Max engine torque: STD: 540Nm (400 lbft) WIDE: 610Nm...

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Transcript of SERVICING INSTRUCTIONS AND ILLUSTRATED PARTS ...Max engine torque: STD: 540Nm (400 lbft) WIDE: 610Nm...