Gearbox Manual DG500 2017 · 2020. 7. 6. · Pole Position DG500 –Revision: 007 Gearbox Manual 2...

Gearbox Manual DG500

2017

2 Gearbox Manual DG500 – Revision: 007 Pole Position

In Gearboxes

Warning Please be aware that information in this manual may be inaccurate, incomplete or contain typographical errors. The content of this manual is subject to

change without notice and should, therefore, be used for informational purposes only. Consequently, replacement parts must always by ordered according

to the part number engraved on the part.

If you find information in this manual that is incorrect or incomplete, we would appreciate your comments and suggestions.


In Gearboxes

Contents Warning ............................................................................................................................................................................................................................................. 2

Contents ............................................................................................................................................................................................................................................ 3

1. Technical Specifications................................................................................................................................................................................................................. 5

1.1. General Specifications ............................................................................................................................................................................................................ 6

1.2. General Dimensions ................................................................................................................................................................................................................ 7

1.3. Oil System ............................................................................................................................................................................................................................... 8

2. Gearbox Assembly ......................................................................................................................................................................................................................... 9

2.1. General Instruction Notes..................................................................................................................................................................................................... 10

2.2. Bearing Assembly .................................................................................................................................................................................................................. 11

2.3. Gearbox Assembly ................................................................................................................................................................................................................ 14

2.4. Rotary Sensor ........................................................................................................................................................................................................................ 58

3. Gear Ratio List ............................................................................................................................................................................................................................. 60

4. Accessories .................................................................................................................................................................................................................................. 62

4.1. Bellhousings / Adaptor Plates ............................................................................................................................................................................................... 63

4.2. Gearbox Brackets .................................................................................................................................................................................................................. 66

4.3. Gear Lever ............................................................................................................................................................................................................................. 67

4.4. DMS Gear Lever .................................................................................................................................................................................................................... 69

4.5. Gear lever Brackets ............................................................................................................................................................................................................... 71

4.6. Gear Indicator ....................................................................................................................................................................................................................... 72

4.7. Display Unit ........................................................................................................................................................................................................................... 73

4.8. Switchbox .............................................................................................................................................................................................................................. 74

4.9. Oil Breather Catchtank ......................................................................................................................................................................................................... 75

4.10 Paddleshift System .............................................................................................................................................................................................................. 76


In Gearboxes

5. Assembly Tooling ......................................................................................................................................................................................................................... 80

6. Contact Information .................................................................................................................................................................................................................... 82

6.1. Contact Details ...................................................................................................................................................................................................................... 83

Appendix A: Technical Bulletins ...................................................................................................................................................................................................... 84

Appendix B: Amendments ............................................................................................................................................................................................................... 86


In Gearboxes

1. Technical Specifications


In Gearboxes

1.1. General Specifications

DG500

Application Circuit, Hill Climb & Rally

Type 6-Speed Sequential

Torque rating 650 Nm

Weight (dry weight) 39 kg


In Gearboxes

1.2. General Dimensions


In Gearboxes

1.3. Oil System A gerotor interal-gear pump is fitted as standard in the end cover of the DG500. The oil pump is used to feed oil to the bearings, gears, dog rings and drop

gears. The oil can be fed to an external oil cooler from the oil-out port and returned to the gearbox using the oil-in port. On the right and left side of the

main housing an M12x1.50 thread is provided to mount oil temperature and pressure sensors. On top of the gearbox a D-06 adaptor is mounted which

needs to be connected to an oil catch tank or has to be replaced with a breather.

Oil Type Motul 75W140 Gear Competition

Oil Quantity 1.8 litres (excluding external oil lines & oil cooler)


In Gearboxes

2. Gearbox Assembly


In Gearboxes

2.1. General Instruction Notes The following information is intended for mechanics to (dis)assemble the gearbox. This is illustrated using exploded views including the corresponding Bill Of

Materials (BOM). Specific notes related to the (dis)assembly of a part are shown in the notes column of the BOM. For more details on the bearing

installation see §2.2 Bearing Assembly.

Please read the manual and make sure all parts are present before starting to assemble. Also ensure that all parts are clean and undamaged. It is

recommended to replace nuts, seals and circlips after removal. Only genuine Drenth Gearboxes parts should be used when overhauling the gearbox.


In Gearboxes

2.2. Bearing Assembly To reduce the risk of bearing or casing damage, heat mounting is used to install or remove bearings. Drenth Gearboxes highly recommend to use an oven to

ensure an even heat distribution. Casings should not be heated above 130°C. Fit the bearings promptly after removing the casing from the oven to avoid

extra heating cycles being required.


In Gearboxes


In Gearboxes

POS Part Number Description QTY NOTE

1 37-08-0070 Roller Bearing 1

2 37-02-0503 Roller Bearing 1 Without inner ring. Supersedes: 37-08-0071

3 37-08-0081 Ball Bearing 1

4 37-08-0010 Front Housing 1

5 37-08-0011 Carrier Bearing 1

6 37-08-0067 Roller Bearing 6 Without inner ring. Supersedes: 38-08-0088 & 44-09-0310

7 37-08-0066 Roller Bearing 2 Without inner ring

8 37-08-0068 Locking Plate 2

9 37-02-0314 Bolt M4 8

10 37-08-0012 Rear Housing 1

11 37-08-0069 Locking Plate 2

12 37-08-0013 Drop Gear Housing 1


In Gearboxes

2.3. Gearbox Assembly


In Gearboxes


1 37-08-0037 Fork 1

2 37-08-0036 Nut M8 1

3 37-08-0033 Stud 1

4 37-08-0035 Oil Seal 1

5 37-08-0034 Nut M24 1

6 37-08-0156 Washer M24 1

7 37-08-0031 Cup 2

8 37-08-0032 Spring 1

9 37-08-0015 Assembly Selector Rod 1

10 37-08-0020 Ball Bearing 1

11 37-08-0039 Circlip 1


In Gearboxes


In Gearboxes


1 37-02-0026 Bolt M10 1 Supersedes: 35-01-0120

2 37-02-0352 Washer M10 2


4 37-08-0043 Selector Lever 1

5 37-02-0351 Spacer 1

6 44-09-0344 Washer M8 1

7 37-08-0112 K-Nut M10 1

8 44-09-0346 K-Nut M5 2

9 44-09-0348 Washer M5 2

10 35-01-0416 Washer M5 2

11 37-08-0042 Spherical Bearing Housing M6 2

12 37-08-0041 Bracket Spherical Bearing 1

13 37-02-0021 Washer M6 2 Supersedes: 44-09-0343

14 37-08-0038 Fitbolt M5 2


In Gearboxes


In Gearboxes


1 37-08-0047 Stud M8 9

2 38-10-0051 Multiseal M10 1

3 37-02-0478 Adaptor D-06xM10 1

4 37-02-0473 End Cap D-06 1 Supersedes: 44-09-0384

5 37-08-0019 Seal M18 1 Supersedes: 35-01-0081

6 35-01-0079 Oil Plug M18 1 Supersedes: 37-08-0018


In Gearboxes


In Gearboxes


1 37-08-0025 Selector Plate 1

2 37-08-0026 Ratch 2

3 37-08-0027 Spring 2

4 37-08-0024 Ratchet Carrier 1

5 37-08-0150 Positioner 1


7 37-08-0028 Spacer 1

8 37-08-0040 Circlip 1

9 37-02-0102 Circlip 1 Supersedes: 37-08-0077 & 38-03-0027

10 37-02-0314 Bolt M4 3


In Gearboxes


In Gearboxes


1 37-08-0085 Stud M6 9

2 37-13-0307 Bolt M8 1

3 44-09-0372 Seal M12 1

4 37-13-0324 Oil Plug M12 1

5 37-02-0325 Seal M24 1

6 37-02-0032 Oil Plug M24 1

7 37-02-0019 Oil Plug M24 - Magnetic 1

8 37-08-0048 Dowel 2

9 37-08-0051 Spacer 1

10 37-08-0054 Cage 1

11 37-08-0052 Idler Gear Reverse (13)-15-(29) 1

12 37-08-0050 Shaft Idler Gear Reverse 1

13 37-08-0053 Spring Dowel 1


In Gearboxes


In Gearboxes


1 37-08-0049 Centering Pin 1

2 37-08-0060 Outputshaft 1

3 37-08-0056 Sliding Gear Reverse (13)-(15)-29 1

4 37-08-0061 Hub Reverse Gear 1

5 37-08-0111 Dog Gear 1st (13)-33 1 Depending on gear ratio

6 37-08-0072 Needle Bearing 4

7 37-08-0062 Hub 1st - 6th Gear 2

8 37-08-0057 Dog Ring 2

9 37-08-0200 Dog Gear (16)-28 1 Depending on gear ratio



12 37-08-0063 Inner Track 1


In Gearboxes


In Gearboxes


1 37-08-0110 Layshaft 13-(33) 1 Depending on gear ratio

2 37-08-0074 Spacer 2

3 37-08-0201 Splined Gear 16-(28) 1 Depending on gear ratio



6 37-08-0075 Inner Track 1


In Gearboxes


In Gearboxes


1 37-08-0058 Selector Fork Reverse Gear 1

2 39-08-0032 Selector Fork 2


In Gearboxes


In Gearboxes


1 37-08-0064 Spacer 1

2 39-08-0032 Selector Fork 1

3 37-08-0072 Needle Bearing 2


5 37-08-0057 Dog Ring 1

6 37-08-0062 Hub 1st - 6th Gear 1


8 37-08-0065 Inner Track 1

9 37-08-0083 Nut M35 1

10 37-08-0084 Retainer Cap 1

11 37-08-0078 Circlip 1


In Gearboxes


In Gearboxes


1 37-08-0076 Spacer 1


3 37-08-0074 Spacer 1


5 37-08-0075 Inner Track 1



In Gearboxes


In Gearboxes


1 37-02-0014 D-Cord 1

2 37-08-0079 O-Ring 1

3 37-08-0048 Dowel 2


In Gearboxes


In Gearboxes


1 37-08-0082 Conveyer Rotary Sensor 1 Make sure that the marks are aligned

2 37-08-0151 Selector Drum 1

3 37-08-0073 Dowel 1

4 37-08-0079 O-Ring 1


In Gearboxes


In Gearboxes


1 37-08-0059 Shaft Selector Fork 1


3 37-08-0108 K-Nut M8 1

4 44-09-0344 Washer M8 1

5 37-02-0014 D-Cord 1


In Gearboxes


In Gearboxes


1 37-08-0105 Circlip 1

2 37-08-0103 Dowel 1

3 37-08-0102 Oil Pump Outer Rotor 1

4 37-08-0101 Oil Pump Outer Rotor 1

5 37-08-0017 Oil Seal 1

6 37-08-0100 Oil Pump Inner Rotor 1

7 37-08-0104 Plain Bearing 1

8 37-08-0099 Oil Filter 1

9 37-08-0107 O-Ring 1

10 37-08-0014 Endcover 1

11 37-02-0458 Multiseal M14 1

12 37-02-0460 Adaptor D-06xM14 1


14 37-02-0190 Oil Seal 1


In Gearboxes


In Gearboxes


1 37-08-0532 Banjo Bolt M14 1

2 37-02-0458 Multiseal M14 2


4 37-08-0531 Banjo Eye D-06xM14 1

5 37-13-0341 Set Screw M10 1


In Gearboxes


In Gearboxes


1 37-08-0109 K-Nut M6 9


3 37-02-0014 D-Cord 1

4 37-08-0079 O-Ring 1


In Gearboxes


In Gearboxes


1 37-08-0091 Bolt M8 1 Torque: 40Nm. Use Loctite 270

2 37-08-0086 Washer Inputshaft 1

3 37-08-0121 Drop Gear (21)-22 1 Depending on gear ratio

4 37-08-0120 Drop Gear 21-(22) 1 Depending on gear ratio

5 37-08-0048 Dowel 2

6 37-08-0089 Oil Seal 1

7 37-08-0090 Inputshaft 1

8 37-08-0013 Drop Gear Housing 1


In Gearboxes


In Gearboxes


1 37-08-0108 K-Nut M8 1

2 44-09-0344 Washer M8 1

3 37-02-0014 D-Cord 1


In Gearboxes


In Gearboxes


1 37-08-0078 Circlip 1

2 37-08-0084 Retainer Cap 1

3 37-08-0083 Nut M35 1

4 37-08-0427 Output Flange 1


In Gearboxes


In Gearboxes


1 37-08-0045 Positioning Pin 1

2 37-02-0331 Spring 1

3 35-01-0082 Seal M14 1

4 37-08-0188 Nut M14x1.5 1

5 37-08-0189 Guide Cable 1

6 37-02-0342 Inner Cable 1

7 37-02-0343 Outer Cable 1

8 37-02-0344 Cover Outer Cable 1

9 37-02-0346 Lock Screw 1


In Gearboxes


In Gearboxes


1 37-02-0721 O-Ring 1

2 25-03-0011 Rotary Sensor 1 See chapter: Rotary Sensor

3 37-02-0315 Washer M4 2

4 37-02-0312 Bolt M4 2


In Gearboxes


In Gearboxes


1 37-02-0449 Rod End M8 (Left) 1

2 37-02-0357 Nut M8 Left 1

3 37-08-0516 Stud M8 Left 1

4 38-10-0038 Rod 1

5 37-08-0517 Stud M8 1

6 37-02-0358 Nut M8 1

7 37-02-0479 Fitbolt M6 1 Supersedes: 37-12-0319

8 44-09-0344 Washer M8 1


10 37-08-0109 K-Nut M6 1

11 37-02-0409 Rod End M8 1


In Gearboxes

2.4. Rotary Sensor

The gearboxes come with a Penny & Giles SRH280DP rotary sensor. The rotary sensor signal is used to show the engaged gear on the Drenth Display Unit /

Drenth Gear Indicator or any other display. For correct gear indication, it is necessary that rotary sensor is properly connected and calibrated. Information

related to the wiring of the sensor is shown in the table below.

Cable Colour Description

Red + 5 V Supply

Yellow Output 1

White Output 2

Black 0 V Supply (GND)

Depending on the type of gearbox, Output 1 or Output 2 is used. The table below shows which output is used for the different types of gearboxes:

Gearbox Type Output Cable Colour

DG350 Output 2 White

DG350 Direct Replacement Output 1 Yellow




DGT250 Output 2 White

DGT350 Output 2 White

Mitsubishi Lancer Evolution VI-IX Output 1 Yellow

Mitsubishi Lancer Evolution X Output 1 Yellow

MPG Output 1 White


In Gearboxes

The connection diagrams when using output 1 or output 2 are shown below:

Please note that the above information does not apply to other sensors!


In Gearboxes

3. Gear Ratio List


In Gearboxes

The available gear ratios for the DG500 are shown in the table below. In addition, customer specific gear ratios can be developed, produced and supplied.

Layshaft Ratios Gear Ratios Drop Gear

Ratios

1st 2nd 2nd, 3rd, 4th, 5th & 6th

3.000 2.400 2.125 1.800 1.556 1.250 0.955 1.130

3.000 2.286 2.067 1.778 1.529 1.227 0.889 1.087

3.000 2.214 2.000 1.750 1.500 1.190 1.048

3.000 2.067 1.938 1.722 1.471 1.130 1.000

2.538 1.882 1.667 1.421 1.083 0.955

1.875 1.611 1.389 1.048 0.920

1.833 1.579 1.316 1.000 0.885


In Gearboxes

4. Accessories


In Gearboxes

4.1. Bellhousings / Adaptor Plates Drenth Gearboxes offers a variety of removable bellhousings and adaptor plates to mount the DG500 into different vehicles. In addition, bellhousings and

adaptor plates for customer specific applications can be developed, produced and supplied.


In Gearboxes


1 37-08-0160 Assembly Bellhouse DG500 - BMW S54 1





In Gearboxes


1 37-08-0175 Assembly Adaptor Plate DG500 - Tremec T56 1 Chevrolet

2 37-08-0177 Assembly Adaptor Plate DG500 - Tremec T56 1 Ford

3 37-08-0180 Assembly Adaptor Plate DG500 - Ginetta G50 1


In Gearboxes

4.2. Gearbox Brackets The Drenth gearbox brackets are designed to mount the DG500 using the existing chassis mounting points of the specific vehicle. Please note that these

brackets can only be used in vehicles where the chassis mounting points and/or the position of the engine have not been modified.


1 37-08-0507 Assembly Gearbox Mount - BMW E92 1 Aluminium


In Gearboxes

4.3. Gear Lever Drenth Gearboxes offers a one-piece aluminium gear lever which, in combination with shift rods or a push/pull cable, can be used on any Drenth sequential

gearbox to change gear. Several gearbox and chassis mounted brackets are available for mounting the gear lever at the desired position.

In order to suit a variety of applications, the gear lever comes in two different lengths:

• 260 mm • 360 mm


In Gearboxes


1 25-03-0052 Assembly Gearlever Long/Short Stud 1

3 25-03-0053 Assembly Gearlever Long/Inter Stud 1

3 25-03-0054 Assembly Gearlever Long/Long Stud 1

4 37-02-0650 Assembly Gearlever Short/Short Stud 1


In Gearboxes

4.4. DMS Gear Lever Drenth Gearboxes offers a one-piece DMS aluminium gear lever with integrated electronics which, in combination with shift rods or a push/pull cable, can

be used on any Drenth sequential gearbox to change gear. The analogue output signal of the gear lever electronics can be used to configure the ignition cut

enabling flat-shifting. An optional Switchbox is used to convert the analogue signal when a digital output signal for programming the ignition cut is required.

The DMS gear lever can also be used to program down shift throttle blip if the car is equipped with drive-by-wire. In addition, several gearbox and chassis

mounted brackets are available for mounting the gear lever at the desired position.

In order to suit a variety of applications, the gear lever comes in two different lengths:

• 260 mm • 360 mm


In Gearboxes


1 25-03-0055 Assembly DMS Gearlever Short/Short Stud 1

3 25-03-0056 Assembly DMS Gearlever Long/Inter Stud 1

3 25-03-0057 Assembly DMS Gearlever Long/Long Stud 1


In Gearboxes

4.5. Gear lever Brackets Drenth Gearboxes offers various types of gear lever brackets for mounting the (DMS) gear lever in the car. There can be chosen between two types of

brackets, namely gearbox mounted gear lever brackets and tunnel mounted gear lever brackets.


1 25-03-0250 Assembly Bracket Gearlever Tunnelmount 1 Aluminium

3 25-03-0255 Assembly Bracket Gearlever Tunnelmount 1 Steel


In Gearboxes

4.6. Gear Indicator Designed to work seamlessly with every Drenth sequential gearbox, the gear indicator uses the rotary sensor signal to show the selected gear. Using the

supplied software, it is possible to show up to 8 forward gears as well as neutral and reverse on the display with integrated light sensor. In addition, the gear

indicator features an option to control the reversing light.

Features:

- Gear indication

- Reverse light

- Automatic calibration


1 25-03-0065 Gear Indicator 1


In Gearboxes

4.7. Display Unit Designed to work seamlessly with every Drenth sequential gearbox, the display unit uses the rotary sensor signal to show the selected gear. Using the

supplied software, it is possible to show up to 8 forward gears as well as neutral and reverse on the display with integrated light sensor. In addition, the

display unit features an adjustable shift light and an option to control throttle blip or the reversing light. In combination with the DMS gear lever, the display

unit can be used for flat-shifting which allows the user to set the cut time for each gear separately. This is also possible when using any other load cell,

Switchbox or switch.

Features:

• Gear indication • Shift light • Flat-shifting • Down shift throttle blip / Reverse light • Automatic calibration

• DMS Gear Lever calibration


1 25-03-0066 Display Unit 1


In Gearboxes

4.8. Switchbox The Drenth Gearboxes Switchbox is an analog-to-digital converter which is used in combination with the Drenth Display Unit or a programmable ECU to

enable flat-shifting. When a digital output signal is required for setting the ignition cut the Switchbox is used to convert the analogue signal. Because the

Switchbox is equipped with two potentiometers, the upshift and downshift threshold levels can be adjusted as desired.

Features:

• Adjustable downshift threshold voltage

• Adjustable upshift threshold voltage


1 25-03-0060 Switchbox DMS Gearlever 1


In Gearboxes

4.9. Oil Breather Catchtank Drenth Gearboxes recommends the use of an Oil Breather Catch Tank for breathing the gearbox. Therefore Drenth Gearboxes offers a universal catch tank

which can be used with any gearbox. The set includes the breather catch tank, oil hose and the necessary adaptors.


1 25-03-0200 Assembly Oil Breather Catchtank 1


In Gearboxes

4.10 Paddleshift System The DG500can be equipped with a paddleshift system from KMP or Geartronics allowing the driver to change gears by using steering wheel mounted shift

paddles. For mounting the actuators of the different paddleshift systems, Drenth Gearboxes has developed various brackets for the DG500. If the preferred

paddleshift system has a safety feature which prevent the driver from selecting neutral and reverse accidentally during downshifts, then the mechanical

blocking system can be replaced and / or removed. In this case the following parts are required:

KMP:


In Gearboxes


1 01-05-11304 KMP Shift Cylinder D4 V2 1

2 35-01-0094 Fitbolt M6 1

3 35-01-0097 Fitbolt M6 1


5 37-08-0108 K-Nut M8 2

6 37-08-0109 K-Nut M6 2

7 37-08-0152 Stud M8 2 Replacement for 37-08-0047

8 37-08-0157 Nut 1 Replacement for 37-08-0188

9 37-08-0159 Positioner Paddleshift 1 Replacement for 37-08-0150

10 44-09-0344 Washer M8 2

11 37-08-0497 Bracket Paddle Shift 1


In Gearboxes

Geartronics


In Gearboxes


1 35-01-0097 Fitbolt M6 1

2 35-01-0414 Fitbolt M5 1

3 35-01-0415 Locking Nut M5 1

4 35-01-0416 Washer M5 1


6 37-02-0351 Spacer 1


8 37-08-0108 K-Nut M8 2

9 37-08-0109 K-Nut M6 1

10 37-08-0152 Stud M8 2 Replacement for 37-08-0047

11 37-08-0157 Nut 1 Replacement for 37-08-0188

12 37-08-0159 Poistioner Paddleshift 1 Replacement for 37-08-0150

13 37-08-0183 Bracket Geartronics Paddleshift 1

14 37-08-0184 Selector Lever Geartronics Paddleshift 1 Replacement for 37-08-0043

15 44-09-0344 Washer M8 2

16 44-098-0346 K-Nut M5 1

17 ACT3232 Geartronics ACT3232 1


In Gearboxes

5. Assembly Tooling


In Gearboxes

Optionally, Drenth Gearboxes provide tools which are used for assembling and disassembling the DG500. The tools listed below make it possible to perform

maintenance on the DG500:


1 70-03-0001 Assembly Flange Fixture Tool 1

2 70-03-0002 Assembly Positioner Puller 1

3 70-03-0005 Tool Outputshaft Lock 1

4 70-03-0006 Assembly Drop Gear Lock Tool 1

5 70-03-0007 Assembly Retainer Cap Puller DG500 1


In Gearboxes

6. Contact Information


In Gearboxes

6.1. Contact Details Drenth Motorsport Gearboxes

Fleuweweg 10

7468 AG Enter

The Netherlands

www.drenth-gearboxes.com

Spare Parts: +31 (0)547 38 26 96 [email protected]


In Gearboxes

Appendix A: Technical Bulletins


In Gearboxes


In Gearboxes

Appendix B: Amendments


In Gearboxes

Date Page Modification 18-10-2017 1st Issue of completely revised manual

28-06-2018 63 & 73-74 Added Adaptor Plates and Paddleshift System

06-07-2018 64 Added Chapter 4.2 Gearbox Brackets

18-07-2018 8 Changed oil type to Motul 75W140 Gear Competition

11-09-2018 64 Deleted POM gearbox mount

01-10-2018 74 Added Paddle Shift KMP

14-10-2019 57 Position Rotary Sensor added

06-07-2020 All Converted to Illustrator

T +31 (0)547 38 26 96 E [email protected] W www.drenth-gearboxes.com

Gearbox Manual DG500 2017 · 2020. 7. 6. · Pole Position DG500 –Revision: 007 Gearbox Manual 2...

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Transcript of Gearbox Manual DG500 2017 · 2020. 7. 6. · Pole Position DG500 –Revision: 007 Gearbox Manual 2...