SERVICING INSTRUCTIONS AND ILLUSTRATED · PDF fileBuild up the mainshaft assembly into the...

© Copyright Hewland Engineering Limited 2010

SERVICING INSTRUCTIONS AND ILLUSTRATED PARTS LIST FOR HEWLAND MLG GEARBOXES

HEWLAND ENGINEERING LTD, WALTHAM ROAD, WHITE WALTHAM, MAIDENHEAD, BERKSHIRE, SL6 3LR, ENGLAND

LAST REVISION:- 23rd December 2013


CONTENTS

Page Gearbox Tooling 28 Installation Details 29 Amendments 32

Page Technical Specification 4 Recommended Torque Settings 5 General Notes 6 Sequential Barrel Setting 7 Gearbox Assembly 8 Changing Gear Ratios 10 Illustrated Parts List 11 Optional Parts 22 Dressed Casing Details 25


ILLUSTRATIONS

Page Fig.1 Fork Setting Fixture 7 Fig.2 Transfer Housing Assembly 13 (Front & Centre Casings) Fig.3 Layshaft Assemblies 14 Fig.4 Mainshaft Assembly 15 Fig.5 Cluster Assembly 16 Fig.6 Rear Casing Assembly 17 Fig.7 Oil Pump Assembly 18 Fig.8 Final Assembly 19 Fig.9 Optional Parts 22 Fig.10 Optional Gear Lever Assembly 23 (MLG-252)

Page Fig.11 Optional Actuator Mounting 24 (Semi-Auto) Fig.12 Dressed Front case 25 Fig.13 Gearbox Tooling 28 Fig.14 Installation Drawing - Gearbox 30 Fig.15 Installation Drawing - Lever 31


TECHNICAL SPECIFICATION The MLG gearbox is an inline gearbox designed for use in Front-engined, rear wheel drive cars. The unit is produced with six forward gears plus reverse. The standard front face is to suit Ford Sierra Type 9 bellhousing. The gear selection mechanism is sequential, and an optional lever arrangement is available that mounts directly to the gearbox rear case (R/H or L/H Drive). A cable operated blocking mechanism is featured to prevent accidental down shifts into neutral and reverse gears. The gear selection order is:- Rev - Neutral - 1st - 2nd - 3rd - 4th - 5th - 6th The drive is taken from the engine via the clutch shaft to a transfer gear set (drop gear). The output drop gear is splined to the layshaft and drive is transferred through gears to the mainshaft shaft, and then on to output (prop-shaft) flange which is inline to the clutchshaft. Gear changing is effected through non-synchronising face dogs. An extensive range of gear ratios provides a wide range of gearing requirements. The gear ratios and drop gears can be changed without removing the gearbox from the vehicle. Hewland specification, heat treated nickel chrome steel is used to manufacture all gears and shafts. The selector forks are also steel. Lubrication is by internal pump with distribution circuit, and the oil is retained by lipped oil seals. In general configuration, the MLG-200 is a high tech racing transmission which achieves the maximum effective use of power. Custom output flanges can be specified and the position can be changed with an alternative housing and flange arrangement (further details available from Hewland Engineering upon request)

1st to 6th gear ratios from 3.083:1 to 0.923:1 Drop gear ratios 27/28, 24/24, 28/27, 24/27 & 27/24 Clutchshaft - made to customers requirements Output flange: MLG-218-GIN (see installation drawing for details). Bespoke flanges made to customers requirements. Gearbox weight 66 lbs (30Kg) + clutchshaft and output flange Oil type SAE 80 or 90 Oil quantity 2.2 pints (1.25 litres) - Not Including cooler or external pipe work. Maximum torque 320 lbs.ft (430 Nm)


RECOMMENDED FITTING TORQUES

General nut and bolt torque settings:- Specific nut and bolt torque settings:- (Where Specific nut and bolt details are a similar size to General nut and bolt details, the tightening torques listed in this section must be adhered to for these components.) Barrel Bolt tightening torque = 35 lbs.ft (48 Nm)


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. N.B. 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 oil filler hole on top of the rear case. The oil will find it's own level within the gearbox. N.B. Too much oil will not directly cause any harm, but is undesirable as it will induce power loss and overheating of the internals.

GENERAL NOTES


Requires special tool No. SK-2444

Build up the mainshaft assembly into the rear case, ensuring the circlip (18) is installed with the thickness of spacer (100) adjusted to suit. The output housing must be secured in place with bolts (92). Fit the fork setting fixture as shown in Fig. 1 & 11. Use the handle (f4) to place the barrel in the neutral position. With neutral position selected, measure and record the dog face clearance for 1st & 2nd gears. Their position in the case, (furthest away from the datum face), means any dog clearance errors due to tolerance build up, will be at their worst. Therefore it is acceptable to adjust the barrel position according to these readings. Any difference in the dog face clearance between these gears must be averaged out by changing the barrel setting spacer (108) ~ various thicknesses available, as shown in Fig.1. In order to change this spacer, the face plate of the fixture, the selector rail (111), selector forks (21 & 112) and the keep plate (66) must be removed. To remove the keep plate, undo the two screws (98). Once the keep plate is out, the barrel (65), along with its spacer (108), bearing (6) and barrel bolt (107) can then be removed. Unscrew the barrel bolt from the barrel (this is made easier if a suitable tool is located into the radial hole in the Barrel). The bearing can then be removed and the spacer changed. Once 1st/2nd fork setting is completed, the clearance of the dogs between the reverse gear (110) and ring (62) should be checked. The nominal clearance is same as 1st/2nd gear, although it can be less in reverse, the clearance should be at least 1mm (.039”).

FIGURE 1

SEQUENTIAL BARREL SETTING

N.B. It is not possible (or necessary) to individually adjust each fork.


a) It is assumed that all bearings, seals, o-rings, studs, oil jets, plugs and dowels are already fitted into their casings.

{FIGURE 2} b) Fit the pawl (101) into the selector rack (67) with dowel pin (123) ensuring afterwards that the pawl is free to rotate in

the rack. Slide the spacers (32 & 33) on to the rack along with spring (103) followed by the spacer (32) and fit circlip (17) to secure in place. Fit the plunger (103), spring (1) and washer (29) into the bore of the selector rack and secure in place with internal circlip (16).

c) Slide the assembled rack into the front case (53) being careful not to damage or dislodge the quad-ring (84). d) Slide bearing (10) on to the barrel driver (99) and assemble into the bearing (9) in the front case [it will be necessary

to ‘duck’ the rack pawl out of the way]. Once in place fit circlip (19) to retain the barrel drive/bearing. e) Fit the detent wheel (85) and spring (86) on to the trunion (34) and ensuring washer (38) is in place, attach the

assembly to front case with screw (43). [The spring will seat against dowel pin (28) and the detent wheel should act against the pins in the barrel driver].

f) Fit the selector rack cover (54) using screws (98). g) Fit spray rail (20) into front case using screw (89) to retain. h) Fit the transfer gears (73) into the bearings (8) in front case. The input transfer gear can be identified by the internal

circlip which is fitted in its bore. i) The clutchshaft (64) can now be installed into input transfer gear with wire ring (45) locating it in position j) Fit the reverse idler post into the centre case (57) and retain with bolt (93). Fit bearing (35) into idler gear (27) and

slide on to the post. Fit washer (114) and retain with circlip (36). k) Attach magnet (115) into place on centre case using screw (89) l) The centre case can now be fitted, using the transfer gear bearings (5) for alignment, push centre case on to front

case until the dowels (49) are home. {FIGURE 3}

m) Slide third input gear (71) followed by forth & fifth (77) input gears on to layshaft (72). Fit spacer (3) then sixth input gear (77) followed by disc spring (4) and finally the inner track (106). [correct orientation of disc spring is important and is shown on Fig.#.] For loose 2nd layshafts, see Fig.#. for spacer arrangement of additional spacers etc. {FIGURE 4}

n) Fit the 2 halves of split bearing (12) into rev. pinion gear (110) and slide on to rev. c/ring hub. Slide this assembly on to the mainshaft (60). Fit pinion gears (72, 71 & 77) and c/rings (76) on to hubs (75) with needle bearings (2) fitted. Slide these on to mainshaft in incremental order (first gear being closest to reverse).

GEARBOX ASSEMBLY


o) Fit spacer (100) followed by bearing (7), noting that the inner track spacer is fitted in opposite position to usual so

that the oil muff (61) now forms the abutment shoulder when fitted on to mainshaft. Fit circlip (18) to the mainshaft assembly. N.B. It maybe necessary to surface grind the spacer (100) to enable the mainshaft stack to assemble with minimum end float. Once the spacer (100) has been adjusted, remove circlip(18), oil muff (61) & bearing (7) but leave the inner track spacer for the bearing on the shaft. Slide needle bearing (11) on to mainshaft (spigot end). {FIGURE 5}

p) Fit the spacer (108) and bearing (6) to the selector barrel (65) and secure with bolt (107) ensuring correct torque is applied. Fit into rear case (70) and clamp in place with keep plate (66) using the two screws (98).

q) Fit assembled layshaft into the bearing (8) in rear case. r) Fit mainshaft bearing (7) into rear case, locate selector forks (21,112) on to the associated c/rings on the mainshaft

assembly. Fit the mainshaft assembly into rear case, locating into inner track of bearing (7). Slide selector rail (111) through forks and locate into rear case. Fit the oil muff (61) on to mainshaft so it abuts the bearing. Fit circlip (18) to secure the mainshaft assembly. {FIGURE 6}

s) Install bearing (13), spacer (56) and bearing (13) into bore of tail housing (55). Fit circlip (14) to retain bearings then insert lipseal (52) and retain with circlip (44).

t) With o-ring (81) fitted, insert plug (58) into output flange (59) and retain with snap-ring (15) u) Ensure o-ring (83) in place on the tail housing (55), then install it into rear case and retain with bolts (92) so that the

rear mainshaft bearing is clamped into place by the tail housing. {FIGURE 7}

v) Fit oil pump rotors (22, 23) into pump body (26) followed by cover (113) and secure in place with screws (91). Slide drive gear (69) on to driving rotor (23) and fit key (24) then retain with circlip (25). {FIGURE 8}

w) Install oil pump into rear casing, taking care not to damage the pump outer o-ring (82). Secure with screws (98). x) Fit the filter (109) and washer (42) into rear case along with two hydraulic fittings (46) and associated washers (119).

Thread reverse lock cable [not standard Hewland supply] through detent plug (31) and spring (104) then into the plunger (30) and secure with two grub screws (94)

y) Install the rear case assembly onto the assembled transfer housing (front & centre cases) ensuring it is fully home on the dowels. Secure with six nuts (78) and washers (120)

z) Fit three washers (122) between two bearings (11) into bore of bellcrank (68) followed by another washer (50) on either side. Locate bellcrank arm into selector rack slot and fix in place under the bracket (74) by screwing the three bolts (90, 97) along with washers (50) into the front and rear casings.


a) With a drip tray placed beneath the gearbox, remove the filter (109) and drain the oil.

b) Disconnect the drive flange (59) from the prop-shaft of the car.

c) Undo the screw connecting gear lever linkage rod to the bellcrank and disconnect linkage. Remove the rearmost of the bellcrank bracket screws (90) from the rear casing.

d) Remove the six k-nuts (78). The rear case can then be separated from the transfer housing assembly (centre & front cases). Two ‘jacking-off’ holes (M6 thread) are located on the rear case flange behind the dowel pins(49) to help ease removal of the rear casing. Care should be taken to ensure the layshaft assembly is supported to prevent it dropping out as the casing is removed. Also ensure that the mainshaft front bearing (117) stays located in the transfer gear.

e) Once the rear casing has been removed, the selector rail (111) can be pulled out and forks (21, 112) swung away from the selector barrel (65).

f) Remove the output housing (55) from the rear case by removing the five screws (92). Three ‘jacking-off’ holes (M6 thread) are located on the output housing flange to help ease removal of the housing. Care should be taken to ensure the drive flange is removed or supported to prevent it dropping out as the housing is removed.

g) Circlip (18) should be removed and the mainshaft assembly can then pulled out along with the layshaft. Care should be taken with the oil muff (61) as this won’t be supported once the mainshaft is out. Also, one should be careful not to loose the layshaft bearing inner track (106) or the adjacent disc spring (4) when the layshaft is removed.

Changing of the transfer gears can be achieved by carrying out steps ‘a’ to ‘d’ (above). The centre plate (57) can then be removed from the front case (53) taking care to support the clutchshaft (64) so as not to damage the lipseal (51). The clutchshaft needs to be removed from the input transfer gear by tapping it out with a aluminumn drift so that the wire ring (45) is released from its locating groove. N.B. When replacing the transfer gears, the input gear has an internal circlip fitted.

CHANGING GEAR RATIOS


ILLUSTRATED PARTS LIST


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FIGURE 2

TRANSFER HOUSING ASSEMBLY (Front & Centre casings)


FIGURE 3b

LAYSHAFT ASSEMBLIES

FIGURE 3

FIGURE 3a

CORRECT ORIENTATION OF INSTALLED 105-234-8 DISC SPRING (ITEM 4)


FIGURE 4

MAINSHAFT ASSEMBLY


FIGURE 5

IMPORTANT NOTE:- ITEM 107 BARREL BOLT MUST BE LOCTITED AND TIGHTENED TO THE TORQUE SPECIFIED ON PAGE 5

CLUSTER ASSEMBLY


FIGURE 6

REAR CASING ASSEMBLY


FIGURE 7

OIL PUMP ASSEMBLY


FINAL ASSEMBLY

FIGURE 8


Item No Part Number Description Qty 38 HP-M-7039 DRUM WASHER 1 39 HP-M-9037 BANJO JOINT 1 40 HP-M-9038 SEALING WASHER 2 41 HP-M-9039 BANJO BOLT 1 42 HP-M-9042 DOWTY WASHER 1 43 HP-M-9054 SOCKET CAP SCREW 1 44 HP-N-9009 CIRCLIP 1 45 HP-N-9010 WIRE RING 1

46 HYD-016 HYD-017

ADAPTOR (-6) ADAPTOR (-8) 2

47 HYD-031 BLANKING PLUG 1 48 HYD-080 PLUG 1 49 LD-201-5 DOWEL 4 50 LD-202-9 WASHER 5 51 LIP-032 LIPSEAL 1 52 LIP-092 LIPSEAL 1 53 MLG-201 FRONT CASE 1 54 MLG-201-1 RACK COVER 1 55 MLG-202-1 OUTPUT HOUSING 1 56 MLG-202-12 SPACER 1 57 MLG-208 CENTRE PLATE 1 58 MLG-218-1 PLUG 1 59 MLG-218-GIN DRIVE FLANGE 1 60 MLG-221 MAINSHAFT 1 61 MLG-221-1 OIL MUFF 1 62 MLG-231-1 REVERSE CLUTCH RING 1 63 MLG-237-1 REVERSE IDLER SPIGOT 1 64 MLG-239- CLUTCH SHAFT 1 65 MLG-260 SELECTOR BARREL ASSY 1 66 MLG-260-2 KEEP PLATE 1 67 MLG-260-3 SELECTOR RACK 1 68 MLG-260-4 BELLCRANK 1 69 MLG-265-10 OIL PUMP DRIVE 1 70 MLG-302 REAR CASE 1 71 MLG-RATIO-HUB HUBBED GEAR SET 1 72 MLG-RATIO-RATIO LAYSHAFT ASSY 1 73 MLG-RATIO-TR TRANSFER GEAR SET 1 74 MLI-201-1 BRACKET - BELLCRANK 1

Item No Part Number Description Qty 1 102-260-9 COMPRESSION SPRING 1 2 104-226-2 NEEDLE ROLLER BEARING 6 3 104-234-4 LAYSHAFT SPACER 1 4 105-234-8 DISC SPRING 1 5 BEA-017 ROLLER BEARING 1 6 BEA-037 BALL BEARING 1 7 BEA-072 ROLLER BEARING 1 8 BEA-093 ROLLER BEARING 3 9 BEA-107 BALL BEARING 1

10 BEA-141 BALL BEARING 1 11 BEA-162 BALL BEARING 2 12 BEA-263 NEEDLE ROLLER BEARING 1 13 BEA-359 NEEDLE ROLLER BEARING 2 14 CIR-004 CIRCLIP 1 15 CIR-050 CIRCLIP 1 16 CIR-082 CIRCLIP 1 17 CIR-084 CIRCLIP 1 18 CIR-169 CIRCLIP 1 19 CIR-185 CIRCLIP 1 20 CPK-201-2 SPRAY RAIL 1 21 CST-250-C SELECTOR FORK ASSY 3 22 DG-265-4 OIL PUMP ROTOR 1 23 DG-265-5 OIL PUMP ROTOR 1 24 DG-265-6 KEY 1 25 DG-265-8 CIRCLIP 1 26 DWT-265-2 OIL PUMP BODY 1 27 EGT-237-1 REVERSE IDLER 1 28 F3A-202-9A DOWEL 1 29 F3D-236-1 WASHER 1 30 FTR-210-35 PLUNGER 1 31 FTR-210-36 PLUG 1 32 FTR-260-4 SELECTOR RACK WASHER 2 33 FTR-260-5 SLEEVE 1 34 FTR-260-8 SPRING TRUNION 1 35 HC-237-2 NEEDLE ROLLER BEARING 1 36 HC-239-0 CIRCLIP 1 37 HC96-202-6 STUD 6


Item No Part Number Description Qty

111 TMT-246 SELECTOR RAIL 1 112 TMT-249-A REVERSE SELECTOR FORK 1 113 TSHD-265-1 OILPUMP ENDCOVER 1 114 MLG-237-2 THRUST WASHER 1 115 VG-201-1A MAGNET 1 116 VG-201-9 SEALING STRIP 1 117 VGC6-237-2 NEEDLE CAGE 1 118 WSH-010 DOWTY WASHER 1 119 WSH-017 DOWTY WASHER 2 120 WSH-028 WASHER 6 121 WSH-065 DOWTY WASHER 1 122 WSH-066 WASHER 3 123 DOW-063 DOWEL 1 124 BEA-190 BEARING 1

110 TMT-231 REVERSE PINION GEAR 1 109 TE-266 OIL FILTER 1 108 TE-260-7 SELECTOR BARREL SPACER 1 107 TE-260-5 SELECTOR BARREL BOLT 1

Item No Part Number Description Qty 75 MLI-226 HUB 3 76 MLI-232 CLUTCH RING 3 77 MLI-RATIO-STD RATIO SET 3 78 NUT-004 KAYNUT 6 79 ORI-001 O-RING 1 80 ORI-118 O-RING 1 81 ORI-126 O-RING 1 82 ORI-171 O-RING 1 83 ORI-212 O-RING 1 84 ORI-227 QUAD-RING 1 85 PCT-260-2 DRUM STOPPER 1 86 PCT-260-3 COIL SPRING 1 87 PLU-030 PLUG 1 88 SCR-003 SOCKET SET SCREW 1 89 SCR-012 SOCKET CAP SCREW 2 90 SCR-069 SOCKET CAP SCREW 2 91 SCR-077 SOCKET CAP SCREW 4 92 SCR-084 SOCKET CAP SCREW 5 93 SCR-090 SOCKET CAP SCREW 1 94 SCR-121 SOCKET SET SCREW 2 95 SCR-133 SOCKET SET SCREW 1 96 SCR-189 SKT BUTTON HEAD SCREW 2 97 SCR-346 SOCKET CAP SCREW 1 98 SGT-244-13 SOCKET CAP SCREW 7 99 SHL-260-1 BARREL DRIVER 1

100 SPA-012 SPACER (3.0mm Thick) 1 100 SPA-012A SPACER (3.5mm Thick) 1 100 SPA-012B SPACER (3.25mm Thick) 1 101 SPH1077-M3 PAWL 1 102 SPH1078-M3 PLUNGER 1 103 SPR-057 COMPRESSION SPRING 1 104 SPR-058 COMPRESSION SPRING 1 105 TE-201-4 COVER PLATE 1 106 TE-234-2 BEARING INNER TRACK 1


FIGURE 9

OPTIONAL PARTS


FIGURE 10

OPTIONAL GEAR LEVER ASSEMBLY (MLG-252)


OPTIONAL ACTUATOR MOUNTING (SEMI-AUTO)

FIGURE 11

Item No Part Number Description Qty 1 MLG-202-4 ACTUATOR PIN 1 2 MLG-202-3 ACTUATOR BRACKET 1 3 WSH-066 WASHER 2 4 SCR-068 SOCKET CAP SCREW 2 5 NUT-001 NUT 1 6 WSH-015 WASHER 2 7 SCR-298 HEX HEAD SCREW 1

Note:- Boss only featured on rear casing for casting MLG-102-V4 onwards


FIGURE 12b

FIGURE 12a

DRESSED REAR CASE (MLG-302) [Early casting design only - MLG-101-V1/2]


FIGURE 12c

DRESSED REAR CASE (MLG-302) [Later casting design only - MLG-101-V3 onwards]

FIGURE 12d

See next page for details of baffle plate installation


DRESSED REAR CASE (MLG-302) [Later casting design only - MLG-101-V3 onwards]

MLG-202-2A BAFFLE PLATE (AFTER BENDING)

THE FLAPS & END TANG OF THE BAFFLE PLATE WILL REQUIRE BENDING UPON ASSEMBLY INTO MLG-201 REAR CASE (AS SHOWN). NOTE:- MLG-302 is a dressed case (i.e. inserts & baffle plate already fitted when purchased from Hewland stores)

FIGURE 12e


GEARBOX TOOLING SK-2444 FORK SETTING FIXTURE

FIGURE 13


INSTALLATION DETAILS


FIGURE 14

INCHES

mm

INSTALLATION DETAILS (Gearbox)


MLG-252 Installation drawing (optional gear lever)

FIGURE 15

INCHES

mm


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Date Modification 10/01/2011 First Issue 02/11/2011 Page 24 - Actuator mounting added. Pages 25-27 - Dressed rear case information updated to show revised oil pickup & baffle. Page 30 - Installation drawing pictorially updated and scale corrected. 13/07/2012 Page 21 - TSR-237-1 replaced by MLG-237-2. 03/10/2012 Page 20 - Item 46 revised to show –6 or –8 options 23/12/2013 Page 21 - SPA-12B additional optional thickness spacer added

Amendments

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