Hewland FTR Servicing Instructions Download

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SERVICING INSTRUCTIONS AND ILLUSTRATED

PARTS LIST FOR THE FTR FAMILY OF HEWLAND

GEARBOXES, COVERING FTR, FTRS, FTRL, JFR &

LJS UNITS.

HEWLAND ENGINEERING LTD

WALTHAM ROAD, WHITE WALTHAM,

MAIDENHEAD, BERKSHIRE,

SL6 3LR, ENGLAND

TELEPHONE: +44 (0)1628 827600

Last Updated 23rd March 2009

Summary of Contents for FTR

Page 1: ...NG INSTRUCTIONS AND ILLUSTRATED PARTS LIST FOR THE FTR FAMILY OF HEWLAND GEARBOXES COVERING FTR FTRS FTRL JFR LJS UNITS HEWLAND ENGINEERING LTD WALTHAM ROAD WHITE WALTHAM MAIDENHEAD BERKSHIRE SL6 3LR ENGLAND TELEPHONE 44 0 1628 827600 Last Updated 23rd March 2009 ...

Page 2: ...PAGE 2 Copyright Hewland Engineering Limited 2001 2008 This page left intentionally blank ...

Page 3: ...llustrated Parts List 19 FTR JFR 6 Speed with FTREL Barrel Illustrated Parts List 28 FTR JFR 6 Speed conversion to 5 Speed 30 FTR 6 Speed fitted with FTRE ratios Illustrated Parts List 31 FTR JFR 5 Speed Illustrated Parts List 39 FTRS 6 Speed Illustrated Parts List 48 Bearing Carrier Options 49 Differential Options Illustrated Parts List 50 Typical Ramp Orientation 64 Gearbox Tooling 65 Installati...

Page 4: ...PAGE 4 Copyright Hewland Engineering Limited 2001 2008 This page left intentionally blank ...

Page 5: ...sembly 6 Speed not FTRE ratios 23 Fig 12 Selector Assembly 6 Speed FTREL Barrel only 28 Fig 13 5 Speed Conversion Assembly 6 Speed Gearbox 30 Fig 14 Casing Associated Parts 6 Speed FTRE ratios 32 Fig 15 Layshaft Assembly 6 Speed FTRE ratios 33 Fig 16 Pinion Shaft Assembly 6 Speed FTRE ratios 34 Fig 17 Selector Assembly 6 Speed FTRE ratios 35 Fig 18 Casing Associated Parts 5 Speed not FTRE ratios 4...

Page 6: ...Flanged LSD Differential Inboard Brake Discs 62 Fig 36 LD 212 63 Fig 37 Ramp Orientation 64 Fig 38 Gearbox Tooling 65 Fig 39 Installation Drawing FTR 68 Fig 40 Installation Drawing JFR 69 Fig 41 Installation Drawing Bearing Carriers 70 Fig 42a c Installation Drawing Flanges 71 73 Fig 43 FTRL Hubbed Gears 74 Fig 44 Technical Bulletin 01A 77 Fig 45 Technical Bulletin 02 78 Fig 46 Technical Bulletin ...

Page 7: ...al configuration the FTR family of gearboxes are high tech racing transaxle units which achieve the maximum effective use of power in conjunction with extremely stiff integral rear suspension mountings Weight Aluminium FTR 6sp 88 lbs 40 Kg Gear ratios from 3 167 1 to 89 1 JFR 6sp 79 lbs 36 Kg Final drive ratio 12 34 9 35 or 9 31 Oil type SAE 80 or 90 Clutch shaft made to customers requirements Oil...

Page 8: ...est 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 ...

Page 9: ...klash readings Fit the nut SK 1718 A to the setting fixture SK 1718 B or SK 2066 for JFR and wind it by hand into position behind the bearing until a firm stop is felt Use a suitable rod to engage in the hole in the nut if necessary Unwind the nut by a quarter turn then whilst rotat ing the pinionshaft backwards and forwards wind the nut in by hand until a firm stop is felt This is important as it...

Page 10: ...reasing it will increase the backlash See Fig 1 Run through procedure described above until the backlash is within specification b Calculate correct shimstack Sideplate shimstack With the setting fixture secured in position and backlash having been set correctly measure DIM A using a depth micrometer This is the distance from the end of the nut to the top face on the setting fixture Record this di...

Page 11: ... 005 from the shimstack used in above section c Finalise the assembly check backlash Fit the spacers and shimstack calculated above together with the standard bearing outer tracks to the maincase and sideplate Allow casings to cool to room temperature and fit diff and sideplate and secure with nuts 55 tightened to 27Nm Check that the backlash is within specification Fig 2 FTR shown DIM D WILL BE E...

Page 12: ...l SK 1709 into the maincase diff bearing bore and use feeler gauges to measure the gap between the tool and the pinion front face This clearance should comply with the dimension indicated on the pinion shaft label also etched on the front face of the pinion shaft and can be adjusted by adding or removing shims 59 from behind the pinion head bearing housing 57 Alternatively the pinion mounting dist...

Page 13: ...ly into the maincase b Slide the fork setting spacer hubs clutch rings forks bearings inner tracks and pinion shaft gears into position on the pinion shaft and secure with the pinion shaft nut c Engage the selector forks 44 into the barrel use special tool SK 1716 and slide the selector rail through the forks to engage the maincase d Rotate the barrel to engage reverse or neutral Measure and recor...

Page 14: ...gear geometry and is not adjustable 2 The ramp angles cut on the side ring gears have an effect on how much of the transmitted torque is converted into sideways clamping force onto the plates For example on the drive side ramp 45 degrees transmits less sideways force than 30 degrees Likewise on the coast side ramp an 80 degree angle will transmit little or no clamping force onto the plates whereas...

Page 15: ...e assembly below Fig 6 Torque the centre bolt 214 to 25Nm and measure the tripod end float There should be 0 025 0 030 of end float If there is more than this remove material from the spacers so to achieve the require end float The top hats are deliberately manufactured so that the initial amount of end float is greater than the end float required When the correct amount of end float is achieved t...

Page 16: ...the differential use tool SK 1623 p54 Insert the tool into the worm and turn the tool anticlock wise to increase the preload Below Fig7 is a graph showing the relationship between turns and preload added 0 5 10 15 20 25 30 35 40 45 0 10 20 30 40 50 60 70 Preload lbft Turns anticlockwise Fig 7 ...

Page 17: ... is free to slide back and forth in the maincase Any stiction here may cause shift problems in service f Put one spacer on the barrel Early barrels only Hold the detent arm against it s spring using a pair of pliers Using a thin rod or stiff wire push the free end of the pawl upwards in the maincase and hold it there whilst sliding the barrel into place Slide on the second spacer Early barrels onl...

Page 18: ...ncase Add the bearing inner track and bearing and slide 2nd gear pair into place p Add another bearing and slide 6th gear pair into position if applicable Add the hub clutch ring bearing inner track and bearings to the pinion shaft slide the spacer onto the layshaft then add 5th gear pair Repeat for 4th and 3rd gear set q Slide the remaining selector forks onto their clutch rings Insert the select...

Page 19: ...PAGE 19 Copyright Hewland Engineering Limited 2001 2009 ILLUSTRATED PARTS LIST FOR 6 SPEED CONFIGURATION OF FTR FTRS FTRL JFR NOT INCLUDING FTRE RATIOS ...

Page 20: ...PAGE 20 Copyright Hewland Engineering Limited 2001 2008 Fig 8 CASINGS ASSOCIATED PARTS 6 SPEED NOT SUITABLE FOR USE WITH FTRE RATIOS ...

Page 21: ...PAGE 21 Copyright Hewland Engineering Limited 2001 2009 Fig 9 LAYSHAFT ASSEMBLY 6 SPEED NOT SUITABLE FOR USE WITH FTRE RATIOS Note orientation of bearing inner track and spacer ...

Page 22: ...PAGE 22 Copyright Hewland Engineering Limited 2001 2008 Fig 10 PINION SHAFT ASSEMBLY 6 SPEED NOT SUITABLE FOR USE WITH FTRE RATIOS ...

Page 23: ... 23 Copyright Hewland Engineering Limited 2001 2009 Fig 11 EARLY SELECTOR BARRELS ONLY SELECTOR ASSEMBLY 6 SPEED NOT SUITABLE FOR USE WITH FTRE RATIOS FOR ALTERNATIVE LIGHTWEIGHT SELECTOR SYSTEM SEE PAGE 28 ...

Page 24: ... SLIDING GEAR 13 2 DGB 239 0 EXTERNAL CIRCLIP 1 FTRL FTRL 231 14 1 DOW 024 DOWEL 37 3 FTR 232 CLUTCH RING 15 1 F3A 202 9A DOWEL 38 2 FTR FTR 234 1 SPACER INPUT SHAFT 16 1 FTR FTR 201 MAINCASE 2 FTRL FTRL 234 1 1 JFR JFR 201 39 1 FTR 237 REVERSE IDLER GEAR 17 1 FTR 201 1 SELECTOR RACK STOP 1 FTRL 237 18 1 BEARING CARRIER BEARING CARRIER 40 2 FTR FTR 237 1 REVERSE IDLER SPIGOT 19 1 FTR 202 2 BEARING...

Page 25: ...G 1 FTRL FTRL RATIO HUB FTRL 235 1A HUBBED GEAR PAIR SPACER REQUIRED 77 1 FTR SCR 117 SOCKET CAP SCREW 4 FTR FTR RATIO STD STANDARD GEAR PAIR 1 JFR SCR 225 4 FTRL FTRL RATIO STD STANDARD GEAR PAIR 79 1 SPH1077 M3 PAWL 55 21 NUT 004 KAYNUT 80 1 SPH1078 M3 PLUNGER 56 1 HC 237 2 NEEDLE ROLLER BEARING 81 2 FTR 260 10 BARREL SPACERS 57 1 HC8 222 1HB PINION HEAD BEARING 82 1 SPR 057 COMPRESSION SPRING 5...

Page 26: ... 023 COUNTERSUNK SKT SCREW 101 1 WSH 051 WASHER 102 2 WSH 011 WASHER 103 2 WSH 069 PLAIN WASHER 104 1 TE 201 4 COVER PLATE 105 2 HP M 9062 SKT BUTTON HEAD SCREW 106 2 HP N 9004 WIRE CLIP 107 2 GAITOR KIT OPT GAITOR KIT 108 4 LD 202 9 WASHER 109 1 WSH 067 SHIM WASHER 172 1 VG 201 9 SEALING STRIP 181 1 FTR 205 4 BEARING SPACER 182 1 FTR 205 3 BEARING SPACER 183 2 HC9 205 3 BALL BEARING 184 2 CS 1628...

Page 27: ...PAGE 27 Copyright Hewland Engineering Limited 2001 2009 6 SPEED VARIABLE PARTS ...

Page 28: ...PAGE 28 Copyright Hewland Engineering Limited 2001 2008 Fig 12 LIGHTWEIGHT ALTERNATIVE SELECTOR ASSEMBLY 6 SPEED NOT FOR USE WITH FTRE RATIO S 211 ...

Page 29: ... PLATE 89 1 ORI 001 O RING 23 1 FTR 210 35 PLUNGER 93 1 NUT 005 KAYNUT 24 1 FTR 210 36 PLUG 94 2 HP N 9006 SOCKET CAP SCREW 43 1 FTRE 246 SELECTOR RAIL 98 1 HP M 9008 SOCKET CAP SCREW 44 3 FTRE 250 SELECTOR FORK 108 4 LD 202 9 WASHER 45 1 FTREL 260 SELECTOR BARREL ASSY 109 1 WSH 067 SHIM WASHER 46 1 FTR 260 2 SPACER TUBE 190 1 FTRE 260 9 PIVOT PIECE 47 1 FTRE 260 3 SELECTOR RACK 191 2 FTRE 260 9A ...

Page 30: ...PAGE 30 Copyright Hewland Engineering Limited 2001 2008 Fig 13 5 SPEED CONVERSION OF 6 SPEED NOT SUITABLE FOR USE WITH FTRE RATIOS ...

Page 31: ...PAGE 31 Copyright Hewland Engineering Limited 2001 2009 ILLUSTRATED PARTS LIST FOR 6 SPEED CONFIGURATION OF FTR FITTED WITH FTRE RATIOS ...

Page 32: ...PAGE 32 Copyright Hewland Engineering Limited 2001 2008 CASINGS ASSOCIATED PARTS 6 SPEED FTRE RATIOS ONLY Fig 14 ...

Page 33: ...PAGE 33 Copyright Hewland Engineering Limited 2001 2009 LAYSHAFT ASSEMBLY 6 SPEED FTRE RATIOS ONLY Fig 15 ...

Page 34: ...PAGE 34 Copyright Hewland Engineering Limited 2001 2008 PINION SHAFT ASSEMBLY 6 SPEED FTRE RATIOS ONLY Fig 16 194 194 ...

Page 35: ...PAGE 35 Copyright Hewland Engineering Limited 2001 2009 SELECTOR ASSEMBLY 6 SPEED FTRE RATIOS ONLY Fig 17 ...

Page 36: ...2 9A DOWEL 46 1 FTR 260 2 SPACER TUBE 16 1 FTR 201 MAINCASE 47 1 FTRE 260 3 SELECTOR RACK 17 1 FTR 201 1 SELECTOR RACK STOP 48 2 FTR 260 4 SELECTOR RACK WASHER 18 1 BEARING CARRIER BEARING CARRIER 49 1 FTRE 260 5 SLEEVE 19 1 FTR 202 2 BEARING RETAINING PLATE 50 1 FTRE 260 7 BELL CRANK 20 1 FTR 205 SIDEPLATE 51 1 FTR 260 8 SPRING TRUNION 21 2 FTR 205 1 SIDEPLATE SHIM 52 1 FTRE 234 ASSY LAYSHAFT ASS...

Page 37: ...TOR KIT 74 1 PCT 260 2 DRUM STOPPER 108 4 LD 202 9 WASHER 75 1 PCT 260 3 COIL SPRING 109 1 WSH 067 SHIM WASHER 76 1 PLU 030 PLUG 172 1 VG 201 9 SEALING STRIP 1 181 1 FTR 205 4 BEARING SPACER 80 1 SPH1078 M3 PLUNGER 182 1 FTR 205 3 BEARING SPACER 82 1 SPR 057 COMPRESSION SPRING 183 2 HC9 205 3 BALL BEARING 83 1 SPR 058 COMPRESSION SPRING 184 2 CS 1628 BEARING CARRIER 8 185 2 HC9 205 4 OUTPUT OILSEA...

Page 38: ...R 202 1 BEA 401 NEEDLE ROLLER 203 1 FTRE 237 REVERSE IDLER GEAR 204 1 SCR 129 SCREW 205 1 FTRE 237 2 BUSH 206 1 FTRE 237 4 INSERT 207 1 FTRE 201 1 PILLAR SPACER 208 1 FTRE 234 2 SPACER 209 1 FTRE 234 3 SPACER 210 1 FTRE 249 REVERSE FORK 211 1 FTR 212 ADJ ADJUSTABLE DIFF ASSEMBLY 212 1 FTR 218 15 OUTPUT FLANGE 213 1 FTR 218 16 OUTPUT FLANGE 214 1 SCR 119 BI HEX BOLT 215 2 FTR 213 9 TOP HAT BUSHES 2...

Page 39: ...PAGE 39 Copyright Hewland Engineering Limited 2001 2009 ILLUSTRATED PARTS LIST FOR 5 SPEED CONFIGURATIONS OF FTR FTRS JFR LJS NOT INCLUDING FTRE RATIOS ...

Page 40: ...PAGE 40 Copyright Hewland Engineering Limited 2001 2008 CASINGS ASSOCIATED PARTS 5 SPEED NOT SUITABLE FOR USE WITH FTRE RATIOS Fig 18 THESE PARTS ARE FTR JFR MAINCASE SPECIFIC ...

Page 41: ...PAGE 41 Copyright Hewland Engineering Limited 2001 2009 Fig 19 LAYSHAFT ASSEMBLY 5 SPEED NOT SUITABLE FOR USE WITH FTRE RATIOS ...

Page 42: ...PAGE 42 Copyright Hewland Engineering Limited 2001 2008 Fig 20 PINION SHAFT ASSEMBLY 5 SPEED NOT SUITABLE FOR USE WITH FTRE RATIOS ...

Page 43: ...PAGE 43 Copyright Hewland Engineering Limited 2001 2009 Fig 21 SELECTOR ASSEMBLY 5 SPEED NOT SUITABLE FOR USE WITH FTRE RATIOS ...

Page 44: ... SLIDING GEAR 13 2 DGB 239 0 EXTERNAL CIRCLIP 37 3 FTR 232 CLUTCH RING 14 1 DOW 024 DOWEL 38 2 FTR 234 1 SPACER INPUT SHAFT 15 1 F3A 202 9A DOWEL 2 FTRL 234 1 16 1 FTR 201 FTR MAINCASE 39 1 FTR 237 REVERSE IDLER GEAR 1 JFR 201 JFR 1 FTRL 237 17 1 FTR 201 1 SELECTOR RACK STOP 40 1 FTR JFR 237 1 REVERSE IDLER SPIGOT 18 1 BEARING CARRIER BEARING CARRIER 1 JFR 19 1 FTR 202 2 BEARING RETAINING PLATE 40...

Page 45: ...5 55 21 NUT 004 KAYNUT 78 2 SCR 121 SOCKET SET SCREW 56 1 HC 237 2 NEEDLE ROLLER BEARING 79 1 SPH1077 M3 PAWL 57 1 HC8 222 1HB PINION HEAD BEARING 80 1 SPH1078 M3 PLUNGER 58 1 FTR FGA 222 1A NUT BMW SPEC FTR ONLY 81 2 FTR 260 10 BARREL SPACERS 0 JFR 82 1 SPR 057 COMPRESSION SPRING 58 1 NUT 031 NUT NOT BMW SPEC 83 1 SPR 058 COMPRESSION SPRING 59 1 HC8 222 2 SHIM 85 8 CROWNWHEEL BOLT CROWNWHEEL BOLT...

Page 46: ...COVER PLATE 105 2 HP M 9062 SKT BUTTON HEAD SCREW 106 2 HP N 9004 WIRE CLIP 107 2 GAITOR KIT OPT GAITOR KIT 108 4 LD 202 9 WASHER 109 1 WSH 067 SHIM WASHER 160 1 HYD 026 BLANKING PLUG 161 1 400 868 4490 41 DOWTY WASHER 162 1 LD 205 2A BEARING SPACER 163 2 LD 205 3 BALL BEARING 164 2 LJS 201 1 BEARING CARRIER 165 1 LJS 221 1 BEARING INNER TRACK 166 2 ORI 006 O RING 168 1 SCR 097 SOCKET SET SCREW 16...

Page 47: ...PAGE 47 Copyright Hewland Engineering Limited 2001 2009 5 SPEED VARIABLE PARTS ...

Page 48: ...LU 059 PLUG BMW SPEC ONLY Position QTY Part Number 50 1 663 6 120 RHS ONLY 52 1 7772376 LAYSHAFT RATIO 12 38 53 1 7772377 GEAR RATIO HUB 15 32 53 1 7772378 GEAR RATIO HUB 15 33 54 1 7772379 GEAR RATIO 15 25 54 1 7772380 GEAR RATIO 16 23 54 1 7772381 GEAR RATIO 17 26 54 1 7772382 GEAR RATIO 17 30 54 1 7772383 GEAR RATIO 18 19 54 1 7772384 GEAR RATIO 18 27 54 1 7772385 GEAR RATIO 18 24 54 1 7772386 ...

Page 49: ...PAGE 49 Copyright Hewland Engineering Limited 2001 2009 Fig 23 BEARING CARRIER OPTIONS ...

Page 50: ...PAGE 50 Copyright Hewland Engineering Limited 2001 2008 ILLUSTRATED PARTS LIST FOR DIFFERENTIAL CONFIGURATIONS ...

Page 51: ...PAGE 51 Copyright Hewland Engineering Limited 2001 2009 Fig 24 TRIPOD DIFFERENTIAL ASSEMBLY REFER TO PAGES 24 26 36 38 6sp OR 44 46 5sp FOR INDIVIDUAL COMPONENT PART NUMBERS ...

Page 52: ...EARING BEA 171 TAPER ROLLER BEARING 20 FTR 205 SIDEPLATE JFR 205 SIDEPLATE 21 FTR 205 1 SIDEPLATE SHIM FTR 205 1 SIDEPLATE SHIM 22 FTR 205 2 SIDEPLATE SPACER FTR 205 2 SIDEPLATE SPACER 69 LIP 042 LIPSEAL LIP 042 LIPSEAL 91 ORI 203 O RING ORI 189 O RING There is a Gaitor kit option with these tripods FTR 212 FD FREE DIFFERENTIAL ASSEMBLY AS USED IN STAR MAZDA SPECIFICATION Fig 25 REFER TO PAGES 24 ...

Page 53: ... FTR JFR Position SIDEPLATE ARRANGEMENT SIDEPLATE ARRANGEMENT Part No Description Part No Description 7 BEA 171 TAPER ROLLER BEARING BEA 171 TAPER ROLLER BEARING 20 FTR 205 SIDEPLATE JFR 205 SIDEPLATE 21 FTR 205 1 SIDEPLATE SHIM FTR 205 1 SIDEPLATE SHIM 22 FTR 205 2 SIDEPLATE SPACER FTR 205 2 SIDEPLATE SPACER 69 LIP 042 LIPSEAL LIP 042 LIPSEAL 91 ORI 203 O RING ORI 189 O RING REFER TO PAGES 24 26 ...

Page 54: ...art No Description Part No Description 7 BEA 171 TAPER ROLLER BEARING BEA 171 TAPER ROLLER BEARING 20 FTR 205 SIDEPLATE JFR 205 SIDEPLATE 21 FTR 205 1 SIDEPLATE SHIM FTR 205 1 SIDEPLATE SHIM 22 FTR 205 2 SIDEPLATE SPACER FTR 205 2 SIDEPLATE SPACER 69 LIP 042 LIPSEAL LIP 042 LIPSEAL 91 ORI 203 O RING ORI 189 O RING FTRL 212 DIFFERENTIAL ASSEMBLY AS USED IN DALLARA F3 2005 SPECIFICATION REFER TO PAG...

Page 55: ... 55 Copyright Hewland Engineering Limited 2001 2009 FTR 212 ADJ PRELOAD ADJUSTABLE DIFFERENTIAL ASSEMBLY WITH TRIPODS Fig 28 REFER TO PAGES 24 26 36 38 6sp OR 44 46 5sp FOR INDIVIDUAL COMPONENT PART NUMBERS ...

Page 56: ... ROLLER BEARING 20 FTR 205 SIDEPLATE JFR 205 SIDEPLATE 21 FTR 205 1 SIDEPLATE SHIM FTR 205 1 SIDEPLATE SHIM 22 FTR 205 2 SIDEPLATE SPACER FTR 205 2 SIDEPLATE SPACER 69 LIP 042 LIPSEAL LIP 042 LIPSEAL 91 ORI 203 O RING ORI 189 O RING FTR 212 ADJ ADJUSTABLE DIFFERENTIAL ASSEMBLY There is a Gaitor kit option with these tripods OUTPUT TRIPODS AVAILABLE FTR 218 15 FTR 218 16 REFER TO PAGES 24 26 36 38 ...

Page 57: ...PAGE 57 Copyright Hewland Engineering Limited 2001 2009 Fig 30 FLANGED FREE DIFFERENTIAL ASSEMBLY REFER TO PAGES 24 26 36 38 6sp OR 44 46 5sp FOR INDIVIDUAL COMPONENT PART NUMBERS ...

Page 58: ...PLATE 21 HC9 206 1 SHIM HC9 206 1 SHIM 22 LD 205 2 SPACER LD 205 2 SPACER 69 LD 205 4 OILSEAL LD 205 4 OILSEAL 91 ORI 203 O RING ORI 189 O RING 162 LD 205 2A LH BEARING SPACER LD 205 2A LH BEARING SPACER 163 LD 205 3 BALL BEARING LD 205 3 BALL BEARING 164 LJS 201 1 BEARING CARRIER LJS 201 1 SBEARING CARRIER 166 ORI 006 O RING ORI 006 O RING 169 FT 219 1A CIRCLIP FT 219 1A CIRCLIP OUTPUT FLANGES AV...

Page 59: ... Part No Description 7 HC9 205 1 BEARING HC9 205 1 BEARING 20 FTR 205 SIDEPLATE JFR 205 SIDEPLATE 21 HC9 206 1 SHIM HC9 206 1 SHIM 22 LD 205 2 SPACER LD 205 2 SPACER 69 LD 205 4 OILSEAL LD 205 4 OILSEAL 91 ORI 203 O RING ORI 189 O RING 162 LD 205 2A LH BEARING SPACER LD 205 2A LH BEARING SPACER 163 LD 205 3 BALL BEARING LD 205 3 BALL BEARING 164 LJS 201 1 BEARING CARRIER LJS 201 1 SBEARING CARRIER...

Page 60: ...60 Copyright Hewland Engineering Limited 2001 2008 FLANGED FREE DIFFERENTIAL ASSEMBLY SUITABLE FOR INBOARD BRAKE DISCS Fig 33 REFER TO PAGES 24 26 36 38 6sp OR 44 46 5sp FOR INDIVIDUAL COMPONENT PART NUMBERS ...

Page 61: ...HC9 205 1 BEARING 20 FTR 205 SIDEPLATE JFR 205 SIDEPLATE 21 HC9 206 1 SHIM HC9 206 1 SHIM 91 ORI 203 O RING ORI 189 O RING 166 ORI 006 O RING ORI 006 O RING 169 FT 219 1A CIRCLIP FT 219 1A CIRCLIP 183 HC9 205 3 BALL BEARING HC9 205 3 BALL BEARING 184 CS 1628 BEARING CARRIER CS 1628 SBEARING CARRIER 185 HC9 205 4 OILSEAL HC9 205 4 OILSEAL 188 CS 1731 LH BEARING SPACER CS 1731 LH BEARING SPACER 189 ...

Page 62: ...opyright Hewland Engineering Limited 2001 2008 FLANGED LIMITED SLIP DIFFERENTIAL ASSEMBLY SUITABLE FOR INBOARD BRAKE DISCS Fig 35 REFER TO PAGES 24 26 36 38 6sp OR 44 46 5sp FOR INDIVIDUAL COMPONENT PART NUMBERS ...

Page 63: ...G 20 FTR 205 SIDEPLATE JFR 205 SIDEPLATE 21 HC9 206 1 SHIM HC9 206 1 SHIM 91 ORI 203 O RING ORI 189 O RING 166 ORI 006 O RING ORI 006 O RING 169 FT 219 1A CIRCLIP FT 219 1A CIRCLIP 181 FTR 205 4 LH BEARING SPACER FTR 205 4 LH BEARING SPACER 182 FTR 205 3 SPACER FTR 205 3 SPACER 183 HC9 205 3 BALL BEARING HC9 205 3 BALL BEARING 184 CS 1628 BEARING CARRIER CS 1628 SBEARING CARRIER 185 HC9 205 4 OILS...

Page 64: ...PAGE 64 Copyright Hewland Engineering Limited 2001 2008 RAMP ORIENTATION Fig 37 ...

Page 65: ...PAGE 65 Copyright Hewland Engineering Limited 2001 2009 GEARBOX TOOLING Fig 38 ...

Page 66: ...N SETTING JIG 3 1 SK 1710 A DIFF HOLDING POST 4 1 SK 1710 B DIFF PRE LOAD TOOL 5 1 SK 1714 BEARING PULLER 6 1 SK 1715 DUMMY OUTER RACE 7 1 SK 1716 COMB TOOL 8 1 SK 1427 REACTION BAR 9 1 SK 247 TYPE 3 PINION SPANNER 10 1 SK 1175 C SOCKET 11 1 SK 2025 FTR TRIPOD REMOVAL TOOL 12 1 SK 2025 A SLIDE HAMMER KIT 13 1 SK 1718 A DUMMY SIDEPLATE CAP 14 1 SK 1718 C DUMMY SIDEPLATE ...

Page 67: ...PAGE 67 Copyright Hewland Engineering Limited 2001 2009 INSTALLATION DRAWINGS MAINCASE AND BEARING CARRIER ...

Page 68: ...PAGE 68 Copyright Hewland Engineering Limited 2001 2008 Fig 39 ...

Page 69: ...PAGE 69 Copyright Hewland Engineering Limited 2001 2009 Fig 40 ...

Page 70: ...PAGE 70 Copyright Hewland Engineering Limited 2001 2008 Fig 41 ...

Page 71: ...PAGE 71 Copyright Hewland Engineering Limited 2001 2009 Fig 42a OUTPUT FLANGE VARIATIONS ...

Page 72: ...PAGE 72 Copyright Hewland Engineering Limited 2001 2008 Fig 42b OUTPUT FLANGE VARIATIONS ...

Page 73: ...PAGE 73 Copyright Hewland Engineering Limited 2001 2009 Fig 42c OUTPUT FLANGE VARIATIONS ...

Page 74: ...PAGE 74 Copyright Hewland Engineering Limited 2001 2008 2nd JUNE 2005 Fig 43 ...

Page 75: ...aces and a set of 30 degree ramps It can be seen from the above formula that 34 percent of the locking action is not provided by the ramps This locking component is due to the reaction forces of the side bevel gears Put another way the locking torque can be approximated using this formula Where µ is the friction coefficient between the plates µ 0 1 can be used for steel plates Lock Percentage urfa...

Page 76: ... attention that there is a possibility of the bearing outer track BEA 002 moving out of position during use To overcome this problem Hewland Engineering will be adding a 5mm tapped and countersunk hole to the bearing carrier for a bearing retaining screw washer to be fitted All our existing and future stock will feature this tapped hole Its is recommended that all FTR 202 Bearing Carriers are modi...

Page 77: ...PAGE 77 Copyright Hewland Engineering Limited 2001 2009 James Batchelor Design Engineer Fig 44 ...

Page 78: ...me this problem Hewland Engineering will be adding 2 5mm DIA x 3 5mm deep dowel holes to the bearing bore faces on the Maincase and Bearing carrier castings to allow an anti rotation dowel to be fitted All our existing and future stock will feature these dowel holes Its is recommended that all FTR 201 Maincases and FTR 202 Bearing Carriers are modified as shown below so that a 2 5mm DIA X 5mm long...

Page 79: ...aincase James Batchelor Design Engineer The bearings BEA 159 BEA 002 will also require modifica tion if the anti rotation dowels are to be fitted The outer tracks of the bearings will need a 3mm wide x 2mm deep slot ma chined on the seating face as shown below Fig 46 ...

Page 80: ...n of the pin was immediately increased and as an act of good faith for the past year all barrels returned to the factory have been re pinned FOC While this service will continue to be available it will with effect from this bulletin cease be FOC A charge of 50 00 will be made for each barrel returned to Hewland Engineering for re pinning Alternatively replace ment pins part DOW 033 are available t...

Page 81: ...r during the course of remanufacture for our stock we have taken the precaution of strengthening the pin The new stronger pins will supersede the earlier version for all new supply and are recognisable from the earlier version by an identification dimple in one end It is not our recommendation that all original pins be changed but should you so wish the new pins are available under the same part n...

Page 83: ...PAGE 83 Copyright Hewland Engineering Limited 2001 2009 gear b o x They a r e d i ...

Page 84: ...PAGE 84 Copyright Hewland Engineering Limited 2001 2008 19th July 2004 ...

Page 85: ...PAGE 85 Copyright Hewland Engineering Limited 2001 2009 25th January 2005 Fig 47 ...

Page 86: ...will be 0 63kg In fact certain of these pirate gears are actually heavier than our standard FTR despite narrower tooth face width The FTRL gears will have narrower face widths than the pirate gears so the competitive advantage is enhanced due to lower inertia as highest diameter mass is less The superior tooth form and superior heat treatment found in genuine Hewland FTR gears will still be presen...

Page 87: ...lutchshafts 2005 spec Our research shows that some FTR clutchshafts could be re designed to save in excess of 0 5Kg any customers who are interested in purchasing lightened clutchshafts for other FTR applications should contact a member of the Hewland En gineering sales team sales hewland com to discuss their specific requirements James Batchelor Design Engineer Hewland Part No Engine Chassis Appr...

Page 88: ...2 34 will now feature a longer thread Fig 1 Longer thread on 12 34 pinionshafts left Customers who run 12 34 FTR pinionshafts need to be aware that the new lengthened thread parts which will be phased in over the next few months require a dif ferent locking nut and locking ring The new lock nut to replace FTR 230 is FTR 230 A and the locking ring is FTR 230 B which will replace HP M 4026 For final...

Page 89: ...PAGE 89 Copyright Hewland Engineering Limited 2001 2009 FTR Technical Bulletin No 013 POSITION OF GEAR INDICATOR POTENTIOMETER Fig 48 ...

Page 90: ...sign used in the FTR It is to be noted that no incidents of this screw coming loose on the FTR has been reported to Hewland To avoid the possibility of it coming loose we have modified the screw to include four holes to facili tate the use of lockwire and have also modified the maincase FTR 201 as well with a hole to pass it through We recommend that this modification be done to all gearboxes that...

Page 91: ... HC8 222 2A into the locknut so making the washer redundant The latest design of locknut has been re numbered as NUT 031 and the relevant tightening torque has been increased to 150 lbs ft 205 Nm As on the earlier locknut the outside face is grooved so leaving a thin section which must be peened over in two positions into the corresponding grooves machined into the bearings threaded diameter The l...

Page 92: ...27 0 239 19 9 M10 x 1 50 40 0 354 29 5 M10 x 1 25 50 0 443 36 9 Nm lbs ins lbs ft 1 4 13 0 115 9 6 5 16 26 0 230 19 2 3 8 43 5 385 32 1 7 16 64 9 575 47 9 RECOMMENDED TIGHTENING TORQUES FOR METRIC COARSE SERIES K NUTS FITTING TO EN16T STUDS RECOMMENDED TIGHTENING TORQUES FOR UNIFIED COARSE SERIES K NUTS THREAD THREAD FITTING TO EN16T STUDS ...

Page 93: ...ring Limited 2001 2009 Manual Modification History Started 4th March 2009 Date Modification 04 03 09 Detail view added to page 21 modification history page added 23 03 09 Part numbers colour change page 29 ommited washer added page 23 ...

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