Introduction. We will strongly recommend that the gearbox will be assembled by skilled technicians.

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2 Introduction The Drenth Gearbox 350 (DG350) sequential racing gearbox is originally developed for the Toyota GT86, but due its design specifications it fits into almost any rear wheel driven car. The gearbox can handle torque levels up to 350 Nm and has a dry weight of 27.5 kg. With his adaptive capability the gearbox can be used in several disciplines like: circuit racing, endurance racing, hill climb, rally(raid) and rally-cross. This document contains information about the DG350 gearbox. It is useful for everyone who is racing with or rebuilding a DG350 gearbox. The user manual includes illustrated part lists, gearbox assembly and calibrations instruction for the shift system. For more detailed information please contact Drenth Gearboxes. We will strongly recommend that the gearbox will be assembled by skilled technicians. Drenth Motorsport Gearboxes Fleuweweg AG Enter The Netherlands Phone: +31 (0) Made by Damas Damen Fax: +31 (0) Last modified: June 2014 Modified by 2

3 Figure I: Rear and side view 3

4 Introduction Technical Specifications General Dimensions Cross-Section Lubrication System Placement Oil Cooler Oil level and placement temperature sensor Thightening torque standards Gearbox Assembly General Instruction Notes Bearing Assembly Main Assembly Rotary Sensor Calibration Run-in Procedure D.M.S. Gearlever General Information Options Drenth Display Unit Drenth Gear Indicator Oil breather catch tank Tools Tool shaft selector fork Fixture tool Fixture tool

5 5.4 Tool for oil seal Contact information Address Contact Persons

6 1.0 Technical Specifications 6

7 1.1 General Dimensions Weight: 27.5 kg Max. torque: 350Nm Spline: 23 x 1 Oil qty: 1.1 litres (Without oil cooler and external oil lines) o o o Oil Type: Castrol SAF-XJ (or comparable) API GL-5 SAE 75W-140 TOTAL?? Figure 2: General dimensions 7

8 Figure 1.1: General dimensions 8

9 1.2 Cross-Section Figure 1.2: Cross-section 9

10 1.3 Lubrication System Pump type: 8 tooth Gerotor. Filter type: o A normal filter on suction side integrated in gearbox. Pump location: Oil pump is located on the lower side of the rear end cover. The spray bar is integrated in the selector shaft of the gearbox. The spraybar sprays on all the gears and dogrings of the outputshaft and on the upper dropgear. There are two connections to fit an external oil cooler. For more information see the next page. Recommended oil specification: o Castrol SAF-XJ o API GL-5 o SAE 75W-140 TOTAL?? Oil Capacity: Without oil cooler and external lines; 1.1 litre. Figure 1.4: Lubrication system 10

11 1.4 Placement Oil Cooler Figure 1.5: Oil cooler placement 11

12 1.5 Oil level and placement temperature sensor Figure 7: Oil level Figure 8: Placement oil sensor 12

13 1.5 Tightening torque standards Metric thread Nm ft lbf M4 x M5 X M6 X M7 x M8 x M10 x M10 x M12 x M12 x

14 2.0 Gearbox Assembly 14

15 2.1 General Instruction Notes First read the manual in general and check if all the parts are there. For an easy and faster assembly lay all the parts in the right order. Every part has got his own personal number. The gearbox assembly is divided in two sections: the bearing assembly and the main assembly. Before the assembly all parts must be clean and without damage. Also a clean tray is recommended. Only genuine Drenth parts should be used when assembling and servicing this gearbox. For durability its recommended to use new nuts, seals and circlips during the re-assembly of the gearbox. When fitting the bearings in the casing it is very important to pre-heat the casing to a temperature of 100 / 110 C. For more information read the next paragraph Bearing Assembly. During the assembly only use lubrications, on bearings and rotating parts, that are recommended by Drenth Motorsports Gearboxes. Oil: Fill the gearbox through the plug hole on the left side (seen form the backside) of the rear main housing. The amount is 1.1 litre. Take notice that the amount is calculated without the use of an oil cooler. Note: too much oil will not directly cause damage to the gearbox itself, but will result in loss of power and shifting problems. 15

16 2.2 Bearing Assembly General information Each bearing has to be slightly lubricated. Not every bearing is assembled under heating conditions. These bearings are controlling the movement of the selector drum and are located in the housing. They will be assembled during the main assembly (see the next paragraph). Bearing assembly: o The oven must be preheated. o Heat each section to a temperature of 100 / 110 C. o When the casing has reached this temperature, give it approximately 30 minutes to insure an even temperature distribution. o Before fitting the bearings make sure the outer track of the bearing is clean. o Once the casing is at the correct temperature and the bearings are clean, fit the bearings promptly and without delay. Try to avoid more heating cycles. For an easier fit use a tool, for example a ring, which fits directly over the outer track of the bearing. o To avoid more damage fit each bearing as straight as possible. o Heating conditions may not exceed 130 Celsius. 16

17 Figure 2.1: Bearing assembly (section view) 17

18 2.3 Main Assembly Figure 2.2: Selector rod assembly 18

19 Figure 2.3: Constante House Assembly 19

20 Figure 3.1: Ratchet Assembly (detail view) 20

21 Figure 2.4: Input shaft Assembly 21

22 Figure 2.5: Constante House / Input shaft Assembly 22

23 Figure 2.6: Constante House / Input shaft Assembly ` 23

24 Figure 2.7: Output shaft Assembly 24

25 Figure 2.8: Secondary shaft Assembly 25

26 Figure 2.9: Drum Assembly 26

27 Figure 2.9: Constante Housing/ shaft/ drum Assembly 27

28 Figure 2.10: Main Housing Assembly 28

29 Figure 2.11: Main Housing Assembly 29

30 30

31 Figure 2.12: Main Housing / Constante Housing Assembly 31

32 Figure 2.13: Main Housing / Gear Assembly 32

33 To tighten the nut nr We recommend Tool fixture, paragraph

34 Figure 2.14: Tool Selector fork 34

35 Figure 2.15: Shaft selector fork Assembly 35

36 Figure 2.16: End Joint Assembly 36

37 37

38 Figure 2.17: End Joint / Gearbox Assembly 38

39 Figure 2.18: Outside Assembly 39

40 40

41 Figure 2.19: Bellhouse Assembly 41

42 Figure 2.20: Gearbox / Bellhouse Assembly 42

43 Figure 2.21: Shaft fork Assembly 43

44 2.4 Rotary Sensor Calibration Penny & Giles The signal, from the white wire provided by the rotary sensor, can be used for gear indication. The signal needs to be adjusted so that the correct information is send to the gear indicator. First make sure that the rotary sensor is mounted in the right position. When mounted, it is possible to turn the rotary sensor to the right position before tightening the bolts (Torque: 4 Nm). With turning, the signal can be calibrated. The signal itself is shown in Volt. You will need a voltmeter to check the level. On the figure 3.18 is shown where the voltmeter must be placed. To start the calibration set the gearbox in the reverse gear. The signal needs to be 0.7 V, if not, slowly rotate the potentiometer. When 0.7 Volt is showing tighten the bolts. While up-shifting, the following values must be shown as described below (or around the value). The red line, shown in figure 3.20, can be displaced over the black and grey zone by turning the rotary sensor. R = V 0 = V 1 = V 2 = V 3 = V 4 = V 5 = V 6 = V Figure 2.21: Detail for the dot (left side) Figure 2.22: Sensor in neutral state 44

45 Figure 3.21: Graph sensor V = ( a)

46 2.5 Run-in Procedure Run through the gears while the gearbox is not mounted underneath the car. Also check if the gear indicator shows the correct information while going through the gears. If not check the calibration of the potentiometer. When this is working and the oil level is correct (1.1 litre), the gearbox can be mounted on a test bench or underneath the car. For the first test the wheels should be tilted from the ground. Before the test run make sure that the gearbox is in the neutral position. During the test run go through all the gears in a low rpm range. When the temperature starts to rise, the engine rpm may also go up. The temperature and the rpm build-up must go up evenly and check the given information on the gear indicator. During the run also concentrate on the noise production, vibrations and the temperature. When one of them is out of the ordinary, stop the test and see what could be wrong. The first test is done when all is operating correctly and the gearbox has reached its operating temperature. After the first test the gearbox is ready for a test drive. The procedure is the same as the first test. Slowly build-up the engine rpm and torque when the temperature level starts to increase. During the warm-up of the gearbox don t warm-up the brakes. 46

47 3.0 D.M.S. Gearlever 47

48 3.1 General Information The D.M.S. gearlever has got a built-in strain gauge which constantly gives several signals. These signals can be used for up and down shifting and other functions. The up shift signal can be used in combination with the Drenth gear indicator (see chapter Options for more information about the gear indicator). The other signals can be used in combination with an aftermarket ECU such as a Motec, TDA or Gems. There are two different D.M.S. gearlevers available, the short version and the long version. Short version: , Length: 240 mm from mounting position Long version: , Length: 360 mm from mounting position Figure 3.1: D.M.S. gearlever 48

49 4.0 Options 49

50 50

51 4.1 Gear ratio s Drenth offers a selection of pre-determined gear ratios to be chosen from. It is also possible to request a custom-made set of gears to better fit the performance of your car. Available gear ratios 1 st gear 2 nd, 3 rd, 4 th, 5 th gear These ratios are calculated with the ratio of the constant gear included. 51

52 4.2 Drenth Display Unit The display unit houses several functions to adjust to the driver s needs and to fine-tune the gearbox. The gear indicator displays the selected gear by measuring the position of the selector barrel with a rotary sensor. This function can be calibrated through the supplied software. It also can be used as a shift light when a preset level of RPM is reached. This preset level and the manner of indicating can be set with the supplied software. The gear indicator, combined with the D.M.S gearlever, can act as a flatshift system (powershift) This means that you can accelerate (full throttle) and shift up without using the clutch or lifting the throttle. This can also be calibrated with the supplied software. The set comes with a separate user manual. For more information contact our sales department or visit our website. Figure 4.1: Display unit 52

53 4.3 Drenth Gear Indicator The Drenth Gear indicator is a display unit that can be used with any Drenth gearbox with a rotary sensor. Any gear order can be accommodated with up to 7 forward speeds besides neutral and reverse. Programming the unit is achieved by the use of a single button and a user-friendly programming routine. Additionally, the unit features a counter to log the total number of gearshifts made useful for tracking the life of critical gearbox components. The set comes with a separate user manual. For more information contact our sales department or visit our website. Figure 4.2: Gear Indicator 53

54 4.4 Oil breather catch tank The DG350 gearbox needs an oil breather system for breathing the gearbox. Drenth gearboxes recommends an oil breather catch tank for breathing the gearbox. The following breather catch tank with the corresponding parts suits for a Drenth gearbox. For installing the oil breather catch tank see figure 6.6. The tank needs to be placed vertical and above the gearbox for a smooth return of the oil. For mounting the tank there are two 6 mm holes, the hose needs to be cut to size. For more information, please contact our sales department. The system consist of: Number QTY. Part Number Description Comments Complete oil breather catch tank Oil breather catch tank Adaptor (hose) Oil hose (1 m) Figure 4.3: Oil breather catch tank 54

55 5.0 Tools 55

56 5.1 Tool shaft selector fork Figure 5.1: Oil breather catch tank 56

57 5.2 Fixture tool Figure 5.2: Oil breather catch tank 57

58 5.3 Fixture tool 58

59 5.4 Tool for oil seal 59

60 Contact information Address Drenth Motorsport Gearboxes Fleuweweg AG Enter The Netherlands Phone: +31 (0) Fax: +31 (0) Contact Persons Sales department: Johan Drenth Engineering: Jeroen Grolleman 60

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