Mazda Global MX-5 Cup ND Sequential Transmission Installation Instructions

Transcription

1 Mazda Global MX-5 Cup ND Sequential Transmission Installation Instructions Revision 2.6,

2 ND Mazda MX-5 Sequential Transmission Installation Instructions Table of Contents ND Mazda MX-5 Sequential Transmission Installation Instructions General: Safety: Intended Use: Thread Locker: Basic Installation Overview: Tools needed: Inventory/shipping damage inspection: Disassembly: Removal of Stock Transmission and Differential Disconnect battery Remove ECU: Remove shifter assembly: Remove strut tower brace: Remove 3 lower chassis braces, front under engine, center and rear transmission tunnel braces: Remove exhaust mid pipe: Remove muffler pipe Drain transmission oil Drain differential oil Reposition or Remove (recommended) header: Remove starter: Remove power plant frame (PPF): Remove driveshaft: Remove transmission:...5 Figure 1: Engine Supported to maintain angle during transmission removal Remove clutch and flywheel assembly: Remove rear subframe: Remove differential from subframe: Subassembly and Vehicle Modifications: Install 3.45 Ring and Pinion: Modify rear subframe for differential mount:...7 Figure 2: Rear Subframe Modification Template Assembly Exploded...7 Figure 3: Locating Holes for Threaded Bungs...8 Figure 4: Threaded Bungs Installed, full weld is required...8 Figure 5: Drilling Template for Rear Sub Frame Modification Installed...9 Figure 6: Modified Rear Subframe Completed, Threaded Bungs and Sleeves Installed Vehicle Wiring Harness Modification: Figure 7: Refrigerant Pressure Sensor Location Figure 8: DTM Connector installed in Place of Refrigerant Pressure Sensor Figure 9: MAF/IAT Wire Modification Location Figure 10 (Left): DTM Connectors Installed and Connected in the Stock Configuration Figure 11(Right): DTM Connectors Installed and Connected to the Sadev Harness Reassembly Figure 12: Sadev MX-5 ND Transmission, Exploded Assembly Install modified clutch line: Figure 13: Modified Clutch Hard Line Install supplied engine blockout plate (Item 3 - Figure 12) to engine block: Install aluminum flywheel (Item 4 - Figure 12): Install 2 disc clutch (Item 6 Figure 12): Measure and set release bearing clearance: Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 1 of 28

3 4.6 Install transmission: Install Transmission Cross Brace: Install starter, ECU and connect battery Connect transmission side wiring with supplied wiring harness: Figure 14: Sadev Transmission Side Connector, Wiring Harness, & Engine Bay Routing / Connector Locations Figure 15: SADEV Wiring Harness undercar routing Connect transmission cooler lines: Figure 16: Transmission Cooler Lines Installation and Routing Figure 17: Transmission Cooler Line Mounting Point Install differential: Figure 18: Differential Installed in Rear Subframe Re-install subframe: Figure 19: Exploded Assembly of Differential Mounting Bracket, Eliminates Power Plant Frame Install driveshaft: Re-install header: Re-install exhaust: Re-install strut tower brace: Install shifter: Re-install stock shifter trim: Install and set Clutch stop: Figure 20: Clutch Stop Assembly Installed Fill transmission with supplied 75w/140 Motul Gear Competition oil: Update AIM MXL2 dash with provided configuration: Download GEMS ND V3 MXL2 ECU Driver from LRR Website: Download MXL2 SADEV Configuration from LRR Website: Nut and bolt: Double check all fasteners are tight and properly torqued Double check all cooler lines are tight Clutch break in procedure: No break in required Basic operating procedures: Ensure AiM MXL2 is updated with proper configuration Starting the Engine: To take off from a standstill: Basic Driving: Maintenance: Figure 21: Assembled Transmission Diagram Max operating temperature: Internal inspection and seal replacement: Basic service after each event: Trouble Shooting: Incorrect Gear Position Display: No Gear Position Displayed: Improper Upshift or Downshift assists: Gear Position Sensor Calibration: Difficulty getting into first gear from neutral: Figure 22: Sadev SCL82-17 ND Wiring Diagram Parts List Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 2 of 28

4 ND Mazda MX-5 Sequential Transmission Installation Instructions 1.0 General: 1.1 Safety: Follow all industry standard safety procedures Follow specific manufacturer safety procedures when available. 1.2 Intended Use: These Instructions are intended to be used to install the SADEV SCL82-17 Transmission to a complete Global MX-5 Cup Race car as built by Long Road Racing from the Mazda MX-5 ND Chassis. 1.3 Thread Locker: All fasteners are to be re-installed using Medium Strength Thread Locker unless otherwise directed in the instructions below. Ny-lock nuts do not require thread locker. 1.4 Basic Installation Overview: Installation of the Sadev SCL82-17 gear box is similar to the standard transmission. The primary differences are as follows: The Power Plant Frame connecting the transmission to the differential is no longer used, this is replaced with a Differential Mounting Bracket The Rear Subframe must be modified with threaded bungs and machined steel sleeves to create mounting points for the Differential Mounting Bracket The middle and rear chassis cross braces are replaced with one Transmission Cross Brace The hard clutch line must be replaced with the supplied modified clutch line to work with the included hydraulic release bearing The vehicle s wiring harness must be modified in two places to accept the included SADEV wiring harness The ECU must be re-flashed by Long Road Racing with a new calibration file to add the upshift assist and auto-blip features The AiM MXL2 configuration must be updated with a new CAN Protocol/ECU driver to allow gear position to display properly on the dash. 1.5 Tools needed: Basic hand tools, including 21mm deep well socket Wire Cutters, Wire Strippers and DTM Crimping Tool Medium strength thread locker on all fasteners High strength thread locker for flywheel bolts and driveshaft bolts. 1.6 Inventory/shipping damage inspection: Review shipment to ensure all parts arrived and are undamaged A full list of parts included can be found in Section Disassembly: Removal of Stock Transmission and Differential 2.1 Disconnect battery. 2.2 Remove ECU: The ECU must be sent to Long Road Racing to be upgraded for Upshift Assist and Auto-Blip Disconnect and Remove ECU after power is off ECU can stay attached to its bracket Call Long Road Racing with the Serial # from the ECU and notify them that the ECU is being shipped in for a SADEV upgrade Package the ECU in bubble wrap or equivalent, and ship to: Long Road Racing, attn. SADEV ECU Update, 2668 Peachtree Rd., Statesville, NC Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 3 of 28

5 2.3 Remove shifter assembly: Unscrew shift knob Unsnap plastic shifter surround and remove Remove 2 Phillips head screws and remove center console by unclipping and sliding over e- brake handle Unbolt 4 nuts (10mm) holding boot down and remove boot Remove rubber sealing grommet around shifter Remove 3 bolts (10mm) holding shifter handle to transmission and remove Place rag in shift tower hole and cover with latex glove or suck oil out with vacuum operated evacuator. 2.4 Remove strut tower brace: (6) 14mm nuts on strut tops (2) 13mm nuts on firewall. 2.5 Remove 3 lower chassis braces, front under engine, center and rear transmission tunnel braces: mm socket bolts front brace bolts each center and rear brace Center and rear braces will be replaced by Transmission Cross Brace (Item 25 Figure 12), keep 4 factory bolts for attachment of the Transmission Cross Brace. 2.6 Remove exhaust mid pipe: Unplug secondary O2 sensor Unbolt O2 sensor bracket (10mm) mm and 15mm sockets for band clamps. 2.7 Remove muffler pipe Disconnect rubber exhaust hangars and remove pipe. 2.8 Drain transmission oil Disconnect cooler lines from transmission. 2.9 Drain differential oil Disconnect cooler lines from differential Reposition or Remove (recommended) header: Unbolt (5) 14mm nuts Unplug and remove O2 sensor Remove header, or position with exit tube pointing down to clear transmission If removing header, engine mount will need to be removed and engine supported Remove starter: Remove 2 bolts holding starter motor on: One from top with collection of extensions to position ratchet by front of motor One from bottom Both are 14mm socket Keep Bolts for Reuse during reassembly Remove power plant frame (PPF): Disconnect ty raps holding transmission cooler lines to PPF Support bottom of transmission with jack Remove (8) 21mm nuts holding power plant frame on, and save for use on differential mount Pry rear of PPF to disengage it from differential Remove driveshaft: Remove 4 driveshaft bolts, 14mm Remove driveshaft from car. Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 4 of 28

6 2.14 Remove transmission: Lower transmission to gain access to top bolts Support engine at the front edge of the oil pan to keep rear of engine pointed down, maintain this downward angle while removing transmission Take special care to not damage the oil pan. Figure 1: Engine Supported to maintain angle during transmission removal Disconnect 2 electrical connectors on transmission wiring harness driver s side Remove bolt holding transmission wiring harness to transmission with 10mm socket Remove transmission wiring harness by pulling up into engine compartment and tying up. Coil together and ty wrap securely to brake lines under master cylinder Remove bolts from bellhousing to engine: (4) bolts from front side with 14mm socket (6) bolts from back side with 14mm socket Slide transmission back until it rotates freely: Rotate transmission counter clock wise until starter housing clears tunnel Slide transmission back until out of car Remove clutch and flywheel assembly: Unbolt 6 pressure plate bolts with 10mm socket Remove pressure plate and disc Unbolt 6 flywheel bolts with 19mm socket Clean and save flywheel bolts for re-use Remove rear subframe: Remove rear calipers and tie up to chassis, taking care not to kink or stress brake lines Unbolt ABS sensor from both rear hubs with 10mm socket and disconnect wires from subframe Unplug rear ride height sensor plug at left rear frame rail Remove both parking brake cables from subframe with 12mm socket Disconnect differential cooler lines Remove rear shocks: Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 5 of 28

7 (2) nuts per side on top with 14mm socket Bolt/nut on bottom with 17mm and 19mm wrenches Support rear subframe with extreme caution as this is a heavy and awkward assembly Remove (6) nuts holding subframe on with 17mm deep well socket Disconnect ty raps holding transmission cooler lines to subframe Lower subframe making sure parking brake cables are clear Remove differential from subframe: Remove (2) bolts holding upper mount to subframe with 17mm socket Disengage axles from differential housing Remove (4) nuts from upper differential mount with 17mm socket. Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 6 of 28

8 3.0 Subassembly and Vehicle Modifications: 3.1 Install 3.45 Ring and Pinion: Have ring and pinion installed by professional driveline specialist Use 0.100in spacer under ring gear and supplied bolts with washers Set ring gear backlash to factory specifications with factory shims as needed. 3.2 Modify rear subframe for differential mount: Modification consists of welding two threaded bungs into pre-existing holes, drilling 7/8 Holes through the subframe in two places, and welding in two steel sleeve inserts into the new holes. Ensure ECU is removed from car and battery is disconnected before welding! Up Front Figure 2: Rear Subframe Modification Template Assembly Exploded Part ID Table for Figure 2 Item # Part Name Description QTY 1 SadevND DMSF SLV Sadev ND Differential Mount Sub Frame Sleeve 2 2 SadevND DMSF Bung Left Round M14x1.5 Threaded Bung for Hole, Left Side 1 3 SadevND DMSF Bung Right Oblong M14x1.5 Threaded Bung for Slot, Right Side SDVND RSF TEMPLATE Template for Drilling Holes in Rear Sub Frame for Differential Mount Sub Frame Sleeves YA M14x1.5x30 Bolt 2 6 Differential Assembly Differential Assembly 1 7 N D Rear Sub-Frame 1 Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 7 of 28

9 3.2.2 Weld threaded bungs (Items 1 and 2 Figure 2) into slot and hole in bottom of subframe: Machined bungs are designed to locate themselves in factory holes at the bottom of the subframe. See Figure 3. Hole for Round M14 Bung (Item 2 Figure 2) Slot for Oblong M14 Bung (Item 3 Figure 2) Figure 3: Locating Holes for Threaded Bungs Insert bungs into holes and weld completely around, ensuring mounting surface remains free of weld and flat. Figure 4: Threaded Bungs Installed, full weld is required Attach supplied template (Item 4 Figure 2) with provided M14 Bolts (Item 6 Figure 2) to locate the horizontal holes in subframe. Face the side labeled Front toward the front of the vehicle. Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 8 of 28

10 Front 1/8 Pilot Hole Guides Rear Figure 5: Drilling Template for Rear Sub Frame Modification Installed Drill 1/8 Pilot holes in subframe in from the front, and in from the rear through the guide holes provided in the Template Remove Template and expand pilot holes on each side to 7/8 diameter using a hole saw or drill bit to allow machined sleeves (Item 1 - Figure 2) to fit all the way through from front to back Insert sleeves (Item 1 - Figure 2) into newly drilled holes from front side of subframe Use Diff Mount Bracket (Item 3 - Figure 19) and M14 through bolts (Item 1 Figure 19) with plain M14x2 nuts to center the sleeves in the holes Tack weld the back side of the sleeve in place, remove Diff Mount Bracket and tack weld the front side of the sleeves in place Weld sleeves completely around on both the front and rear faces of the subframe Protect threads in bungs, and spray paint over all welds to prevent corrosion. Front View Rear View Figure 6: Modified Rear Subframe Completed, Threaded Bungs and Sleeves Installed Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 9 of 28

11 3.3 Vehicle Wiring Harness Modification: This modification requires installation of DTM Connectors. If unfamiliar with DTM Connectors, information can be found here: Gear Position Sensor to Refrigerant Pressure Sensor: This is adding a single DTM connector in place of the factory connector to connect the SADEV Gear Position Indicator Locate Refrigerant Pressure Sensor connector, , in the Right Front area of the Engine bay. This is usually ty rapped to the Radiator Fan Shroud. It may be easier to access with the Airbox removed. Figure 7: Refrigerant Pressure Sensor Location Cut Connector off as close to the connector as possible Strip Wires and crimp DTM Sockets to all three wires using DTM Crimping tool Install DTM06-4S connector with the following pin out Position 1: Black/Green (or white) (Vref) Position 2: Brown/Orange (or Blue) (Ground) Position 3: Black/Blue (or Green/Yellow) (Signal) Airbox Overflow Connected to Sadev Harness Installed DTM Connector Figure 8: DTM Connector installed in Place of Refrigerant Pressure Sensor This Sensor is not used during normal use of the Global MX-5 Cup car. If reverting back to the stock transmission, simply unplug this connection and leave the DTM06-4S connector installed Gear Shift Indicator to MAF/IAT Sensor: This is adding two DTM connectors 7 to 8 inches away from the factory connector to splice 3 of the 5 wires to connect the SADEV gear shift indicator using a short jumper to the MAF signal. The remaining 2 wires stay intact Locate Mass Air Flow / Intake Air Temperature Sensor connector, , at the Airbox. Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 10 of 28

12 Cut 3 of 5 wires here Figure 9: MAF/IAT Wire Modification Location Pull back wire sheathing to expose 7 to 8 inches of wire Cut the following 3 wires 7 to 8 inches away from the factory connector, see Figure 9: Do not cut wire A Black/Green, and wire E Black/Blue Cut wire B Black/Red (or Green) (Ground) Cut wire C Black (or Blue) (MAF Signal) Cut wire D Black/Green (or White) (MAF Vref) On the Factory Connector Side, strip the three cut wires and install DTM Sockets Install DTM06-4S with the following pin out: 1. Position 1: Black/Green (or White) (MAF Vref). 2. Position 2: Black (or Blue) (MAF Signal). 3. Position 3: Black/Red (or Green) (Ground) On the Car side, strip the three cut wires and install DTM Pins Install DTM04-4P with the following pin out: 1. Position 1: Black/Green (or White) (MAF Vref). 2. Position 2: Black (or Blue) (MAF Signal). 3. Position 3: Black/Red (or Green) (Ground) Trim factory sheathing and reuse to protect wires as needed If these two connectors are plugged into each other the three wires should match and be continuous as if stock If reverting back to the stock transmission, simply unplug the SADEV jumper harness and connect these two connectors to keep all five wires continuous. Figure 10 (Left): DTM Connectors Installed and Connected in the Stock Configuration. Figure 11(Right): DTM Connectors Installed and Connected to the Sadev Harness. Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 11 of 28

13 4.0 Reassembly Figure 12: Sadev MX-5 ND Transmission, Exploded Assembly Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.3 Page 12 of 28

14 Item # Part Name Part ID Table for Figure 12 Description Torque Spec Tool Size 1 M10x1.5x40 SHCS Screws with Washers, Bell Housing to Engine (1 to w/washer Starter) 32 ft-lbs 8mm Hex 7 *2 M10x1.25x16 SHCS Screws & Washers, Blockout Plate to Bell Housing. w/washer (*Length Specific to this Location) 32 ft-lbs 8mm Hex 2 *3 M10x1.25x45 Hex Bolt Hex Bolts with Washers, (2) Engine to Bell Housing, (1) 17mm 32 ft-lbs w/washer Starter to Bell Housing. (*Length Specific to this Location) Socket 3 4 AASCO Flywheel Flywheel M12x1x22 Bolts Stock Bolts from Flywheel to Crank 34/57/80 19mm ft-lbs Socket 6 6 Tilton Clutch Assembly Clutch Assembly /16-24 bolt w/washer Bolts with Washers, Clutch to Flywheel 18 ft-lbs 1/2" Socket 6 8 M8x1.25x16 SHCS Screws, Shift Lever Clevis Assembly to Shift Relocate Plate 24 ft-lbs 6mm Hex 4 9 Shift Knob Shift Knob Reverse Lockout Collar Reverse Lockout Collar Shift Lever Arm Shift Lever Arm Shift Lever Clevis Assembly Shift Lever Clevis Assembly M8x1.25x30 SHCS Socket Head Cap Screw for Shift Rod Pin 24 ft-lbs 6mm Hex 1 14 M8 Lock Nut Lock Nut for Shift Rod Pin 24 ft-lbs 6mm Hex 1 15 Shift Relocate Plate 3/8" Steel Relocation Plate for Shift Lever Assembly M8x1.25x16 SHCS Screws, Shift Relocate Plate to Transmission Tail 24 ft-lbs 6mm Hex 4 17 Shift Rod Shift Rod Assembly Shift Sensor Sensor to Indicate Upshift Gear Position Sensor Sensor to Indicate Gear Position M10x1.5x16 Bolt 17mm Bolts from Transmission Mount to Rubber Isolator 30 ft-lbs w/washer Socket 2 21 Transmission Mount Transmission Mount Assembly M10x1.5x25 Flange Bolt Serrated Flange Bolts, Transmission Mount to 15mm 37 ft-lbs Transmission Socket 2 23 M10 Rubber Isolator Rubber Isolators, Transmission Mount to Transmission Cross Brace Reverse Lockout Pin Reverse Lockout Pin (*cable to shift lever not shown) Transmission Cross Brace Transmission Cross Brace Assembly Sadev SCL82-17 Sadev Transmission *27 M12x1.75x20 SHCS Screw and Washer, Bell Housing to Transmission, *Length Specific to this Location. Pre-Installed. 92 ft-lbs 10mm Hex 1 28 M12x1.75x30 SHCS Screws and Washers, Bell Housing to Transmission. Pre-Installed. 92 ft-lbs 10mm Hex 6 29 Sadev ND Bell Housing Bell Housing " Release Bearing Shim Release Bearing Shim (Optional) mm Release Bearing Shim Release Bearing Shim HRB Tilton Release Bearing M6x1x25 SHCS Screws for Release Bearing 11 ft-lbs 5mm Hex 3 34 M8x1.25x25 Flange Bolt Stock Flange Bolt from Factory Cross members 12mm 19 ft-lbs reused with Transmission Cross Brace. Socket 4 35 Blockout Plate Blockout Plate to Cover Bell Opening Note: SHCS = Socket Head Cap Screw Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 13 of 28 QTY

15 4.1 Install modified clutch line: Remove stock clutch hard line and Adel clamp. Transfer clamp to new line Install modified clutch line with -3 tube nut, see Figure 13. Stock Clutch Hard Line Clutch Hard Line with -3 Tube Nut Figure 13: Modified Clutch Hard Line 4.2 Install supplied engine blockout plate (Item 3 - Figure 12) to engine block: Confirm 2 dowel pins are still present in block Locate plate on dowel pins and press onto block. 4.3 Install aluminum flywheel (Item 4 - Figure 12): Place flywheel on end of crankshaft making sure both surfaces are clean Apply high strength thread locker to stock flywheel bolts (Item 5 Figure 12) and install Torque (6) bolts with 19mm socket in alternating pattern in three stages at 34/57/80 ft-lbs. 4.4 Install 2 disc clutch (Item 6 Figure 12): Measure clutch discs and write thickness on a non-wear area of the discs to keep track of the wear Install 2 disc clutch per factory instructions: Tilton OT-II 7.25 (185mm)Metallic Racing Clutches Installation Instructions included with kit, or online here: Use supplied alignment tool Use 5/16-24 bolts supplied with clutch kit (Item 7 Figure 12), torque to 18 ft-lbs with ½ socket and medium strength thread locker. 4.5 Measure and set release bearing clearance: See Tilton 60-12XX Hydraulic Release Bearing Instructions included with kit, or online here: Sheet.pdf Release bearings are pre-installed at Long Road Racing with a 6mm shim (Item 31 Figure 12) If additional adjustment is necessary, use additional supplied shim(s) (Item 30 - Figure 12). One additional shim, up to thick can be placed on each side of the 6mm shim. 4.6 Install transmission: Remove Shift Lever by removing (4) M8 SHCS with 6mm Hex. (Item 8 Figure 12) Make sure front of engine is still supported, see Figure 1 - Section Rotate transmission counterclockwise so starter pocket clears tunnel and install Rotate clockwise and slide onto dowel pins on engine block. Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 14 of 28

16 4.6.5 Install (2) M10x1.25x16 SHCS with washers and (2) M10x1.25x45 bolts with washers from front side (Items 2 & 3 Figure 12). Note that the two shorter screws (Item 2) are for the two bottom holes Install (6) supplied M10x1.5x40 socket head cap screws with washers from back side (Item 1 Figure 12) Torque (10) bellhousing bolts to engine to 32 ft-lbs using 8mm Hex Drive Socket and 17mm Socket Remove temporary front engine support Install jack under transmission tail to support until Transmission Cross Brace (Item 25 Figure 12) is installed. 4.7 Install Transmission Cross Brace: Bolt Transmission Cross Brace (Item 25 Figure 12) up in place of middle and rear factory cross braces (see Figure 15 & 17) using (4) M8x1.24x25 factory bolts, (Item 34 - Figure 12) Torque (4) bolts to 19 ft-lbs using 12mm Socket Install (2) M10x1.5x16 bolts (Item 20 Figure 12) through cross brace into rubber transmission mounts, (Item 23 Figure 12) Torque to 30 ft-lbs using 17mm Socket. 4.8 Install starter, ECU and connect battery Install starter with (1) M10x1.5x40 SHCS w/washer (Item 1 Figure 12) from the Bell Housing to the Starter and (1) M10x1.25x45 Hex Bolt w/washer (Item 3 Figure 12) from Starter to Bell Housing and torque to 32 ft-lbs with 8mm Hex and 17mm Socket Install updated ECU, and re-connect battery. 4.9 Connect transmission side wiring with supplied wiring harness: 4 pin Connector to Refrigerant Pressure Wiring Harness 6 pin Connector Transmission Side 4 pin Splice to MAF/IAT 6 pin Connector Refrigerant Pressure Connector 4 pin Splice to MAF/IAT Figure 14: Sadev Transmission Side Connector, Wiring Harness, & Engine Bay Routing / Connector Locations Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 15 of 28

17 4.9.1 Plug 6 pin connector into transmission Feed wiring up tunnel into engine compartment. Routing shown in Figures 14 and Secure with Adel clamp on existing stud (Figure 15), and with ty-raps to brake lines and existing wiring harness as needed. 6 Pin Connector Adel Clamp Figure 15: SADEV Wiring Harness undercar routing Plug 4 pin connector into Refrigerant Pressure Sensor modified in Section 3.3, See Figure Plug 4 pin splice into MAF/IAT wires modified in Section 3.3, See Figure Connect transmission cooler lines: Replace cooler line from filter to transmission with Part # LRR LRR-024 is a 29 line with straight fittings supplied in kit Service inline filter, then run line from filter to lower port on transmission and tighten with supplied 11/16 wrench, see Figure Replace cooler line from cooler to transmission with Part # LRR LRR-025 is a 100 line with one straight fitting and one 90degree fitting Run line from cooler with the 90 degree fitting going to the upper port on transmission and tighten with supplied 11/16 wrench, see Figure Attach cooler lines to Transmission Cross Brace with ty raps using pre-installed ty rap blocks riveted to transmission mount, see Figure 16. LRR-025, Return from Cooler Ty Rap Blocks on Cross Brace LRR-024, Send to Filter Lines pass under transmission in front of mount Figure 16: Transmission Cooler Lines Installation and Routing Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 16 of 28

18 Ensure cooler lines are secured away from exhaust and drive shaft Install supplied ty rap block to doubled layer of metal in transmission tunnel with rivet, making sure to only drill through first layer, see Figure Secure cooler lines to block with ty rap. Ty Rap Block Figure 17: Transmission Cooler Line Mounting Point 4.11 Install differential: Verify breather cap is installed, see Figure Install top differential mount, see Figure Torque (4) stock nuts to 50 ft-lbs with 17mm socket Place differential in subframe Install axles Install differential top mount bolts, see Figure Torque (2) stock bolts to 50 ft-lbs with 17mm socket. Breather Cap Differential Top Mount Figure 18: Differential Installed in Rear Subframe 4.12 Re-install subframe: Re-install is the reverse of removal (see section 2.16 above) Service inline filter and fill differential with supplied 75w/90 Castrol Syntrax Limited Slip. Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 17 of 28

19 Install Lower Differential Mounting Bracket: Item # Figure 19: Exploded Assembly of Differential Mounting Bracket, Eliminates Power Plant Frame. Part Name Part ID Table for Figure 19 Description Torque Spec Tool Size 1 M14x2x100 Flange Bolt Bolts for front to back connection through the sleeves in the modified rear sub frame. 125 ft-lbs 18mm Socket 2 2 M14x2 Flange Lock Nut Nuts for front to back connection through the sleeves in the modified rear sub frame. 125 ft-lbs 21mm Socket 2 3 SDVND Diff Mount Differential Mounting Bracket SadevND DM Spacer Differential Mount Spacer Stock Flange Nut Stock Flange Nut for Differential Mount 125 ft-lbs 21mm Socket 4 6 9YA M14x1.5x30 Flange Bolt for up connection into threaded bungs in the modified rear sub frame. 125 ft-lbs 19mm Socket Place Differential Mounting Bracket (Item 3 Figure 19) over 4 studs on differential Loosely install (4) spacers (Item 4 Figure 19) and 4 nuts (Item 5 Figure 19) Loosely install (2) bolts (Item 6 Figure 19) up through threaded bungs. Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 18 of 28 QTY

20 Loosely install (2) through bolts (Item 1 Figure 19) and 2 nuts (Item 2 Figure 19) through sleeved holes in subframe Tighten (4) M14 nuts on differential to 125 ft-lbs with 21mm Socket Tighten (2) bolts (Item 6 Figure 19) up through bungs to 125 ft-lbs with 19mm Socket Tighten (2) through bolts (Item 1 Figure 19) with nuts (Item 2 Figure 19) to 125 ft-lbs with 18mm and 21mm Sockets Install driveshaft: Apply small amount of transmission oil to front driveshaft yoke Install supplied driveshaft using factory hardware with high strength thread locker Torque (4) bolts to 40 ft-lbs with 14mm Socket Re-install header: Install O2 sensor with a small amount of anti-seize Install (5) nuts with anti-seize and torque to 40 ft-lbs with 14mm socket/wrench Plug in O2 sensor connector Re-secure wiring for O2 sensor back to factory location Re-install exhaust: Torque (2) clamps to 25 ft-lbs with 13mm and 15mm sockets Re-install strut tower brace: Tighten (6) nuts on strut towers to 40 ft-lbs with 14mm socket Tighten (2) nuts on fire wall to 18 ft-lbs with 13mm socket Install shifter: Use supplied (4) M8x1.25x16 SHCS (Item 8 Figure 12) Torque to 24 ft-lbs with 6mm Hex Use ty raps to hold reverse lockout cable in a manner that keeps the metal connector able to swivel freely Connect shift rod (Item 17 - Figure 12) to shifter clevis (Item 12 Figure 12) Torque M8 nut and bolt (Items 13 & 14 Figure 12) to 24 ft-lbs with 6mm Hex Re-install stock shifter trim: Install rubber boot Install rubber bezel with (4) nuts with 10mm socket Install center console Remove ring on top of boot Install shift boot Install and set Clutch stop: Install supplied clutch stop to clutch pedal with supplied ty raps Adjust clutch stop by following the supplied clutch installation instructions See Tilton 60-12XX Hydraulic Release Bearing Instructions included with kit, or online here: content/uploads/2013/07/ xx-hrb-instruction- Sheet.pdf Figure 20: Clutch Stop Assembly Installed Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 19 of 28

21 4.20 Fill transmission with supplied 75w/140 Motul Gear Competition oil: Flush old 75w/90 oil from transmission cooler lines and cooler Add 75w/140 oil to cooler and lines by sucking oil through lines with transmission cooler pump Connect cooler lines to transmission with minimal fluid loss, see section From the engine compartment, remove fill plug, see Figure 21, from top of transmission with 8mm Hex socket. Fill transmission with 1.26qt of Motul oil included with kit Bleed Clutch per Tilton factory instructions linked in section Update AIM MXL2 dash with provided configuration: 5.1 Download GEMS ND V3 MXL2 ECU Driver from LRR Website: Open Race Studio3, click on the CAN PROTOCOLS Icon Import the downloaded MXL2 ECU Driver After Import, Manufacturer should say Mazda, Model should say Gems ND V Download MXL2 SADEV Configuration from LRR Website: In Race Studio3, click on the Configurations Icon Import the downloaded MXL2 Configuration Connect Computer to Vehicle using MXL2 USB Cable, turn power on and Transmit the configuration file Once transmission is complete verify that ECU information such as RPM, Gear Position, Engine Coolant Temperature (ECT), etc is displaying correctly on the MXL If all items are displaying correctly, turn power off and disconnect computer. 6.0 Nut and bolt: 6.1 Double check all fasteners are tight and properly torqued. 6.2 Double check all cooler lines are tight Check for leaks after running the vehicle. 7.0 Clutch break in procedure: 7.1 No break in required. 8.0 Basic operating procedures: A video with basic operating procedures can be viewed here: Ensure AiM MXL2 is updated with proper configuration This is to ensure the Gear Position is accurately displayed on the dash, see section 5.0 above. 8.2 Starting the Engine: Turn Power On, depress the Clutch and hold the start button down until the engine starts The clutch must be depressed to start the engine Verify that the transmission is in Neutral on AiM MXL2 display before releasing the clutch. 8.3 To take off from a standstill: Depress clutch and engage first gear by pulling back on the shift lever The Aim MXL2 should now display 1 st gear Apply throttle and slowly release the clutch. 8.4 Basic Driving: Upshifts: As you accelerate engage the next highest gear by pulling back on the shift lever. Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 20 of 28

22 No clutch or throttle lift is necessary It is recommended to use the clutch at parking lot/paddock speeds to smooth out any gear changes at low speed The ECU will apply a short engine cut when it receives the upshift signal Downshifts: As you lift off the throttle and apply brake, engage the next lowest gear by pushing the shift lever forward Be certain the vehicle has slowed to an appropriate speed for the next lowest gear before downshifting to prevent over-rev No clutch or throttle blip is necessary It is recommended to use the clutch at parking lot/paddock speeds to smooth out any gear changes at low speed The ECU will auto blip to allow the engine to match rpm for the next gear Reverse/Neutral To engage Reverse from 1 st gear, while stationary, depress the clutch, pull the Reverse Lockout Collar (Item 10 Figure 12) up and push the shift lever one full click forward The AiM MXL2 will display R for reverse To engage Neutral from 1 st gear, with clutch depressed, pull the Reverse Lockout Collar (Item 10 Figure 12) up and push the shift lever one half click forward The AiM MXL2 will display N for Neutral To engage Neutral from Reverse, depress clutch and pull the shift lever one half click back Always verify Neutral gear position on the AiM MXL2 display before releasing the clutch Gear change sequence: N-R 9.0 Maintenance: Up Shift Down Shift Transmission Cooler Line In Oil Fill Plug, 8mm Hex Transmission Cooler Line Out to Filter Figure 21: Assembled Transmission Diagram Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 21 of 28

23 9.1 Max operating temperature: deg C or 230 deg F. 9.2 Internal inspection and seal replacement: Disassemble and Inspect every 2400 miles or 30 hours of track time for inspection and seal replacement Transmission service is offered by Long Road Racing. 9.3 Basic service after each event: Change transmission oil and clean in-line filter Inspect driveshaft yoke and u joints Inspect all mounts Inspect all bushings Trouble Shooting: 10.1 Incorrect Gear Position Display: Make sure the correct Configuration File is loaded in the MXL2, See Section 5.0 above Make sure the Proper ECU Driver to support the Configuration File has been uploaded into AiM Race Studio 3. See section 5.1 above Make sure the Gear Position Sensor is calibrated. See Section No Gear Position Displayed: Make sure the correct Configuration File is loaded in the MXL2, See Section 5.0 above Make sure the Proper ECU Driver to support the Configuration File has been uploaded into AiM Race Studio 3. See section 5.1 above Verify wiring modifications are correct. See Section Confirm SADEV wiring harness is connected properly with no damage to wires Improper Upshift or Downshift assists: If you are getting additional throttle blips, or engine cuts while running at speed it s possible that the Gear Position Sensor is no longer calibrated. See Section 10.4 below for instruction on calibrating the Gear Position Sensor Gear Position Sensor Calibration: The Gear Position Sensor (Item 19 Figure 12) should read the following Voltages for each Gear Position: Gear Voltage % Gear Position Displayed in AiM Voltage R 12% 0.5 N 18% % % % % % % To see the Gear Voltage % in AiM: Open RaceStudio3 on your computer and connect it to the car with the AiM USB cable Ensure that the transmission is in Neutral Turn the car s power and ignition on and click the icon at the top of the screen, then click on serial number or ID displayed on the bottom left for the connected MXL Click Live Measures in the top center of the screen Gear Voltage is one of the items available in the live data stream. Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 22 of 28

24 Optionally, the voltage can be measured between the signal wire and ground wire on the gear position wiring connector either at the Transmission, or at the modified Refrigerant Pressure Connector. See wiring diagram in Figure To Adjust and Calibrate the Gear Position Sensor: Loosen the two M5 Socket Head Cap Screws using a M4 Hex drive socket or wrench just enough that the body of the Sensor can be rotated by hand With the Transmission in Neutral, view the Gear Voltage % or Voltage as described in section Rotate the body of the Gear Position Sensor (Item 19 Figure 12) until the Gear Voltage % = 18% or Voltage = 0.5 volts Once matched, tighten the two M5 cap screws to lock the sensor in place Cycle through the gears to verify that all gears are reading correctly on the MXL2, or that all Voltage % or Voltages match the corresponding gear in the table in Difficulty getting into first gear from neutral: Partially release the clutch to rotate transmission internals and try again Check Clutch Stop and adjust as needed per section 4.20 above. Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 23 of 28

25 Figure 22: Sadev SCL82-17 ND Wiring Diagram Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 24 of 28

26 11.0 Parts List Bag Label / Assembly Part number Description Qty Reference Factory Packaging MA MAZDA Ring and pinion Not Shown M12x1 x 24.1 bolt w/washer M12x1 x 24.1mm flange hex bolt Gr12.9 for Ring Gear Shim with Washers 10 Not Shown SADEV ND Differential 132 Sadev ND Diff Shim Ring Gear Shim 1 Not Shown Modification Kit MA51-27-XXX MAZDA Differential Shims (Reference only, Not Included) 0 Not Shown SADEV Rear Subframe Modification Parts (Preinstalled in Subframe sold in Package 3 and 4) SADEVND DMSF SLV Differential mount weld in sleeve 2 Item 1 Fig 2 SADEVND DMSF Bung Left Steel Left side differential mount weld in bung 1 Item 2-Fig 2 SADEVND DMSF Bung Right Steel Right side differential mount weld in bung 1 Item 3-Fig SDVND RSF TEMP 14ga Rev1 Template for locating holes in rear subframe 1 Item 4-Fig 2 Bulk Packed SDVND Diff Mount Differential mount 1 Item 3 Fig 20 SADEV ND Differential Mounting Hardware M14x2.0x100 FB FTB Flange Bolts Front to Back 14x2.0x100, (98.6mm long) Black Phos 10.9, Differential 2 Item 1-Fig 20 M14x2.0 FN FTB Flange Lock Nuts Front to Back 14x2.0, 18.2 tall, Yellow Zn, 10.9, Differential 2 Item 2-Fig 20 9YA Bolts Up 14x1.5x30, Zinc, SADEV Differential, Bolts up into threaded bungs. 2 Item 6-Fig SADEVND DM Spacer Differential mount spacer 4 Item 4-Fig 20 Tilton Factory Packaging Tilton HBF Clutch cover 1 Item 6-Fig 12 Tilton Factory Packaging Tilton AC-30, 2 disc Clutch disc kit 1 Item 6-Fig 12 Tilton Factory Packaging Tilton /16-24 bolts w/washers, Tilton Clutch bolt kit. 6 Item 7-Fig 12 AASCO Factory AASCO Flywheel Packaging 1 Item 4-Fig 12 Factory Packaging 1" 23 spline Clutch alignment tool 1 Not Shown Bulk Packed SDVND CLCH LINE ND Modified Clutch hard line 1 Figure 13 Sadev Wire Harness SADEV Wire Harness Wiring Harness for SADEV SLC82-17 Transmission, with Adel clamp. 1 Figure 14 SADEV ND Wiring Modification Kit SADEV ND Transmission Cross Brace to Rubber Isolator Hardware / Transmission Cooler Line Ty Rap Block DTM06-4S DTM06-4S with sockets and lock 2 Figure 8 & 10 DTM04-4P DTM04-4P with pins and lock 1 Figure 8 & 10 M10x1.5 x 16mm Bolt M10 Bolts for Sadev Transmission Mounts 2 Item 20-Fig 12 M10 washers M10 Washers for Sadev Transmission Mounts 2 Item 20-Fig 12 TM2S8-MO Transmission cooler line ty rap block 1 Figure 17 1/8" Steel Rivet Rivet for ty rap block. 1 Figure 17 Bulk Packed SDVND Trans Brace Transmission cross brace 1 Item 25-Fig 12 Transmission Cooler Lines LRR-025 Transmission cooler line - cooler to trans 100" 1 Figure 16 LRR-024 Transmission cooler line - trans to filter 29" 1 Figure 16 LRR -6 line wrench Line Wrench for Transmission Cooler Lines 1 Not Shown Factory Packaging Motul 75w/140 Motul 75w/140 transmission oil 1L bottle 3 Not Shown Factory Packaging Castrol 75w/90 Castrol Syntrax 75w/90 gear oil 1qt bottle 3 Not Shown Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 25 of 28

27 Bag Label / Assembly Part number Description Qty Reference Sadev SCL82-17 Sadev Transmission 1 Item 26-Fig 12 SDVND Blockout Plate Blockout Plate to Cover Bell Opening 1 Item 3-Fig 12 M8x1.25x16 SHCS Screws, Shift Lever Clevis Assembly to Shift Relocate Plate 4 Item 8-Figu 12 Shift Knob Shift Knob 1 Item 9-Fig 12 Reverse Lockout Collar Reverse Lockout Collar 1 Item 10-Fig 12 Shift Lever Arm Shift Lever Arm 1 Item 11-Fig 12 Shift Lever Clevis Assembly Shift Lever Clevis Assembly 1 Item 12-Fig 12 M8x1.25x30 SHCS Socket Head Cap Screw for Shift Rod Pin 1 Item 13-Fig 12 M8 Lock Nut Lock Nut for Shift Rod Pin 1 Item 14-Fig 12 Shift Relocate Plate 3/8" Steel Relocation Plate for Shift Lever Assembly 1 Item 15-Fig 12 M8x1.25x16 SHCS Screws, Shift Relocate Plate to Transmission Tail 4 Item 16-Fig 12 Transmission Mount Transmission Mount Assembly 1 Item 21-Fig 12 SADEV SCL82-17 LRR M10x1.5x25 Flange Bolt Serrated Flange Bolts, Transmission Mount to Transmission 2 Item 22-Fig 12 Assembly M10 Rubber Isolator Rubber Isolators, Transmission Mount to Transmission Cross Brace 2 Item 23-Fig 12 M12x1.75x25 SHCS Screw and Washer, Bell Housing to Transmission, *Length Specific to this Location. Pre-Installed. 1 Item 27-Fig 12 SADEV ND Bell Housing to Engine Hardware Kit ND Clutch Stop Assembly M12x1.75x30 SHCS Screws and Washers, Bell Housing to Transmission. Pre-Installed. 6 Item 28-Fig 12 Sadev ND Bell Housing Bell Housing 1 Item 29-Fig XX Release Bearing Shim Release Bearing Shims (Optional) 0.030, and included. 3 Item 30-Fig 12 6mm Release Bearing Shim Release Bearing Shim 1 Item 31-Fig HRB Tilton Release Bearing 1 Item 32-Fig 12 M6x1x25 SHCS Screws for Release Bearing 3 Item 33-Fig 12 BA7-M16-6BK -6 Male to M16 Banjo 1 Not Shown ACW-06 Crush Washer 2 Not Shown BJB-08-M16-3 Banjo Bolt M16x1.5 1 Not Shown LRR-C01 Clutch Pressure Line 1 Not Shown LRR-C02 Clutch Bleed Line 1 Not Shown M10x1.5x40 SHCS Sadev Bell Housing to Engine Upper (1 for starter) 7 Item 1-Fig 12 M10x1.25x16 SHCS Sadev Bell Housing to Engine Lower 2 Item 2-Fig 12 M10x1.25x45 Bolt Sadev Engine to Bell Housing (1 for starter) 3 Item 3-Fig 12 M10 Washer Sadev Bell Housing to Engine Washers 12 Items 1-3-Fig 12 SDVND Clutch Stop Clutch stop w/ weld nut 1 M8x1.25x16 Bolt Adjustment bolt 1 M8x1.25 lock Nut Lock Nut for Adjustment Bolt 1 Figure 20 TY27MX Clutch stop zip tys 2 Bulk Packed SDVND Drive Shaft 34" Driveshaft 1 Not Shown Factory Packaging MS A Differential Assembly - Included in package 2 and 4 only 1 Item 6-Fig 2 Installed in Differential B39M Differential Breather Installed in Differential Included in package 2 and 4 only 1 Figure 18 Bulk Packed N D Subframe - Included in package 3 and 4 only 1 Item 7-Fig 2 Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 26 of 28

28 Revision Log: 2.4, : Updated service hours/ miles from 1600 miles / 20 hours, to 2400 miles / 30 hours based on info from Bertrand at Sadev. 2.5, : Updated Wiring picture for Refrigerant connector to show alternate wire colors we see in our first 2018 car. 2.6, : Updated wiring picture for AIT/MAF connector to show alternate wire colors in 2018 cars. Long Road Racing, SADEV SCL MX-5 ND Installation Instructions, Rev 2.6 Page 27 of 28