Tel. : (00 33) Fax : (00 33)

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1 GEARBOX TYPE TECHNICAL DETAILS For further information, please contact the company: Plant Address: SADEV 6, rue des Grand Montains SAINT PROUANT France Postal Address: SADEV BP CHANTONNAY France Tel. : (00 33) Fax : (00 33) sadev@sadev-tm.com September 2011 Update

2 MECHANICAL GEARBOXES 1- Glossary 1- Glossary... page Characteristics... page Gearbox presentation... page Pinions technical data... page Differential technical data... page Lubrication... page Sensors... page Assembly informations... page Glue components... page Tools... page Exploded views... page Primary gear train... page Secondary gear train... page Gear selector... page Limited slip differential... page Housing... page Servicing... page Servicing planning... page Gearbox rebuild... page Appendix 1 : Clutch bearing... page Clutch bearing... page Slave cylinder... page Appendix 2 : Installation drawings... page Appendix 3 : Ratios and final drives... page Ratios ranges... page Final drive ratios... page Appendix 4 : Limited slip differential... page Differential plates... page Preload spacers 11- Appendix 5 : Standard differential output... page Appendix 6 : Special differential output... page Appendix 7 : Adaptation kits... page 13-1 September 2011 Update Page 1-1

3 1- GEARBOX PRESENTATION MECHANICAL GEARBOXES 2- Characteristics The SADEV sequential gearbox type, consists of 6 front gears and one reverse. It weights about 38.5 kg without reverse gear cable. It is equipped with a self locking differential with friction discs and pressing plates with ramps. It is assembled in SADEV aluminium-funded special housings. It exists 3 types : - Housing for clutch bearing. - Housing for slave cylinder. - Housing for montage VAG avec démarreur coté boîte (butée hydraulique nécessaire). The reverse gear unlocking cable is also provided, so as the release bearing (mounting at your own specifications, see 1st and 2 nd appendix), lubrication fittings, gearbox supports inserts and the gearing potentiometer. 2- PINIONS TECHNICAL DATA You can choose gear ratios in the list provided in the 3 rd appendix: The output shafts are defined in the 2 nd appendix. Special assemblies can be made on demand, following that appendix. It is naturally followed by an increase in price and delivery period. LIMITS OF GEARBOX USE: Max engine torque : 25 m.kg or Max engine power : 240 CV or Max engine speed: 9000 Tr/min NOTE. Servicing recommendations are forecast for these maximal use conditions. A more severe use will decrease life expectancy of details without control. 3- DIFFERENTIAL TECHNICAL DATA Four friction discs differential and pressing plates with ramps that act symmetrically or asymmetrically when accelerating or decelerating. Set-up can be modified using parts chosen in the list provided in the 4 th appendix. NB. The limited slip differential running in (60 kilometres) entails a preload drop of about 15%. NB. The preload measured under cold conditions (workshop) is about 15% higher than the one measured under hot conditions. NOTE : The standard differential outputs are optional, and defined in the 5 th appendix. Special differential outputs can be performed on demand following the 6 th appendix. September 2011 Update Page 2-1

4 4- LUBRICATION MECHANICAL GEARBOXES 2- Characteristics Capacity : 1.4 Litre (corresponds to the level) Recommended cooler : of your supply Filtering coupling: included (to clean after race) 1st oil change Oil change frequency Quality viscosity After first 50 km Each meeting 6AE 75W90 PARTICULAR PRECAUTIONS No additives should be added to the oil. The resulting consequences are in any circumstances not covered by the SADEV supplier. When topping up the gearbox oil, do not mix any other oil with that already into the gearbox. STORAGE ON USE Be particularly careful with any bottles which are open when used : - Close the bottle again correctly after use so as to prevent the introduction of water or dirt. - Store bottles horizontally, protected from severe weather. - Do not store bottles close to a washing station. - Do not decant oil into larger containers. WASHING UNDER PRESSURE When the gearbox is removed, seal all openings correctly to prevent the introduction of water into the gearbox. 5- SENSORS : Gearing Potentiometer : ref. F A = Red Wire = +5V B= Blue Wire = GND C = White Wire = Signal Engine cut off sensor : ref. F K Not polarized Reverse gear sensor : ref Not polarized September 2011 Update Page 2-2

5 MECHANICAL GEARBOXES 3- Information about various components assembly 1- GLUE COMPONENTS Glue components and tightening torques are shown in the 3D exploded views. WARNING : Glue components have been chosen during test sessions. Only «Loctite» brand components must be used. Consequences resulting of false glue components choice or a disregard on Loctite glue indications can t be covered by SADEV supplier. September 2011 Update Page 3-1

6 MECHANICAL GEARBOXES 4- Tools Ref. SADEV FOUT Anti-splay plate Ref. SADEV FOUT Fork repositioning tool September 2011 Update Page 4-1

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12 MECHANICAL GEARBOXES 6- Servicing 1- SERVICING PLANNING This planning value unit accounts for the special stage distance. Parts Action Frequency Clutch shaft Change 2000 km Differential bearings Change 2000 km Primary and secondary shaft bearings Change 2000 km Drain plug seals Change All drain Drain plug Cleaning and check All drain Selector spring Change 2000 km Shaft screws (primary & secondary) Change All disassembly Crown wheel screw Change All disassembly Differential case screw Change All disassembly Differential preload Check gearbox and revision pocket (o rings, security screws ) Check and setting in conformity if necessary Disassembly/Assembly to check all parts 500 km 500 km Release bearings Change 1000 km Note : This planning may change during the life span of product. A revision kit (sealing and security screws) is available for the following versions : Outputs type Standard Special Clutch bearing type Mechanical Hydraulic Mechanical Hydraulic Kit reference KITREVST75142 KITREVST75143 KITREVST75144 KITREVST75145 In case of update release edition, the manufacturer will be informed thanks to a technical note and will transfer the information to its own customers. As every mechanical part which is dedicated to racing, no guarantee is ensured. September 2011 Update Page 6-1

13 2- GEARBOX REBUILD MECHANICAL GEARBOXES 6- Servicing 1 - Intervention in SADEV workshop: Notes : The gearboxes are delivered leaded and numbered. The absence of the SADEV lead seal imposes a careful attitude in the event of minor or major problem, and applies to complete reserve of our share if necessary. Return gear boxes to revision: At the time of gearboxes return in our buildings, a certain delivery procedure has to be respected, so that our intervention can be total, and practical (casing closed for passage to the bench). We must receive the complete product as described below : Release bearing in place Engine cut off sensors and reverse gear sensors in place Gearbox drained and cleaned. Bouchons de vidange et leurs joints en place, légèrement serrés Différentiel en place A card specifying the kilometres of the special stage and connection since the last service is available near our sales department. The reverse gear unlocking cable, except in the event of breakdown, has not to be sent to us, and will be able to remain on the vehicle. The absence of elements can be specified on the card, but in the case of doubt, the material will be sent back re-equipped. Administrative procedure: 1. send a request for service to SADEV sales department. 2. forward the material and its card in our workshop.(description above) 3. approve the estimate presented by SADEV sales department. 4. APPROXIMATELY 2 TO 3 WEEKS OF DELIVERY TIME MUST BE CONSIDERED. 2 - Personal revision: After sale, the parts for customers who want to proceed a revision by themselves, are delivered only buy SADEV sales service. SADEV COMPANY IS NOT RESPONSIBLE FOR ANY DAMAGE FOLLOWING A REVISION NOT EXECUTED IN A SADEV AGREED TECHNICAL SERVICE (LIST ON DEMAND). September 2011 Update Page 6-2

14 MECHANICAL GEARBOXES 7- APPENDIX 1 : Clutch Bearing 1- CLUTCH BEARING a ) Clutch bearing BTC-DTC Ø54 Rep. Ref. Parts Coef. Glu Torque (DaN.m) Bolt CHC M10x30 cl 8.8 ZN Washer sps Ø F Bolt CHC M10x23 cl8.8 ZN F Clutch cable stop 1 5 F Spacer fork ball pivot (standard mouting) 1 F fork ball pivot (TU mouting) Bolt M8x Clutch fork 1 F Clutch bearing BTC-DTC Ø54 A 9 F Clutch bearing BTC-DTC Ø54 B 1 F Clutch bearing BTC-DTC Ø54 C Clutch bearing Ø F Clutch bearing guiding tube Clutch bearing guiding tube Ø25.9 inter 1 11* F Clutch bearing guiding tube seal 1 (*) Parts into the revision kit (cf. page 6-1) September 2011 Update Page 7-1

15 MECHANICAL GEARBOXES 7- APPENDIX 1 : Clutch Bearing b ) Clutch bearing BTC-DTC Ø50 Rep. Ref. parts Coef. Glu Torque (DaN.m) Bolt CHC M10x30 cl 8.8 ZN Washer sps Ø F Bolt CHC M10x23 cl8.8 ZN F Clutch cable stop 1 5 F spacer fork ball pivot (standard mouting) 1 F fork ball pivot (TU mouting) Vis M8x Fourchette d embrayage 1 F Clutch bearing BTC-DTC Ø50 A 9 F Clutch bearing BTC-DTC Ø50 B 1 F Clutch bearing BTC-DTC Ø50 C Clutch bearings Ø F Clutch bearing guiding tube Clutch bearing guiding tube Ø25.9 inter 1 11* F Clutch bearing guiding tube seal 1 (*) Parts into the revision kit (cf. page 6-1) September 2011 Update Page 7-2

16 c ) Clutch Bearing Renault Ø35 MECHANICAL GEARBOXES 7- APPENDIX 1 : Clutch Bearing Rep. Ref. Parts Coef. Glu Torque (DaN.m) Bolt CHC M10x30 cl 8.8 ZN Washer sps Ø F Bolt CHC M10x23 cl8.8 ZN F Clutch cable stop 1 5 F Spacer fork ball pivot (standard mouting) 1 F fork ball pivot (TU mouting) Bolt M8x Clutch fork Cutch bearing Renault Ø Clutch bearing guiding tube 1 11* F Clutch bearing guiding tube seal 1 (*) Parts into the revision kit (cf. page 6-1) September 2011 Update Page 7-3

17 MECHANICAL GEARBOXES 7- APPENDIX 1 : Clutch Bearing 2- SLAVE CYLINDER Rep. Ref. Parts Coef. Glu Torque (DaN.m) F Slave cylinder 1 1* O ring seal Ø43x3 1 2 F Slave cylinder spacer Bolt CHC M7x20 cl 10.9 ZN Bleeding hose Pressure hose Bolt CHC M7x16 cl 10.9 ZN F Slave cylinder 1 8* Twin-lip seal Ø24x36x7 1 (*) Parts into the revision kit (cf. page 6-1) Other models on demand September 2011 Update Page 7-4

18 implantation butée BTC-DTC - Ø50 or Ø54 - (BR) GB face/bearing face distance (cluched) - (BS) GB face/bearing face distance (decluched) splines number : LENGTH C BR A B BS LENGTH E LENGTH D Ref. Description BR BS F BTC-DTC Ø54 A F BTC-DTC Ø54 B F BTC-DTC Ø54 C F BTC-DTC Ø50 A F BTC-DTC Ø50 B F BTC-DTC Ø50 C arbre d'embrayage et butée BTC/DTC

19 27,08* 3,8** LONGUEUR C ØA ØB LONGUEUR E LONGUEUR D

20 A B 10,9* LENGTH C LENGTH E LENGTH D

21 142,05 138,89 74,1 80,54 15,7 15, ,27 80,54 145,25 57, ,51 95,1 6,73 15, ,5 122,97 114,98 326,25 146,16 136,24 76,18 60,73 56,41 45,01 36, ,5 88,9 81, ,51 47,63 78,32 208,32 168,65 230

22 15, ,98 136,24 142,05 74,1 15,7 15, ,27 138,89 80,54 80,54 145, ,1 6,73 115,51 122,97 146,16 60,73 57,6 175,5 76,18 56,41 45,01 36, ,5 326,25 88,9 81,46 42,51 47,63 78,32 208, ,65 230

23 68,43 114,98 136,24 142,05 74,1 15,7 15, ,27 128,97 80,54 80, ,51 95,1 6,73 122,97 175,5 146,16 245,5 326,25 56,41 45,01 57,6 42,51 47,63 78,32 208,32 36, ,18 60,73 88,9 81,46 168,

24 MECHANICAL GEARBOXES 9- APPENDIX 3 : Ratios list 1- RATIOS RANGE Ratio Z1 Z2 Reference Application 3, First D J6J 2, Second 2, First D J6J 2, Second 2, First D J6J 2, Second 3, First D J6J 2, Second 3, First 2, Second 2, E J First 2, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th C J 3 rd to 6 th C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 1, C J 3 rd to 6 th 0, C J 3 rd to 6 th 0, C J 3 rd to 6 th For other ratios, contact SADEV company. September 2011 Update Page 9-1

25 MECHANICAL GEARBOXES 9- APPENDIX 3 : Ratios list 2- FINAL DRIVE RATIOS Ratios Z1 Z2 Reference 3, CPL , CPL , CPL , CPL , CPL , CPL , CPL , CPL , CPL , CPL , CPL , CPL , CPL September 2011 Update Page 9-2

26 MECANICAL GEARBOX 10- APPENDIX 4 : LIMITED SLIP DIFFERENTIAL 1 - LIMITED SLIP DIFFERENTIAL PLATES (DIFFERENTIEL SET-UP) ACCEL ( DEG) DECCEL ( DEG) Reference F F F F F F F F F F F F F F F F F F F September 2011 Update Page 10-1

27 MECANICAL GEARBOX 10- APPENDIX 4 : LIMITED SLIP DIFFERENTIAL 2- BELLEVILLE WASHERS (PRELOAD SET-UP) Belleville Washer thickness Reference 0,6 mm F ,8 mm F mm F ,2 mm F ,35 mm F ,5 mm F ,7 mm F ,85 mm F mm F ,2 mm F ,4 mm F ,6 mm F Your usual contact with SADEV will give you the tare and preload for each combination. September 2011 Update Page 10-2

28 1- PRECISIONS : MECHANICAL GEARBOXES 11- APPENDIX 5 : Standard Differential Output The standard output flanges (in option) are defined to receive LOBRO type seals diameter 100mm. The left output flange and the right one are identical in this case (no right intermediary shaft). (refer to the following page) September 2011 Update Page 11-1

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30 MECHANICAL GEARBOXES 12- APPENDIX 6 : Special differential output To define your specific transmission with the less possible risk, please ask your usual contact at SADEV. September 2011 Update Page 12-1

31 L O N G U E U R 1 " L O N G U E U R 1 ' 143,35 220,85 L O N G U E U R 2 " LONGUEUR 2 L O N G U E U R 2 '

32 LON GUEUR 1 ' LONGUEUR 2 143,35 LONGUEUR 4 LONGUEUR 3 L O N G U E U R 2 '

33 MECHANICAL GEARBOXES 13- APPENDIX 7 : Adaptation Kits The following pages present kits designed by SADEV company on customers demand to adapt gearbox with various engine block. So you will find on the following pages : - A TU type engine block assembly for PSA - A XU type engine block assembly for PSA - K20A type engine block assembly for HONDA - A S type engine block assembly for VAG (This one requires particular conditions) There are two other assemblies : - A F4R engine block assembly (Renault), used on Clio coupe, available in Alpine shop. - A EW10 type engine block assembly (PSA), used on 206RCC coupe, available in PEUGEOT SPORT shop. (This assembly requires a specific clutch bearing and casing configuration) Whatever the choice, we advise you to contact our team which will guide you for the best option for your project. September 2011 Update Page 13-1

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