Gearbox Manual DG500 2017 - Drenth Gearboxes · Pole Position DG500 –Revision: 005 Gearbox Manual...

Gearbox Manual DG500

2017

2 Gearbox Manual DG500 – Revision: 005 Pole Position

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Warning Please be aware that information in this manual may be inaccurate, incomplete or contain typographical errors. The content of this manual is subject to

change without notice and should, therefore, be used for informational purposes only. Consequently, replacement parts must always by ordered according

to the part number engraved on the part.

If you find information in this manual that is incorrect or incomplete, we would appreciate your comments and suggestions.


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Contents Warning ............................................................................................................................................................................................................................................. 2

Contents ............................................................................................................................................................................................................................................ 3

1. Technical Specifications................................................................................................................................................................................................................. 5

1.1. General Specifications ............................................................................................................................................................................................................ 6

1.2. General Dimensions ................................................................................................................................................................................................................ 7

1.3. Oil System ............................................................................................................................................................................................................................... 8

2. Gearbox Assembly ......................................................................................................................................................................................................................... 9

2.1. General Instruction Notes..................................................................................................................................................................................................... 10

2.2. Bearing Assembly .................................................................................................................................................................................................................. 11

2.3. Gearbox Assembly ................................................................................................................................................................................................................ 14

2.4. Rotary Sensor ........................................................................................................................................................................................................................ 56

3. Gear Ratio List ............................................................................................................................................................................................................................. 58

4. Accessories .................................................................................................................................................................................................................................. 60

4.1. Bellhousings / Adaptor Plates ............................................................................................................................................................................................... 61

4.2. Gearbox Brackets .................................................................................................................................................................................................................. 64

4.3. Gear Lever ............................................................................................................................................................................................................................. 65

4.4. DMS Gear Lever .................................................................................................................................................................................................................... 67

4.5. Gear lever Brackets ............................................................................................................................................................................................................... 69

4.6. Gear Indicator ....................................................................................................................................................................................................................... 70

4.7. Display Unit ........................................................................................................................................................................................................................... 71

4.8. Switchbox .............................................................................................................................................................................................................................. 72

4.9. Oil Breather Catchtank ......................................................................................................................................................................................................... 73

4.10 Paddleshift System .............................................................................................................................................................................................................. 74


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5. Assembly Tooling ......................................................................................................................................................................................................................... 78

6. Contact Information .................................................................................................................................................................................................................... 80

6.1. Contact Details ...................................................................................................................................................................................................................... 81

Appendix A: Technical Bulletins ...................................................................................................................................................................................................... 82

Appendix B: Amendments ............................................................................................................................................................................................................... 84


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1. Technical Specifications


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1.1. General Specifications

DG500

Application Circuit, Hill Climb & Rally

Type 6-Speed Sequential

Torque rating 650 Nm

Weight (dry weight) 39 kg


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1.2. General Dimensions


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1.3. Oil System A gerotor interal-gear pump is fitted as standard in the end cover of the DG500. The oil pump is used to feed oil to the bearings, gears, dog rings and drop

gears. The oil can be fed to an external oil cooler from the oil-out port and returned to the gearbox using the oil-in port. On the right and left side of the

main housing an M12x1.50 thread is provided to mount oil temperature and pressure sensors. On top of the gearbox a D-06 adaptor is mounted which

needs to be connected to an oil catch tank or has to be replaced with a breather.

Oil Type Motul 75W140 Gear Competition

Oil Quantity 1.8 litres (excluding external oil lines & oil cooler)


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2. Gearbox Assembly


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2.1. General Instruction Notes The following information is intended for mechanics to (dis)assemble the gearbox. This is illustrated using exploded views including the corresponding Bill Of

Materials (BOM). Specific notes related to the (dis)assembly of a part are shown in the notes column of the BOM. For more details on the bearing

installation see §2.2 Bearing Assembly.

Please read the manual and make sure all parts are present before starting to assemble. Also ensure that all parts are clean and undamaged. It is

recommended to replace nuts, seals and circlips after removal. Only genuine Drenth Gearboxes parts should be used when overhauling the gearbox.


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2.2. Bearing Assembly To reduce the risk of bearing or casing damage, heat mounting is used to install or remove bearings. Drenth Gearboxes highly recommend to use an oven to

ensure an even heat distribution. Casings should not be heated above 130°C. Fit the bearings promptly after removing the casing from the oven to avoid

extra heating cycles being required.


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2.3. Gearbox Assembly


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2.4. Rotary Sensor

The gearboxes come with a Penny & Giles SRH280DP rotary sensor. The rotary sensor signal is used to show the engaged gear on the Drenth Display Unit /

Drenth Gear Indicator or any other display. For correct gear indication, it is necessary that rotary sensor is properly connected and calibrated. Information

related to the wiring of the sensor is shown in the table below.

Cable Colour Description

Red + 5 V Supply

Yellow Output 1

White Output 2

Black 0 V Supply (GND)

Depending on the type of gearbox, Output 1 or Output 2 is used. The table below shows which output is used for the different types of gearboxes:

Gearbox Type Output Cable Colour

DG350 Output 2 White

DG350 Direct Replacement Output 1 Yellow




DGT250 Output 2 White

DGT350 Output 2 White

Mitsubishi Lancer Evolution VI-IX Output 1 Yellow

Mitsubishi Lancer Evolution X Output 1 Yellow

MPG Output 1 White


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The connection diagrams when using output 1 or output 2 are shown below:

Please note that the above information does not apply to other sensors!


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3. Gear Ratio List


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The available gear ratios for the DG500 are shown in the table below. In addition, customer specific gear ratios can be developed, produced and supplied.

Layshaft Ratios Gear Ratios Drop Gear

Ratios

1st 2nd 2nd, 3rd, 4th, 5th & 6th

3.000 2.400 2.125 1.800 1.556 1.250 0.955 1.130

3.000 2.286 2.067 1.778 1.529 1.227 0.889 1.087

3.000 2.214 2.000 1.750 1.500 1.190 1.048

3.000 2.067 1.938 1.722 1.471 1.130 1.000

2.538 1.882 1.667 1.421 1.083 0.955

1.875 1.611 1.389 1.048 0.920

1.833 1.579 1.316 1.000 0.885


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4. Accessories


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4.1. Bellhousings / Adaptor Plates Drenth Gearboxes offers a variety of removable bellhousings and adaptor plates to mount the DG500 into different vehicles. In addition, bellhousings and

adaptor plates for customer specific applications can be developed, produced and supplied.


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4.2. Gearbox Brackets The Drenth gearbox brackets are designed to mount the DG500 using the existing chassis mounting points of the specific vehicle. Please note that these

brackets can only be used in vehicles where the chassis mounting points and/or the position of the engine have not been modified.


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4.3. Gear Lever Drenth Gearboxes offers a one-piece aluminium gear lever which, in combination with shift rods or a push/pull cable, can be used on any Drenth sequential

gearbox to change gear. Several gearbox and chassis mounted brackets are available for mounting the gear lever at the desired position.

In order to suit a variety of applications, the gear lever comes in two different lengths:

• 260 mm • 360 mm


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4.4. DMS Gear Lever Drenth Gearboxes offers a one-piece DMS aluminium gear lever with integrated electronics which, in combination with shift rods or a push/pull cable, can

be used on any Drenth sequential gearbox to change gear. The analogue output signal of the gear lever electronics can be used to configure the ignition cut

enabling flat-shifting. An optional Switchbox is used to convert the analogue signal when a digital output signal for programming the ignition cut is required.

The DMS gear lever can also be used to program down shift throttle blip if the car is equipped with drive-by-wire. In addition, several gearbox and chassis

mounted brackets are available for mounting the gear lever at the desired position.

In order to suit a variety of applications, the gear lever comes in two different lengths:

• 260 mm • 360 mm


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4.5. Gear lever Brackets Drenth Gearboxes offers various types of gear lever brackets for mounting the (DMS) gear lever in the car. There can be chosen between two types of

brackets, namely gearbox mounted gear lever brackets and tunnel mounted gear lever brackets.


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4.6. Gear Indicator Designed to work seamlessly with every Drenth sequential gearbox, the gear indicator uses the rotary sensor signal to show the selected gear. Using the

supplied software, it is possible to show up to 8 forward gears as well as neutral and reverse on the display with integrated light sensor. In addition, the gear

indicator features an option to control the reversing light.

Features:

- Gear indication

- Reverse light

- Automatic calibration


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4.7. Display Unit Designed to work seamlessly with every Drenth sequential gearbox, the display unit uses the rotary sensor signal to show the selected gear. Using the

supplied software, it is possible to show up to 8 forward gears as well as neutral and reverse on the display with integrated light sensor. In addition, the

display unit features an adjustable shift light and an option to control throttle blip or the reversing light. In combination with the DMS gear lever, the display

unit can be used for flat-shifting which allows the user to set the cut time for each gear separately. This is also possible when using any other load cell,

Switchbox or switch.

Features:

• Gear indication • Shift light • Flat-shifting • Down shift throttle blip / Reverse light • Automatic calibration • DMS Gear Lever calibration


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4.8. Switchbox The Drenth Gearboxes Switchbox is an analog-to-digital converter which is used in combination with the Drenth Display Unit or a programmable ECU to

enable flat-shifting. When a digital output signal is required for setting the ignition cut the Switchbox is used to convert the analogue signal. Because the

Switchbox is equipped with two potentiometers, the upshift and downshift threshold levels can be adjusted as desired.

Features:

• Adjustable downshift threshold voltage

• Adjustable upshift threshold voltage


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4.9. Oil Breather Catchtank Drenth Gearboxes recommends the use of an Oil Breather Catch Tank for breathing the gearbox. Therefore Drenth Gearboxes offers a universal catch tank

which can be used with any gearbox. The set includes the breather catch tank, oil hose and the necessary adaptors.


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4.10 Paddleshift System The DG500can be equipped with a paddleshift system from KMP or Geartronics allowing the driver to change gears by using steering wheel mounted shift

paddles. For mounting the actuators of the different paddleshift systems, Drenth Gearboxes has developed various brackets for the DG500. If the preferred

paddleshift system has a safety feature which prevent the driver from selecting neutral and reverse accidentally during downshifts, then the mechanical

blocking system can be replaced and / or removed. In this case the following parts are required:

KMP:


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Geartronics


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5. Assembly Tooling


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Optionally, Drenth Gearboxes provide tools which are used for assembling and disassembling the DG500. The tools listed below make it possible to perform

maintenance on the DG500:


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6. Contact Information


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6.1. Contact Details Drenth Motorsport Gearboxes

Fleuweweg 10

7468 AG Enter

The Netherlands

www.drenth-gearboxes.com

Spare Parts: +31 (0)547 38 26 96 [email protected]


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Appendix A: Technical Bulletins


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Appendix B: Amendments


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Date Page Modification 18-10-2017 1st Issue of completely revised manual

28-06-2018 63 & 73-74 Added Adaptor Plates and Paddleshift System

06-07-2018 64 Added Chapter 4.2 Gearbox Brackets

18-07-2018 8 Changed oil type to Motul 75W140 Gear Competition

11-09-2018 64 Deleted POM gearbox mount

01-10-2018 74 Added Paddle Shift KMP

T +31 (0)547 38 26 96 E [email protected] W www.drenth-gearboxes.com

Gearbox Manual DG500 2017 - Drenth Gearboxes · Pole Position DG500 –Revision: 005 Gearbox Manual...

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Transcript of Gearbox Manual DG500 2017 - Drenth Gearboxes · Pole Position DG500 –Revision: 005 Gearbox Manual...