Hewland TMT-200 Manuel utilisateur

Hewland Engineering Ltd

Waltham Road, White Waltham

Maidenhead, Berkshire, SL6 3LR, UK

+44 (0) 1628 827600

info@hewland.com

www.hewland.com

GEARBOX MANUAL

Issue: 20

Date: 16/10/2020

TMT-200

©Hewland Engineering Limited 2017 1

LIMITATION OF LIABILITY AND WARNING

The Hewland products and transmissions which are detailed herein are intended to be used in motorsport activities and are therefore subject to the following warning:

A) Hewland products are intended for use in or as high speed and high performance racing vehicles. The racing of high speed and high performance vehicles can be a very hazardous

activity and therefore involves a high risk of personal injury or even death. Hewland products will not withstand all foreseeable impacts during their normal intended use in or as a racing vehicle

without the likelihood of serious personal injury or death to the driver and/or passenger(s) or of damage to the Hewland products themselves which may impact the products performance and safe

use.

B) Hewland products should only be driven or used:

1. By a driver with the requisite training, skill and experience necessary both for the conditions under which the products are to be used and for the racing of high speed and high

performance vehicles

2. On specially designed racing tracks and under the supervision of official and approved racing organisations or otherwise under proper and reasonable operating conditions supported

by appropriate safety, medical and rescue services

3. With proper maintenance and repairs effected to parts and gearboxes as all parts and gearboxes, being mechanical devices, are inherently subject to wear and tear, fatigue or

disintegration and/or damage due to collision or improper use.

WARNING

The information and/or graphics presented in this Hewland Gearbox Service Manual may include inaccuracies or typographical errors. Changes and/or improvements may also be made to the

information presented herein without notice at any time. Hewland Engineering Limited makes no representations about the suitability, reliability, availability, timeliness or accuracy of the information

and/or graphics presented herein. All such information and/or graphics are provided on an “AS IS” basis without warranty, representation or guarantee of any kind, express or implied. Hewland

Engineering Limited hereby disclaims, to the fullest extent permitted under law, all warranties and conditions with regard to this information and/or graphics, including all implied warranties and

conditions of merchantability, fitness for a particular purpose, and workmanlike effort.

The user of the information and/or graphics contained in thisHewland Gearbox Service Manual is solely responsible for its use. If the user is dissatisfied with any such information and or graphics,

or with the terms of use, the user’s sole and exclusive remedy is to discontinue using the information and/or graphics. In no event shall Hewland Engineering Limited be liable for any direct,

indirect, incidental, special or consequential damages whatsoever, including without limitation, damages for accident, injury, property damage, loss of use, loss of data or loss of profits (whether

such damages are based on contract, tort, negligence, strict liability or otherwise, even if Hewland Engineering Limited has been advised of the possibility of damages arising), arising out of or in

any way connected with:

1. The use or performance of the information and/or graphics presented in this Hewland Gearbox Manual

2. Any inability to use such information and/or graphics,

3. any other use of such information and/or graphics.

©Hewland Engineering Limited 2017 2

CONTENTS

Limitation Of Liability And Warning.............................................................................................................................................................................................................................................. 1

Figures............................................................................................................................................................................................................................................................................................. 4

Technical Specification.................................................................................................................................................................................................................................................................. 5

Recommended Tightening Torques............................................................................................................................................................................................................................................ 6

Recommended Loctite Use .......................................................................................................................................................................................................................................................... 7

General Notes................................................................................................................................................................................................................................................................................. 8

Differential Bearing Preload.......................................................................................................................................................................................................................................................... 9

Pinion Height Settings................................................................................................................................................................................................................................................................. 10

Pinion Bearing Preload................................................................................................................................................................................................................................................................ 11

Crownwheel & Pinion Backlash Setting.................................................................................................................................................................................................................................... 12

Sequential Barrel Setting ............................................................................................................................................................................................................................................................ 13

DIFFERENTIALS............................................................................................................................................................................................................................................................................... 14

Powerflow Differential................................................................................................................................................................................................................................... 15

Differential Settings....................................................................................................................................................................................................................................... 16

TPT Differential Assembly ........................................................................................................................................................................................................................... 17

Gearbox Assembly –(Manual Gear Shift)................................................................................................................................................................................................................................ 18

Gearbox Assembly –(Pneumatic Gear Shift).......................................................................................................................................................................................................................... 20

Changing Gear Ratios................................................................................................................................................................................................................................................................. 21

ILLUSTRATED PARTS LIST .............................................................................................................................................................................................................................................................. 22

Output Assembly.......................................................................................................................................................................................................................................................................... 23

Casing Parts (Without Integral Gear Shift Compressor) ........................................................................................................................................................................................................ 24

Casing Parts (With Integral Gear Shift Compressor).............................................................................................................................................................................................................. 25

Layshaft Assembly....................................................................................................................................................................................................................................................................... 26

Pinion Shaft Assembly................................................................................................................................................................................................................................................................. 27

Gear Shift Assembly (Manual Gear Shift Only)....................................................................................................................................................................................................................... 28

Gear Shift Assembly (Pneumatic Gear Shift Only) ................................................................................................................................................................................................................. 29

©Hewland Engineering Limited 2017 3

Input Assembly............................................................................................................................................................................................................................................................................. 30

Barrel/Potentiometer Interfaces ................................................................................................................................................................................................................................................. 31

Temperature & Pressure Sensor Positions.............................................................................................................................................................................................................................. 32

Part Numbering ............................................................................................................................................................................................................................................................................ 33

Output Flange Options ................................................................................................................................................................................................................................................................ 41

TMT Typical Oil System Layout................................................................................................................................................................................................................................................. 43

Running Without An Oil Cooler.................................................................................................................................................................................................................................................. 44

Revision History............................................................................................................................................................................................................................................................................ 45

©Hewland Engineering Limited 2017 4

FIGURES

Figure 1-This table is taken from Hewland Standard: DOS-006-V4 ...................................................................................................................................................................................................... 6

Figure 2-This table is taken from Standard: DOS-006-V4 ..................................................................................................................................................................................................................... 7

Figure 3- Dierenal Bearing Preload................................................................................................................................................................................................................................................... 9

Figure 4-Pinion Height Seng ............................................................................................................................................................................................................................................................ 10

Figure 5- Pinion Bearing Preload......................................................................................................................................................................................................................................................... 11

Figure 6- Crownwheel & Pinion Backlash Seng ............................................................................................................................................................................................................................... 12

Figure 7- Sequenal Barrel Seng ..................................................................................................................................................................................................................................................... 13

Figure 8- Powerow Dierenal......................................................................................................................................................................................................................................................... 15

Figure 9- Dierenal Sengs ............................................................................................................................................................................................................................................................. 16

Figure 10- TPT Dierenal Assembly .................................................................................................................................................................................................................................................. 17

Figure 11- Output Assembly ............................................................................................................................................................................................................................................................... 23

Figure 12- Casing Parts Without Integral Gear Shi Compressor ....................................................................................................................................................................................................... 24

Figure 13- Casing Parts With Integral Gear Shi Compressor ............................................................................................................................................................................................................ 25

Figure 14- Laysha Assembly.............................................................................................................................................................................................................................................................. 26

Figure 15- Pinion Sha Assembly........................................................................................................................................................................................................................................................ 27

Figure 16- Gear Shi Assembly (Manual Gear Shi)........................................................................................................................................................................................................................... 28

Figure 17- Gear Shi Assembly (Pneumac Gear Shi)...................................................................................................................................................................................................................... 29

Figure 18- Input Assembly .................................................................................................................................................................................................................................................................. 30

Figure 19- Barrel / Potenometer Interfaces ..................................................................................................................................................................................................................................... 31

Figure 20- Temperature & Pressure Sensor Posions ........................................................................................................................................................................................................................ 32

Figure 21- Output Flange Opons....................................................................................................................................................................................................................................................... 41

Figure 22- Transmission Tooling ......................................................................................................................................................................................................................................................... 42

Figure 23- TMT Typical Oil System Layout .......................................................................................................................................................................................................................................... 43

Figure 24- Running Without An Oil Cooler.......................................................................................................................................................................................................................................... 44

©Hewland Engineering Limited 2017 5

TECHNICAL SPECIFICATION

The TMT gearbox is a transaxle unit, designed for mid-engined, rear wheel drive cars. The unit is produced with six forward gears, reverse, and a powerflow

differential.

The gear selection mechanism is sequential, and is available as either a pneumatically actuated semi-automatic or a mechanically operated direct link, both

have reverse engagement locked out.

The gear selection order is Rev - Neutral - 1st 2nd 3rd 4th 5th & 6th

The drive is taken from the engine via the clutch shaft, to the layshaft, through gears to the pinion shaft, and then onto the crownwheel and differential assembly.

Gear changing is effected through non-synchronising face dogs. An extensive range of gear ratios provides a wide range of gearing requirements. The gear

ratios and differential assembly can easily be changed without removing the gearbox from the vehicle.

Heat treated nickel chrome steel is used to manufacture all gears and shafts. The selector forks are also steel. Lubrication is by internal pump with distribution

circuit, and the oil is retained by lipped oil seals.

In general configuration, the TMT-200 is a high tech racing transaxle unit which achieves the maximum effective use of power, in conjunction with extremely

stiff integral rear suspension mountings.

1st to 6th gear ratios from 3.083:1 to 0.9230:1

Note: Overdrive ratios need proof maching found in TMT-202 version 12 and above.

Final drive ratios 8/35, 9/35, 10:31 & 11/31

Clutchshafts made to customer's requirements

WEIGHT

Aluminium 49.5kg / Magnesium 44.5kg

OIL GRADE

SAE 80 or SAE 90

OIL QUANTITY

1.75ltr (not including oil cooler circuit)

MAXIMUM TORQUE

320lbs.ft (430Nm) –reduced to 275lbs.ft (373Nm) for 8:35 final drive

©Hewland Engineering Limited 2017 6

RECOMMENDED TIGHTENING TORQUES

Final Drive Bolts

100

Pinion Shaft Nut

163

Differential Centre Bolt

Selector Barrel Bolt

All Studs

Nm lb/ft Nm lb/ft Nm lb/ft Nm lb/ft Nm lb/ft Nm lb/ft

Fine M3x0.35 1.4 1.1 0.8 0.6 0.5 0.4 1.7 1.2 1.2 0.9 0.7 0.6

Course M3x0.5 1.4 1.0 0.8 0.6 0.5 0.4 1.6 1.2 1.3 0.9 0.8 0.6

Fine M4x0.5 3.5 2.5 2.0 1.4 1.2 0.9 4 3 3 2 1.8 1.3

Course M4x0.7 3.0 2.5 1.8 1.4 1.2 0.9 4 3 3 2.5 2 1.4

Fine M5x0.5 7 5 4 3 2.5 2 8 6 5 4 3.5 2.5

Course M5x0.8 6 5 4 3 2.5 2 7 5 6 4 3.5 3.0

Fine M6.0.75 11 8 7 5 4 3 13 10 10 7.0 6 4.5

Course M6x1.0 11 8 6 5 4 3 13 910 8 7 5

Fine M8x1.0 27 20 16 12 10 732 23 23 17 14 11

Course M8x1.25 26 19 15 11 10 731 23 24 18 15 11

Fine M10x1.25 53 39 31 22 19 14 62 46 44 33 28 21

Course M10x1.5 51 38 30 22 19 14 60 44 46 34 29 22

Fine M12.x1.5 91 67 53 39 34 25 107 79 76 56 48 36

Course M12x1.75 89 66 52 38 33 24 104 77 79 58 50 37

UNF 1/4x28 14 10 8.0 6.0 5.0 4.0 16 12 12 9 8 6

UNC 1/4x20 13 10 8.0 6.0 5.0 3.5 16 12 14 10 9 6

UNF 5/16x24 27 20 16 12 10 732 24 23 17 15 11

UNC 5/16x18 26 19 15 11 10 731 23 25 19 16 12

UNF 3/8x24 48 35 28 20 18 13 56 41 38 28 24 18

UNC 3/8x16 46 34 27 20 17 12 54 40 43 32 27 20

UNF 7/16x20 76 56 44 32 28 21 89 66 61 45 39 29

UNC 7/16x14 73 54 42 31 27 20 86 63 68 50 43 32

Metric

Imperial

Direct in material

Steel Insert (Helicoil, Timesert, Keensert)

Nut Torque

Nut on EN16 Stud

Torque in Magnesium

Torque in Steel

Torque in Aluminium

Torque in Magnesium

Torque in Aluminium

Unless otherwise specied within this manual.

Figure 1-This table is taken from Hewland Standard: DOS-006-V4

©Hewland Engineering Limited 2017 7

RECOMMENDED LOCTITE USE

Loctite

222

Loctite

243

Loctite

270

Loctite

542

Loctite

648

Permanent

fixings

Studs being fitted to holes tapped directly into base material

✔

Fixing timesert or keensert into tapped hole in base material

✔

General fixings

Screws / bolts being fitted to holes tapped directly into base material

✔

Screw / bolt into timesert

✔

Screws / bolts fitted to heli-coil fixings

(LAST RESORT IF LOCKWIRE CANNOT BE USED)

✔

Specific

fixings

Oil line blanking plugs

✔

Differential cap bolts / studs

✔

Pinion / Mainshaft / Layshaft nut

(ONLY IF LOCKING DEVICE IS NOT INCORPORATED INTO DESIGN)

✔

Crownwheel bolts / studs

✔

Selector barrel Nut

✔

Pinion bearing retaining bolts

✔

Figure 2-This table is taken from Standard: DOS-006-V4

Unless otherwise specied within this manual.

©Hewland Engineering Limited 2017 8

GENERAL NOTES

Read these instructions carefully and with reference to the illustrations.

Before dismantling the gearbox, see that a clean tray is available, in which to place the parts.

Thoroughly clean and inspect all parts before reassembly. Discard any worn or damaged components and replace with new ones.

Use only genuine Hewland parts as replacements. These are manufactured in our workshops to the fine tolerances necessary and are rigorously

inspected.

Always ensure that locknuts, and oil seals are in good condition when reassembling.

All studs and screws must be Loctited or wirelocked in position, unless stated otherwise.

Bearing Replacement :-

oBearings can only be removed or renewed if the casings have been warmed in an oven, or with a blowlamp. In the latter case, keep the blowlamp

moving while heating the casing.

oNB. Do not overheat. Test 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 seating’s without delay, thus eliminating the needto reheat. At the correct temperature, fitting the bearings

should present no difficulty.

oDuring cooling, or when the casings have cooled, it is advisable to once more lightly press the bearings to ensure that they are correctly seated.

Oil:-

oFill the gearbox through the oil filler hole on top of the maincase. The oil will find its own level within the gearbox.

oNB. Too much oil will not directly cause any harm, but is undesirable as it will induce power loss and overheating of the internals.

DIFFERENTIAL BEARING PRELOAD

Using the original shims (40) as a guide, fit the outer races of bearings (37) to

the maincase and side cover. Fit the inner races of the bearings to the differential

case. Offer up the differential assembly to the maincase and fit the sideplate.

Adjust shims (40) as necessary to achieve 0.012”/0.015” of preload, giving 4/6 lb

ft (5.4/8.1 Nm) torque to turn.

(With bearings oiled.)

Refer to page 19 for part references.

The table below is to inform you of which sideplate spacers should be used with

which crownwheel when mounted on a TPT differential. The reason that there

are two sets of spacers, is that the crownwheels have different mounting

distances. The table also shows which crownwheel Bolts should be used with

each crownwheel, as shorter bolts are required for the 11/31 CW.

PART NUMBER

RATIO

MOUNTING

DISTANCE

ITEM (41)

ITEM (68)

CW BOLTS

ITEM (126)

TMT-221-EW

8/35

2.100”

FGC-206-2D

NLT-206-2

VG-221-1

TMT-221-CW

9/35

2.200”

FGC-205-2A

NMT-205-2A

VG-221-1

NMT-221-BW

10/31

2.316”

FGC-206-2A

NMT-205-2

VG-221-1

NMT-221-AW

11/31

2.316”

FGC-206-2A

NMT-205-2

VG-221-1C

Refer to page 19 for part references.

Figure 3- Dierenal Bearing Preload

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