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TRANSCRIPT
Gearbox Manual MPG
2017
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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................................................................................................................................................................................................................. 6
1.1. General Specifications ............................................................................................................................................................................................................ 7
1.2. General Dimensions ................................................................................................................................................................................................................ 8
1.3. Oil System ............................................................................................................................................................................................................................... 9
2. Gearbox Assembly ....................................................................................................................................................................................................................... 10
2.1. General Instruction Notes..................................................................................................................................................................................................... 11
2.2. Bearing Assembly .................................................................................................................................................................................................................. 12
2.2.1 Bearing Assembly Endcover MPG Flange ........................................................................................................................................................................ 13
2.2.2 Bearing Assembly Endcover MPG Corvette .................................................................................................................................................................... 13
2.2.3 Bearing Assembly Endcover MPG Slip Yoke .................................................................................................................................................................... 15
2.2.4 Bearing Assembly Housing MPG ................................................................................................................................................................................ 16
2.2.5 Bearing Assembly Drop Gear Housing .................................................................................................................................................................... 17
2.3.1 Assembly Rachet MPG .................................................................................................................................................................................................... 18
2.3.2 Assembly Oilpump .......................................................................................................................................................................................................... 21
2.3.3 Assembly Layshaft ........................................................................................................................................................................................................... 23
2.3.4 Assembly Outputshaft MPG Flange & Corvette ....................................................................................................................................................... 24
2.3.5 Assembly Outputshaft MPG Slip Yoke ........................................................................................................................................................................... 27
2.3.6 Assembly Shafts Endcover .............................................................................................................................................................................................. 31
2.3.7 Assembly Selector Drum ................................................................................................................................................................................................. 32
2.3.8 Assembly Selector Forks ................................................................................................................................................................................................. 32
2.3.9 Assembly Reverse ........................................................................................................................................................................................................... 34
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2.3.10 Assembling Housing MPG Flange/Slip Yoke .................................................................................................................................................................. 35
2.3.11 Assembling Housing MPG Corvette .............................................................................................................................................................................. 36
2.3.12 Assembly Rotary Sensor ................................................................................................................................................................................................ 37
2.3.13 Assembly Drop Gear...................................................................................................................................................................................................... 39
2.3.14 Assembly Inputshaft MPG Flange ................................................................................................................................................................................. 40
2.3.15 Assembly Inputshaft MPG Corvette ............................................................................................................................................................................. 41
2.3.16 Assembly Inputshaft MPG Slip Yoke ............................................................................................................................................................................. 44
2.3.17 Assembly Drop Gear Housing ....................................................................................................................................................................................... 46
2.3.18 Assembly Oil Plug’s ....................................................................................................................................................................................................... 48
2.3.19 Asssembly Flange MPG ................................................................................................................................................................................................. 49
2.3.20 Assembly Splined Bush MPG Corvette .......................................................................................................................................................................... 50
2.3.21 Assembly Selector Lever ............................................................................................................................................................................................... 51
2.3.22 Assembly Reverse/Neutral Cable .................................................................................................................................................................................. 53
2.3.23 Assembly Adaptor Plate MPG Corvette ........................................................................................................................................................................ 55
2.3.24 Assembly Adaptor Differential MPG Corvette .............................................................................................................................................................. 56
2.3.25 Assembly Shift Rod ........................................................................................................................................................................................................ 58
2.6. Rotary Sensor ........................................................................................................................................................................................................................ 60
3. Gear Ratio List ............................................................................................................................................................................................................................. 62
4. Accessories .................................................................................................................................................................................................................................. 64
4.1. Bellhousings / Adaptor Plates ............................................................................................................................................................................................... 65
4.2. Gear Lever ............................................................................................................................................................................................................................. 67
4.3. DMS Gear Lever .................................................................................................................................................................................................................... 69
4.4. Gear Indicator ....................................................................................................................................................................................................................... 71
4.5. Display Unit ........................................................................................................................................................................................................................... 72
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4.6. Switchbox .............................................................................................................................................................................................................................. 73
4.7. Oil Breather Catchtank ......................................................................................................................................................................................................... 74
4.8. Paddleshift System ............................................................................................................................................................................................................... 75
5. Assembly Tooling ......................................................................................................................................................................................................................... 77
6. Contact Information .................................................................................................................................................................................................................... 79
6.1. Contact Details ...................................................................................................................................................................................................................... 80
Appendix A: Technical Bulletins ...................................................................................................................................................................................................... 81
Appendix B: Amendments ............................................................................................................................................................................................................... 83
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1. Technical Specifications
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1.1. General Specifications
MPG
Application Circuit & Hill Climb
Type 5-Speed Sequential
Torque rating 950 Nm
Weight (dry weight) 39 kg
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1.2. General Dimensions
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1.3. Oil System An internal-gear pump is fitted as standard in the end cover of the MPG. 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 1.40 Liters (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.
This manual contains three versions for the MPG:
- MPG Flange
- MPG Corvette
- MPG Slip Yoke
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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2.2.1 Bearing Assembly Endcover MPG Flange
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2.2.2 Bearing Assembly Endcover MPG Corvette
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2.2.3 Bearing Assembly Endcover MPG Slip Yoke
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2.2.4 Bearing Assembly Housing MPG
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2.2.5 Bearing Assembly Drop Gear Housing
Note: Drop Gear Housing Slip Yoke is: 35-18-0013
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2.3 Gearbox Assembly MPG
2.3.1 Assembly Rachet MPG
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2.3.2 Assembly Oilpump
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2.3.3 Assembly Layshaft
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2.3.4 Assembly Outputshaft MPG Flange & Corvette
Note: Pos 4 & 5 only needed for MPG Flange type.
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2.3.5 Assembly Outputshaft MPG Slip Yoke
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2.3.6 Assembly Shafts Endcover
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2.3.7 Assembly Selector Drum
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2.3.8 Assembly Selector Forks
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2.3.9 Assembly Reverse
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2.3.10 Assembling Housing MPG Flange/Slip Yoke
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2.3.11 Assembling Housing MPG Corvette
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2.3.12 Assembly Rotary Sensor
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2.3.13 Assembly Drop Gear
NOTE: Item 3 for Inner Track Slip Yoke version is: 35-18-0074
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2.3.14 Assembly Inputshaft MPG Flange
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2.3.15 Assembly Inputshaft MPG Corvette
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2.3.16 Assembly Inputshaft MPG Slip Yoke
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2.3.17 Assembly Drop Gear Housing
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2.3.18 Assembly Oil Plug’s
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2.3.19 Asssembly Flange MPG
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2.3.20 Assembly Splined Bush MPG Corvette
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2.3.21 Assembly Selector Lever
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2.3.22 Assembly Reverse/Neutral Cable
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2.3.23 Assembly Adaptor Plate MPG Corvette
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2.3.24 Assembly Adaptor Differential MPG Corvette
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2.3.25 Assembly Shift Rod
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2.6. 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
DG400 Output 2 White
DG450 Output 2 White
DG500 Output 2 White
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 MPG 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
3.000 2.214 1.938 1.389 1.042 1.333 0.923
3.000 2.063 1.800 1.333 1.000 1.227 0.885
2.267 1.684 1.273 0.960 1.130 0.815
1.625 1.227 0.889 1.083 0.750
1.579 1.190 0.724 1.042
1.500 1.130 1.000
1.450 1.083 0.960
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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 DG450 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. 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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4.3. 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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4.4. 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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4.5. 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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4.6. 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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4.7. 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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4.8. Paddleshift System The MPG can be equipped with a paddleshift system 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 MPG. 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:
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5. Assembly Tooling
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1
Optionally, Drenth Gearboxes provide tools which are used for assembling and disassembling the MPG. The tools listed below make it possible to perform
maintenance on the MPG:
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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
02-07-2018 66-67 Added chapter 4.1 Adaptor Plates
03-07-2018 76-77 Added chapter 4.8 Paddleshift System
04-07-2018 78-79 Added chapter 5. Assembly Tooling
18-07-2018 8 Changed oil type to Motul 75W140 Gear Competition
23-07-2018 66 Added Bellhousings to chapter 4.1
24-07-2018 6 Updated Gear Sequence to the correct model
31-10-2018 56-57 Added 37.08.0078/35.18.0.0151/152 to Slip Yoke Assembly, 35.01.0068 to MPG Flange Assembly
05-02-2019 60-68 Added Corvette Application
04-04-2019 All 3 in 1 Manual: MPG Slip Yoke, Flange and Corvette Application
13-05-2019 20 Updated Ratch carrier & Ratch
14-10-2019 61 Position Rotary Sensor added
T +31 (0)547 38 26 96 E [email protected] W www.drenth-gearboxes.com