MAINTENANCE SERVICING OF HEWLAND FT 200, FG 400, FGA
Contents
1. MAIN CASE REAR FACE H SETTING JIG STUDS a Z s 920 SPACER FOR FGB 5 SPEED AOS N WOON NN 362. illustration E p AA DIFFERENTIAL amp FINAL DRIVE PARTS LIST FT 200 INBOARD BRAKES Illustration E Mn Fe mme an mew m m9 Crown Wheel amp Pinion 9 31 FT 221A Crown Wheel amp Pinion 8 31 FT 2218 Crown Wheel amp Pinion 10 31 FT 221C Crown Wheel amp Pinion 13 36 FT 221M Side Plate FT 206B Drive Shaft H S 1300 FT 218A Drive Shaft H S C V Joint FT 2188 Drive Shaft V W C V Joint FT 218F Tab Washer FT 2212 Bolt FT 2211 Tie Bar FT 262A Nut 5 16 in UNF Nyloc FT 2013 Washer FT 2027 Screw FT 20128 Limited Slip Differential FT 212 Side Plate FT 205B Oil Seal FT 2054 Bearing FT 2053 Circlip FT2191A Spacer L H FT 2052A Spacer R H not illus FT 20624 Shim 3 5 10 15 20 thou FT 2061 Bearing FT 2051 Plunger Carrier FT 214 Inner Cam Track FT 216 Plungers FT 217 Outer Track FT 215 Outer Housing FT 213 Crown Wheel amp Pinion 7 31 221 Co 2 2 2 4 8 3 2 6 4 21 DIFFERENTIAL amp FINAL DRIVE FG 400 OUTBOARD BRAKES 26 long DIFFERENTIAL 8 FINAL DRIVE PARTS LIST FG 400 OUTBOARD BRAKES Illustration EEC Nut 7 16 in UNF Nyloc Bolt Drive Shaft 5 in p c d Nut 5 16 in UNF Nyloc Washer Side Plate Oil Seal Bearing Circlip Shim 35 10 15 25 thou Bearing Limited Slip Differential Plunger Carrier Inner Cam Track Plunger Outer Cam Track FT 2195 FT 2192 DG 219 FT 2013 FT 2027 FG 205 LG 2054 LG 2053 LG 2052 DG 2061
3. DG 2051 DG 212 DG 214 LG 216 LG 217 LG 215 6 2 6 6 2 2 2 e N man Fee Tram Ten 23 Outer Housing Side Plate Crown Wheel 8 Pinion 7 31 Crown Wheel 8 Pinion 9 31 Crown Wheel 8 Pinion 8 31 Crown Wheel amp Pinion 10 31 Tab Washer Bolt Circlip Bolt Drive Shaft HS 1400 Nut 3 B in UNF Nyloc Tie Bar Tie Bar Washer Dowel DG 213 FG 206 FG 221 FG 221A FG 221 B FG 221C FT 2212 FT 2211 LG 2191 LG 2193 DG 218 FT 2196 LG 262 DG 262 FT 2585 DG 213A N 00 On DIFFERENTIAL amp FINAL DRIVE PARTS LIST FG 400 INBOARD BRAKES Illustration G Cm ne Tram GI G2 G3 G4 G5 G6 G7 G8 G9 G1 Screw Cap 14 in UNC Oil Seal Bearing Nut 5 16 in UNF Nyloc Washer Side Plate Circlip Retaining Plate Washer Shim 3 5 10 15 20 thou Bearing Limited Slip Differential Plunger Carrier Inner Cam Track Plunger Outer Cam Track FG 2233 LG 2054 DG 2053A FT 2013 FT 2027 FG 2058 DG 2191A DG 206Al FT 2585 DG 2061 DG 2051 DG 212 DG 214 LG 216 LG 217 LG 215 ES me No e v 25 Outer Housing Side Plate Crown Wheel amp Pinion Crown Wheel amp Pinion Crown Wheel amp Pinion Crown Wheel amp Pinion Tab Washer Bolt Dowel Drive Shaft H S 1400 Drive Shaft 100 ST Drive Shaft 89 ST Drive Shaft C V Nut 3 8 in UNF Tie Bar Tie Bar 7 31 9 31 8 31 10
4. 212 Plunger Carrier TL2 214 Inner Cam Track TL2 216 Plungers thickness 3 8 in LG 217 Outer Cam Track TL2 215 Outer Housing TL2 213 Fitted as standard from gearbox number FGA 169 Illustration J 33 OIL PUMP Illustration K The oil pump is located on the end cover of the gearbox unit It is extremely strong and unlikely to suffer serious wear To Remove 1 Slacken and remove the 516 UNF nyloc end cover securing nuts 8 off Gently tap the end cover off gearbox housing Remove circlip 8 and pull off gear 7 remov ing the key on the shaft Remove the cap screws 1 and take off top cover 3 Remove both gears from housing Clean and check gears and body for possible scouring Re assemble in reverse order 34 18 Bung used when alternator drive is not required Pump Screws 2BA Pump Body Combined End Coverl Pump Cover Gear Gear key Gear Internal Circlip Gear Plug use only when Alternator not required FT 265 DG 26510 FT 2652 FT 2653 DG 2654 DG 2655 DG 2656 FT 2657 DG 2658 FT 2659 FT 26512 OIL PUMP FT amp FG illustration NI N 2 N3 N4 7 9 N11 Body Oil Pump Selector Finger Pump Cover End Key Rotor Driver Rotor Idler Body Pump Pump Cover Front Screw 4BA Gear Rotor Driver Circlip Screw 2 Nut Nyloc 5 16 in Washer 516 in Stud Short OIL EXIT FT 203P FGA6 252 FGA6 2652A
5. 31 213 FG 2068 FG 221 FG 221A FG 221 FG 221 2212 2211 213A 218A 2188 2180 218 FT 2196 LG 262 DG 262A NY o DIFFERENTIAL amp FINAL DRIVE PARTS LIST FGA Illustration H Drive Shaft 12 holes FGA 218A Plunger Carrier TL 214 Drive Shaft 100 ST FGA 2188 Inner Cam Track TL 216 Drive Shaft H S 1400 FGA 218C Plungers thickness 5 16 in TL 217 Washer FT 2585 Outer Track TL 215 Stud FGA 2012 Outer Housing TL 213 Nut 5 16 in UNF Nyloc FT 2013 Side Plate FGA 206A Washer FT 2027 Crown Wheel amp Pinion 7 31 FG 221 Side Plate FGA 205C Crown Wheel amp Pinion 9 31 FG 221A Oil Seal FT 2054 Crown Wheel amp Pinion 8 31 FG 221 B Bearing TL 2053 Crown Wheel amp Pinion 10 31 FG 221C Spacer FGA 20522 Tab Washer FT 2212 Spacer R H not illus FGA 20624 Bolt FT 2211 Shim 3 5 10 15 20 thou FT 2061 Circlip FT 2191A Bearing FT 2051 Tie Bar LG 262 Limited Slip Differential TL 212 Tie Bar DG 262A Nut 3 8 in UNF Nyloc FT 2196 8 5 0 2 2 2 8 27 DIFFERENTIAL ASSEMBLY FGB amp illustration M DIFFERENTIAL ASSEMBLY PARTS LIST FGB 8DGB Illustra tion M FGB 212 DIFFERENTIAL ASSEMBLY AS ILLUSTRATED DGB 212 DIFFERENTIAL ASSEMBLY NOT ILLUSTRATED End Plate Bolt Tab Washer Clutch Plate Belville Disc Clutch Plate Ring Side Gear Side Gear Pinion Gea
6. DG 2656 DG 2655 DG 2654 FGA6 2652 FGA6 2653 FGA 26510 FGA6 2657 DG 2656 DG 2651 FT 2013 FT 2027 20312 O c 35 Screw 2BA Washer Washer Fixed Gear Idler Oil Pump Bearing Idler Gear Shaft Idler Gear Stud long Nut Nyloc 3 B in Gear Drive Oil Pump Circlip Bearing Retaining Bearing Drive Shaft Ball Locating Drive Shaft Pump Drive Insert Layshaft Dowel FGA6 2651 FGA6 2651 FGA6 2659C FGA6 2659A FGA62659D FT 2651 OB FGA6 2026 FT 2196 FT 2659A HC9 2342 FT 2659D FT 2659E FT 2659C FT 26598 FGA6 2029A SETTING GEAR POSITIONS FOR GEARBOXES WITH ROTATING GEAR THRUST WASHER SETTING GEAR POSITIONS IN MAIN CASE Fig 4 1 With pinion set up in main case slide front hub onto pinion shaft 2 Slide spacer next to froht hub 3 With the aid of a machined straight edge check the level of the spacer relative to main case rear face If lower Use longer front hub or shim at position X X If higner proud Use shorter front hub or grind face of hub at position X X If level flush Setting is correct SETTING GEAR POSITIONS WITH SELECTOR FORK JIG 1 Using methods described above achieve spacer level with front face of bearing carrier 2 Set selector forks Notes All bearing carriers set by this method are interchangeable on main cases Clearance between fop gear thrust bearing and casting is not to a critical tolerance min 0 020 in
7. inserting bearing 42 care should be taken to ensure that the locating hole on bearing 42 is in line with bolt 33 DISMANTLING THE SUB ASSEMBLIES DIFFERENTIAL illustration D The following instructions apply to the cam and paw type differential FT 200 Gearbox 1 Bend back the tabs 18 remove the bolts 19 and take off the crown wheel 17 2 Remove in turn the outer housing 15 outer cam track 14 and inner cam track 12 3 Remove the eight plungers pawls 13 from the plunger carrier 11 4 Wash and examine for wear or damage with particular attention to and profiles of the cam tracks Ensure that 5 The splines of the inner cam track are towards the drive shaft 3 6 New bolts and tabs are used for the crown wheel Tighten with a torque spanner to 75 fe Smear bolts with locking fluid NB On reassembly use a good quality grease to lubricate the inner cam track bearing surfaces We recommend the use of Molyslip grease for this purpose Reassemble in reverse order to above FINAL DRIVE OUTBOARD BRAKES Left Hand Side Plate illustration D 1 Remove the drive shaft circlip 20 and knock out the shaft 3 2 Support the side plate on fire bricks and warm it having first covered the oil seal 6 with a block of metal for protection The outer track of the differential bearing 10 and the shims 9 should now drop out 3 Remove the large circlip 6 which retains the side
8. main case to cool 31 USING THE HEWLAND SETTING GAUGE TO CHECK PINION DEPTH 7 Put setting gauge in position in place of side plate of main case bolt across face 8 Using a feeler gauge determine the clearance between the setting gauge and the pinion The correct clearance is marked on the pinion and should be achieved using shims 7 9 When pinion clearance is correct remove old nut 5 and fit new nut Use a little Locktite and tighten to a torque of 200 ft Ibs 10 Using round nosed punch knock the grooved part of nut into the cut in thread of bearing SETTING PINION OF FGB Refer to Illustration L 1 When fitting a new pinion it is also advisable to fit a new pinion bearing 2 Press bearing 9 onto pinion shaft making sure flanged shoulder is correct way round 3 Select a shim 10 i e used undamaged shims from removed pinion Warm up outside of main case 4 Insert shim 10 in correct position and fit pinion and bearing into main case 5 Insert 6 bolts 8 with plain washers to protect magnesium face and tighten 6 Allow main case to cool 10 11 Use the Hewland setting gauge to check pinion depth as for FG400 or FGA Adjust shimming as required until correct clear ance is obtained Finally re assemble 6 bolts 8 with new tab washers and tighten Tab over washers Check the position of Hubs as this may vary with new setting of pinion as described on page 36 and adjust
9. the cam tracks 5 Assemble in reverse order making certain that splines of the inner cam track are towards the left hand drive shaft 6 Always use new bolts and tabs for crown wheel Tighten to 75 ft lbs Smear bolts with locking fluid N B On reassembly use a good quality grease to lubricate cam lobes and bearing faces Moly slip is recommended FINAL DRIVE FG 400 SIDE PLATES FOR OUTBOARD BRAKES llus 1 Remove drive shaft circlip 22 and knock out shaft 2 Support the side plate on fire bricks and warm it having first covered the oil seal 7 with a block of metal for protection The outer track of the differential bearing 11 and the shims 10 should now drop out 3 Remove the large circlip 9 which retains the side plate bearing 8 and oil seal 7 so that both can be withdrawn Re assemble in reverse order to above fitting new oil seals if necessary FINAL DRIVE 400 SIDE PLATES FOR INBOARD BRAKES llus 1 Remove drive shaft circlip 7 and knock out shaft 2 Remove six cap screws 1 from oil seal re tainer 8 and take off retainer 3 Support side plate on fire bricks and warm it The outer track of the differential bearing II the shims 10 and drive shaft bearing should now drop out Re assemble in reverse order to above fitting new oil seals if necessary FINAL DRIVE FGA illus H 1 Remove drive shaft circlip 22 and knock out shaft 2 Su
10. 12 FT 2012A FT 20128 FT 2582 FT 2581 FT 2583 FT 258 FT 259 Spring Clutch Fork Swivel Bolt Clevis Pin Pivot Washer Circlip Circlip Bearing Oil Seal Spigot state length A when ordering Screws Cap 14 in UNC Bearing Carrier state length B when ordering Bearing Clutch Shaft state engine adaptor etc when ordering Screw Retaining Split Pin Split Pin Washers Bearing Inspection Plug Washer FT 2584 FT 254 FT 256 FT 257 FT 255 FT 2551 FT 2390 FT 24410 FT 24412 FT 24411 FT 244 FT 24413 FT 245 FT 245A FT FT 2342 DG 2571 FT 2377 FT 2585 2291 TL 2011 FGB 2018 THE CASE FG 400 amp FGA FIR for Note In later gearboxes items 4 5 6 amp 7 are reversed and item 23 is omitted illustration C 12 CASE PARTS LIST FG 400 amp FGA illustration eee ee d c3 c4 c4 c5 c5 C6 c7 C8 C9 CIO 12 14 C15 CI6 CI7 Not Illus Not Illus CI8 C19 C20 21 Main Case Drain Plug Inspection Plug Bearing Inset C Bearing Inset D Nut Inset C Nut Inset D Spacer Pinion Bearing Shims Dowel Reverse Idler Complete Reverse Idler Gear Bearing Spigot Washer Nut Stud Retainer Reverse Stud Screw Stud FGA only Cylinder Nut Bolt Rod FG 201 FT 2011 TL 2011 HC8 2221 FGA 2221 HC8 2221 A FGA 2221 A HC8 2222A HC8 2222 FT 2015 FT 237 FT 2371 FT 2372 FT 2373
11. 2 FG 239 THE MAIN CASE amp DIFFERENTIAL COMPARTMENT FG 400 FGA 8 FGB Removal and Replacement of Units and Assemblies Refer to Illus DIFFERENTIAL AND DRIVE 1 Remove the slave cylinder securing bolts and washers and take off slave cylinder 18 complete with clutch push rod 2 Take off the left hand side plate having first removed the nuts and washers 5 16 in UNF and nuts 3 8 in UNF on the four tie bars Loosen with light blows from a plastic mallet and remove differential assembly 3 Remove the right hand side plate Re assemble in reverse order to above CLUTCH SHAFT 1 Slacken off the top and bottom swivel pins 25 and slide the thrust bearing 36 and carrier 35 off the end of the clutch shaft 2 Remove the clutch fork 24 after taking out the split pin and clevis pin 3 Unscrew spigot from case and remove complete assembly Alternate method without removal of spigot 3 a Remove clutch shaft circlip 29 and knock shaft out through front of spigot 4 Remove circlip 30 and knock bearing out of spigot into differential compartment Remove oil seal Reassemble in reverse order to above noting the following 5 Check spigot is tight in case 6 Fit a new oil seal 32 Renew circlips if required and pay particular attention to bearings 7 Check that the bearing carrier rotates freely after tightening down the two swivel pins 25 PINION REMOVAL To remove pinion proc
12. FT 2374 FT 2375 FT 2014 FT 2376 FT 2012A FT 20126 FGA 2012 FG 2582 FT 2581 FT 2583 LG 258 Nosepiece Spacer Pinion Head Clutch Fork Swivel Bolt Clevis Pin Pivot Washer Circlip Circlip Bearing Oil Seal Spigot state length A when ordering Bearing Carrier state length when ordering Bearing Clutch Shaft state engine adaptor etc when ordering Screw Retaining Split Pin Split Pin Washer Bearing Roll Pin reversed pinion bearing Washer FT 259 FG 2222 DG 254 FT 256 FG 257 FG 255 FT 2551 FT 2390 FT 24410 FT 24412 FT 24411 244 245 245 239 2342 2571 2377 2585 2291 2222 FGB 2018 GEARBOX COMPONENTS FGB illustration L 14 GEARBOX COMPONENTS PARTS LIST FGB Illus No LI Illustaton L Main Case Washer Oil Feed Plug Dowel Oil Union Crown Wheel amp Pinion 8 31 Crown Wheel amp Pinion 8 35 Tab Washer Bolt Pinion Bearing Shim various sizes Hub Rear Inner Track Nut Pinion LH Bearing Carrier Clutch Shaft Note State engine adaptor etc when ordering FGB 201 FGB 2018 FGB 2017 FT 2031 FGB 2015 FGB 221 B FGB 221D TL2 2233 TL 2251 TL2 2221 FGB 2232 FGB 228 FGB 229 FGA6 230 FGB 202 FGB 239 15 Replaces Parts on FGA No FG 201 TL 2011 FT 2015 FG 221 B FG 221D FGA 2221 HC8 2222 FG 228 FT 229 FT 2294 FT 230 FT 20
13. MAINTENANCE SERVICING OF HEWLAND FT 200 FG 400 FGA amp FGB TRANSAXLE GEARBOX UNITS X HEWLAND ENGINEERING LTD WALTHAM White WALTHAM MAIDENHEAD BERKSHIRE 6 TEL 44 0 1628 827600 Fax 44 0 1628 829706 e mail technicalahewland engineering co uk CONTENTS GENERAL NOTES GEARBOX UNIT amp Removing the Unit Changing Gear Ratios Gear Train Disassembly Setting up the Selector Forks MAIN CASE amp DIFFERENTIAL COMPARTMENT FT200 Differential amp Drive Clutch Shaft Pinion Removal Layshaft Bearing DISMANTLING Differential Final Drive Outboard Brakes Final Drive Inboard Brakes S e MAIN CASE amp DIFFERENTIAL COMPARTMENT FGA00 FGA amp FGB Differential amp Drive Clutch Shaft Pinion Removal Layshaft Bearing DISMANTLING THESUB ASSEMBLIES Differential Final Drive FG400 Side Plates for Outboard Brakes Final Drive FG400 Side Plates for Inboard Brakes Final Drive FGA SETTING UPCROWN WHEEL PINION Setting Pinion of FT200 Using Hewland Setting Gauge to Check Pinion Depth Setting Pinion of FG400 FGA Using Hewland Setting Guage to Check Pinion Depth Setting Pinion of FGB Adjusting Pre load of Differential FT200 FGA amp FGB Page OO CO OO P Q P c 18 18 18 18 17 17 17 17 17 31 31 31 31 31 31 32 Adjusting the Backlash 200 Oil Pump Removal 8 Re assembly
14. SETTING GEAR POSITIONS FOR GEARBOXES WITH ROTATING TOP GEAR THRUST WASHER Setting Gear Positions in Main Case Setting Gear Positions with Selector Fork Jig ILLUSTRATIONS Gearbox Unit FT200 FG400 amp FGA Main Case amp Differential Compartment FT200 MainCase FG400 amp FGA Gearbox Components FGB E A h Ee EL TS EUM DES D Differential amp Final Drive FT200 Outboard Brakes Differential amp Final Drive FT200 Inboard Brakes Differential amp Final Drive FG400 Outboard Brakes Differential 8 Final Drive FG400 Inboard Brakes Differential 8 Final Drive Differential Assembly FGB 8 Alternative Differential FGA b zs Eug 5 2 E 64 cue de Bee eS Oil Pump FT amp FG INSET ILLUSTRATIONS Hewland Forksetting Jig Using Dial Gauge to Measure Backlash Hewland Pinion Depth Setting Gauge Setting Gear Position in Main Case Selector Fork Jig Page 32 34 38 38 38 10 12 14 18 20 22 24 26 28 33 34 35 30 30 36 FT200 FG400 FGA 8 TRANSAXLE GEARBOX UNITS GENERAL NOTES ON MAINTENANCE AND OVERHAUL Only genuine Hewland spares should be used as TORQUE SETTINGS replacements These are manufactured in our own workshops to the fine tolerances necessary and Pinion Nut L H 2 s s 719 ftllbs rigorously inspected and tested Layshaft Nut RH _ 80 165 Crownwhee
15. ase to cool USING THE HEWLAND SETTING GAUGE TO CHECK PINION DEPTH 7 Place setting gauge in position in place of side plate of main case Bolt across face 8 Using a feeler gauge determine the clearance between the setting gauge and the pinion The correct clearance is marked on the pinion and should be achieved using shims 5 9 When pinion clearance is correct remove clamp bolts 3 put on clamp plate tab washers 4 smear Locktite on threads re fit bolts 3 and tighten into clamp plate 7 Knock ever tab washers SETTING PINION OF FG400 8 FGA Refer to Illustration 1 When fitting a new pinion it is also advisable to fit a new pinion bearing All FGA gearboxes are fitted with a larger pinion bearing 4 FGA2221 and to some FG 400 gear boxes up to 1976 The pinion bearing is fitted re versed in some FG gearbox main cases prior to 1976 and in all FG gearboxes subsequently When separating the pinion from the main case make special note of order and location of pinion bearing shims and any spacers that might be present to ensure correct re assembly 2 Press bearing 4 onto pinion shaft ensuring flanged shoulder is correct way round 3 Select shim 7 ie used shims from removed pinion Warm up the outside of main case 4 Insert shim 7 in correct position and fit pinion and bearing into the main case 5 Using old nut 5 and spacer 6 if fitted lock bearing into main case 6 Allow
16. eed as follows 1 Remove bearing retaining nut 5 2 Warm up outside area of main case sufficiently to remove pinion bearing 3 Particular attention should be given to the shims under pinion bearing 16 LAYSHAFT BEARING 1 To remove the layshaft bearing first remove the reverse idler gear by taking out the split pin 40 from the castellated nut 14 remove nut and washer Check gear and bearing for wear 2 Remove the locating bolt 38 on under side of the main case Warm up the main case surround ing the bearing area until sufficiently warm to allow bearing to be lightly tapped out 3 Remove all drain plugs Wash out the main case to remove any sludge 4 Warm up main case and re assemble in reverse order When inserting bearing 42 care should be taken to ensure that the locating hole on bearing is in line with bolt DISMANTLING THE SUB ASSEMBLIES Refer to Illustrations F G orH DIFFERENTIAL The following are general instructions that cover the cam and pawl type differential Minor differences do however occur between FG 400 and FGA gearboxes Reference to parts list may be required 1 Bend back the tabs 20 remove the bolts 21 take off crown wheel 19 2 Remove in turn the outer housing 17 outer and inner cam tracks 16 14 3 Remove the eight plungers pawls 15 from the plunger carrier 13 4 Wash and examine for wear or damage with particular attention to pawls and profiles of
17. en changing a gear ratio take off the slackened layshaft nut and remove the layshaft from the bearing carrier Gears are exchanged in pairs one from the layshaft and one from the pinion shaft Each gear is etched with two sets of numbers It is essential that gears should be correctly paired according to these numbers GEAR TRAIN DISASSEMBLY 1 Remove hubs clutch rings and gears Wash and inspect for wear and cracks particularly to the clutch rings 2 Examine forks for heavy or uneven wear and test for excessive play between forks and clutch rings 3 If forks are not to be dismantled check that self locking nuts are tight Continue disassembly as follows To Remove Selector Finger Housing 5 4 Remove selector finger housing as follows 1 Remove bung spring and plunger 18 19 20 from the selector finger housing and withdraw selector finger 35 2 Slacken and remove UNC Allen cap screw 5 16 In 3 Slacken and remove UNF Nyloc nut inside housing 5 16 in 51 5 Remove gasket from bearing carrier 6 To remove forks remove nut 50 Remove all three sets and lift off forks 47 46 48 7 Slacken and remove all three cap screws 40 and take out the top selector rod springs and balls 38 amp 39 Then take out the three selector rods one at a time collecting the bottom balls and springs 8 Remove the UNC cap screw 3 8 in and push out the locking slugs 41 9 Inspect pinion and la
18. ews 34 Tap out complete clutch shaft assembly 4 Remove circlip 29 from clutch shaft press out clutch shaft Remove circlip 30 from spigot housing 33 and withdraw bearing and oil seal Re assemble in reverse order to above noting the following 5 Fit a new oil seal 32 Replace circlips if re quired and pay particular attention to bearings 6 When bolting the spigot to its housing put a smear of locking fluid on the three cap screws and jointing compound on spigot face 7 Check that the bearing carrier rotates freely after tightening down the two swivel pins 25 PINION REMOVAL To remove the pinion proceed as follows 1 Knock back tab washers 4 and remove bolts 3 2 Remove clamp plate 7 3 Warm up outside area of main case sufficiently to remove pinion bearing 4 Particular attention should be given to the shim or shims under pinion bearing LAYSHAFT BEARING 1 To remove the layshaft bearing first remove the reverse idler gear by taking out the split pin 40 from the castellated nut 14 Check the gear and bearing for wear and re assemble in the reverse order Remove the locating bolt 38 on under side of the main case Warm up the main case surround ing the bearing area until sufficiently watm to allow the end bearing to be lightly tapped out Remove all drain plugs Wash out the main case to remove any sludge Warm up main case and re assemble in reverse order When
19. ghten the pinion nut Then check for correct clearance on top gear 008 in to 010 in For FGB see page 31 5 Remove from jig Fit selector forks to rods together with nuts and washers 6 Build up the hubs gears and clutch rings and slide them back on to the setting jig 7 Adjust the forks individually Correct positioning requires that aThe clutch ring should be centred on its hub between the two gears b The clutch ring should engage fully with either gear Fig 1 Hewland Forksetting Jig c When fully engaged with either gear there should still be 0 005 in clearance between the gear and clutch ring faces d If clutch ring is over engaged it could result in gears overheating and seizing up or cause excessive wear on selector fork 8 Tighten all three selector rods using new nuts and tabs at the same time make sure that the selector rod heads are correctly aligned and that there is clearance between them but not excessive Remove From Jig 9 Warm up surrounding area and fit layshaft bearing Build up the complete layshaft assembly with gears spacers and thrust washer Replace in bearing carrier 10 Put the complete assembly back into the jig Re check all clearances Test all movements When satisfied remove the assembly from jig and bolt it into the gearbox using a jointing compound 11 Tighten the nyloc nuts around the bearing carrier Replace nuts on pinion layshaft and tighten to
20. if reguired ADJUSTING PRE LOAD OF DIFFERENTIAL FT200 FG400 FGA FGB Although differences exist between the method of retaining the drive shaft bearing in the side plate the method of setting the crown wheel up is the same in all cases Assemble the drive shaft bearings in the side plates where they take the differential thrust FT inboard FGA together with spacers With other gearboxes this can be accomplished at a later stage Assemble differential unit and fit crown wheel Use solid dummy bearings in place of the two differential taper bearings The thickness of shims is critical If they have to be replaced make sure it is with shims of the same thickness Fit the differential unit and side plates to the main case Bolt up including tie bars to normal tension 9 Turn the pinion shaft by hand to test the pre load Adjust by means of shims until satisfactory Turn the pinion with hubs removed Using reasonable effort it should be possible to turn it by gripping the splines by hand but more effort will be needed with dummy bearings than with real ones Make sure there is some evidence of backlash Absence of backlash will give a false impression of pre load TO ADJUST THE BACKLASH For this operation you will reguire a post mounted dial indicator with an extended probe Fig 2 page 30 1 Remove the solid dummy bearings from the differential unit and replace them with dummy bearings Real bea
21. l Bolts 75ft llbs New nuts circlips oil seals and gaskets should always All 5 16 in UNF Nuts 20 ft ibs be used on re assembly When warming the casings keep the blow lamp moving Test with a spot of moisture which will bounce off at correct temperature Do not overheat Oil Capacity 1 75 litres Type of Oil SAE 80 or 90 SAE 80 or 90 SAE 80 or 90 SAE 80 or 90 Notes Oil capacity given for transmission without oil cooler etc THE GEARBOX UNIT FT 8 REMOVING THE UNIT Refer to Illustration End Cover 1 Remove the UNF Nyloc nuts 1 and washers 2 securing the end cover Take off cover and gasket Remove the split pins from the castellated pinion and layshaft nuts Push the heads of the two outside selector rods thus engaging the gears This locks the gear box by engaging 2 gears Remove the pinion nut left hand thread and slacken off the layshaft nut conventional right hand thread Now withdraw the two outside selector rods to disengage the gears Bearing Carrier 1 Remove the bearing carrier securing nuts and washers 5 i6UNF Using a plastic mallet tap the bearing carrier and remove it from the main case complete with lay shaft assembly and gear train Support the gears hubs and clutch rings with the hand as they slide off the pinion The gearbox unit is now completely removed To re fit assemble in reverse order to above CHANGING GEAR RATIOS Wh
22. plate bearing 7 and oil seal 6 so that both can be withdrawn Right Hand Side Plate Follow the same procedure as above Reassemble in reverse order to above fitting new oil seals if necessary FINAL DRIVE INBOARD BRAKES Left Hand Side Plate illustration E 1 Remove the drive shaft circlip 4 and knock out shaft 2 Support the side plate on fire bricks and warm it having first covered the oil seal 2 with a block of metal for protection The outer track of the differential bearing 7 the shims 6 the spacer 5 and the drive shaft bearing 3 should now drop out Right Hand Side Plate Follow same procedure as above Re assamble in reverse order to above fitting new oil seals if necessary THE MAIN CASE amp DIFFERENTIAL COMPARTMENT FT 200 See 017 for part numbers and ratios illustration 19 MAIN CASE PARTS LIST FT 200 illustration BI B10 12 B13 B14 B15 B16 B17 B17 Not illus B18 B19 321 Main Case Drain Plug Bolt 5 16 in UNF Tab Washer Shims 3 5 10 15 25 Thou Bearing Clamp Plate Dowel Reverse Idler Complete Reverse Idler Gear Bearing Spigot Washer Nut Studs Retainer Reverse Stud outboard brakes Stud inboard brakes Screw inboard brakes Cylinder Nut Bolt Rod Nosepiece FT 201 FT 2011 FT 2251 FT 2252 FT 2253 FT 2221 FT 225 FT 2015 FT 237 FT 237 1 FT 2372 FT 2373 FT 2374 FT 2375 FT 2014 FT 2376 FT 20
23. pport the side plate on fire bricks and warm it having first covered the oil seal 7 with a block of metal for protection The outer track of the differential bearing 1 the shims 10 the spacer 9 and the drive shaft bearing should drop out Re assemble in reverse order to above fitting new oil seals if necessary DIFFERENTIAL amp FINAL DRIVE FT 200 OUTBOARD BRAKES 16 right hand 7 fifustration 2 18 DIFFERENTIAL 8 FINAL DRIVE PARTS LIST FT 200 OUTBOARD Illustration D BET ww ser Nut 7 16 in UNF Nyloc FT 2195 Bolt Drive Shaft 5 in p c d FT 2192 Bolt Drive Shaft 4 7 16 in p c d FT 2192A Drive Shaft 514 in p c d FT 219 Drive Shaft 4 7 16 in p c d FT 219A Nut 5 16 in UNF Nyloc FT 2013 Side Plate FT 205 Oil Seal FT 2054 Bearing FT 2053 Circlip FT 2052 Shims 3 5 10 15 20 FT 2061 Bearing FT 2051 Plunger Carrier FT214 inner Cam Track FT 216 Plungers FT 217 Outer Cam Track FT 215 Outer Housing FT 213 Side Plate FT 206 Crown Wheel amp Pinion 7 FT 221 Crown Wheel amp Pinion 9 FT 221A Crown Wheel amp Pinion 8 FT 221B Crown Wheel amp Pinion FT 221C Crown Wheel amp Pinion 13 FT 221M Tab Washer FT 2212 Bolt FT 2211 Circlip FT 2191 Limited Slip Differential FT 212 Drive Shaft H S 1300 FT 218 Bolt FT 2193 Nut 3 8 in UNF Nyloc FT 2196 Washer FT 2027 Tie Bar FT 262 r5 CG
24. r Differential Case Screw FGB 214 FGB 2211 FT 2212 LG 2139 LG 2138 LG 21310 FGB 2137 TL2 2136 LG 2135 FGB213 FGB 21312 29 End Plate Bolt Tab Washer Clutch Plate Belville Disc Clutch Plate Ring Side Gear Side Gear Pinion Gear Differential Case Screw DGB 214 FGB 2211 FT 2212 LG 2139 LG 2138 LG 21310 FGB 2137 LG 2136 LG 2135 DGB 213 FGB 21312 P N N N L N e Fig 2 Using the Dial Recording Micrometer to measure backlash Fig 3 Hewland Setting Gauge in Position SETTING UP THE CROWN WHEEL amp Crown wheel and pinion sets are supplied as matched and lapped pairs tested and passed before leaving the factory and therefore should only be fitted to run as a pair marked with a number on each part Setting up is possible with the use of engineers blue but the faster and more positive method is to use a Hewland pinion depth gauge Procedure is as follows SETTING PINION ON FT 200 Refer to illustration B 1 When fitting a new pinion it is also advisable to fit a new pinion bearing 6 2 Press bearing 6 onto pinion shaft ensuring flanged shoulder is correct way round 3 Select a shim 5 i e used undamaged shims from removed pinion Warm up the outside of main case 4 Insert shim in correct position and drop pinion and bearing into the main case 5 Fit clamp plate 7 insert four bolts 3 tighten into clamp plate 6 Allow main c
25. ring with increased tolerances for easy substitution 2 Insert the probe of the dial indicator through spigot housing until it touches one of the teeth of the crown wheel Note the reading on the dial indicator Turn pinion by hand to rotate crown wheel and take at least 12 readings 14 readings are standard practice in our workshops Mini mum reading should be 004 in 3 To increase or decrease backlash change shims from one side of differential to the other but remember that once the pre load has been set you can use only the shims that are already there 32 Re assemble as follows 4 Press inner bearings onto differential assembly 5 Warm up one side plate FT outboard FG 400 and fit oil seal drive shaft bearing and circlip or plate 6 Press the drive shaft into the bearing and retain with circlip 7 Insert shim or shims and bearing outer track Place heavy weight on bearing track to flatten shimming Allow to cool 8 Repeat for other side plate After cooling assemble one side to the main case Complete the assembly of the differential and drive unit as described above N B If renewing the differential bearings make certain that the width of the new bearings also when using dummy bearings are the same as old bearings being replaced Any differences must be adjusted in final shimming ALTERNATIVE DIFFERENTIAL FCA Illus No Description Part No Qty Limited Slip Differential TL2
26. the correct torque See note Put in split pins 12 Replace the selector finger housing and selector finger renewing gasket 6 Fit new gasket 4 and replace the end cover Note The correct torque is 115 ftllbs for pinion nut and 80 ftllbs for nut THE GEARBOX UNIT FT 200 FG 400 8 NIE SEE GEAR RATIO CHART SUPPLIED ON REQUEST dL QU END illustration GEARBOX UNIT PARTS LIST ee Te RAT s e Clutch Ring FG FGA DG 232 Nut 5 16 in UNF Nyloc FT 2013 Washer 5 16 in Chamfered flat End Cover Standard Gasket End Cover Selector Finger Housing Gasket Selector Finger Housing Nut Layshaft R H Split Pin Bearing Layshaft Stud Screw Bearing Retaining Bearing Carrier Screw Spring Ball Plunger Spring Plug Thrust Washer Spacer Layshaft see ratio chart Bearing First and Reverse Sliding Gear Hub Front FT only Hub Front Length 3 1 16in Hub Front Length 2 15 16 Needle Bearing Clutch Ring FT only FT 2027 FT 204 FT 260 FT 203 FT 261 FT 236 FT 2301 FT 2343 FT 2026 FT 2293 FT 202 FT 2026 FT 2034 FT 2033 FT 2030 FT 2032 FT 2035 FT 2345 FT 2346 FT 234 FT 2291 FT 231 FT 226 FG 226 FGA226 FT 2261 FT 232 Hub Centre FT only Hub Centre FG FGA Hub Rear FT only Hub Rear FG FGA Inner Track 5th Gear Thrust Washer Stud Nut Pinion L H Selector Finger Bush 0 Ring Spring Ball Scre
27. w Plunger Screw not illus Selector Rod 1stlRev Selector Rod 2ndl3rd Selector Rod 4thl5th Selector Fork Ist Rev Selector Fork 2ndl3rd Selector Fork 4th 5th Nut Screw Spacer Plate Screw Spacer various sizes FT 227 FG 227 FT 228 FG 228 FT 229 FT 2294 FT 2025 FT 230 FT 252 FT 2036 FT 2037 FT 2022 FT 2021 FT 2023 FT 2024 FT 2031 FT 246 FT 247 FT 248 FT 249 FT 250 FT 251 FT 2462 FT20311 FT20310 FT 2030 FT 2039 FT 2463 WOOD gt INO Oo P gt gt THE MAIN CASE amp DIFFERENTIAL COMPARTMENT FT 200 Removal and replacement of units and assemblies Refer to Illustration 5 DIFFERENTIAL AND DRIVE 1 Remove the slave cylinder securing bolts and washers and take off cylinder 18 complete with clutch push rod unhook spring attached to side plare 2 Take off the left hand side plate having first removed the UNF Nyloc nuts and washers and UNF nuts 5 16in on the tie bars Loosen with light blows from a plastic mallet and remove differential assembly 3 Remove the right hand side plate Re assemble in reverse order to above CLUTCH SHAFT 1 Slacken the top and bottom swivel pins 25 and slide off the thrust bearing 36 and bearing carrier 35 from the end of the clutch shaft 2 Remove the clutch fork split pin 39 and clevis pin 26 and detach clutch fork 24 3 Remove the cap scr
28. yshaft tail bearings and re new if necessary To remove warm up surround area Bearings are located by cap screws 13 Re assemble in reverse order to above noting the following 10 When replacing bottom balls and springs set up to correct height About one third of the balls should be exposed Continue by inserting locking slugs and selector rods then top balls and springs 11 Any hub replaced should be identical in length with the original If replacing all hubs or main bearing carrier check that overall length of pinion assembly has not been altered Clearance is essential to avoid overheating and seizure but too much clearance will cause excessive wear See Setting the Selector Forks page 5 para4 THE GEARBOX UNIT continued SETTING UP THE SELECTOR FORKS Extreme accuracy in setting up is imperative to ensure that gears engage freely and to avoid uneven or excessive wear The use of a Hewland Forksetting Jig is strongly recommended Designed specifically for FT FGT will save costly setting up time and vastly reduce the possibility of error Fig 1 Note that when two layshaft gears run together their chamfered sides must face each other see diagram 1 Warm the bearing carrier and drop in the pinion tail bearing as described above 2 Place the jig in a vice Slide the hubs with top gear and thrust washer on to the dummy pinion 3 Attach the bearing carrier to the jig using temporary nuts 4 Ti
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