GTR GEARBOX SERVICE MANUAL
Contents
1. NOTE It may be helpful to try and support the pin on the under side to remove the Circlip Washer Rollers from the top If the gearbox is being completely disassembled do not worry if the parts fall into the gear train so long as they are retrieved after the Maincase is removed Now remove the Spiral Actuator Remove the Maincase from the Sandwich plate To do this you must first remove 2 x M8 Capscrews from the rear of Sandwich Plate HOLINGER 9 ENGINEERING It is desirable to now hold support the gearbox in a vertical position with the Sandwich Plate bolted to a solid fixture This allows the Maincase to be easily removed Tap the Maincase gently away from the Sandwich Plate to expose the forward Gear Train You can now remove all the parts starting with the Input Shaft then the Layshaft the Mainshaft and Selector Forks Rods Whilst not totally necessary the Spiral Actuator can be removed by knocking out the Roll Pin in the sleeve on the rear side of the Sandwich Plate NOTE It is best to support the Rod in a Vice close to the pin you are removing Do not strike the rod if only supported by the Sandwich Plate as this maybe damage the bore the Rod Slides in THOROUGHLY INSPECT AND CLEAN ALL PARTS HOLINGER 10 ENGINEERING RE ASSEMBLY NOTE Before commencing ensure all parts are clean and that all worn parts have been replaced with new ones It is best to begin by bolting the sandwich plat2. Now the cast Rear Cover can be placed over the plungers Make sure it is sealed with an appropriate sealer Now return to the front of the Gearbox Make sure the correct Endfloat Shims are placed in front of the appropriate shaft bearings then install the Bellhousing Ensure the Cam Bearing has not fallen out and that the detent plunger is removed HOLINGER ENGINEERING 17 The Bellhousing must be sealed with an appropriate sealant all the way around the edges along with the internal M8 bolts Finally secure the housing with the external Studs Nuts and Washers NOTE If installing a new Camshaft or Bearing the Shim underneath the bearing may need to be adjusted Please contact Holinger directly to receive proper instruction on how to calculate the required thickness Finally install the Detent Plunger Spring Cap and Gear Position Potentiometer Detent Plunger Ensure the plunger is inserted with the guiding slot aligned with the roll pin in the bore The blackened cap that retaines the plunger and spring must also be set to the appropriate depth and sealed with Loctite 243 Blue Do this by first inserting the plunger and spring and then wind the plug into a depth that still exposes several threads Push the Gear Change Rod forwards twice to engage 2nd gear and then backwards once to engage 1st again you may need to turn the input shaft to do this You need to be able to change between 1st and 2nd gear by pulling back o
3. HOLINGER NEERING GTR GEARBOX SERVICE MANUAL 2012 12 14 Southfork Drive Kilsyth Vic 3137 Australia Phone 61 3 9761 7964 Fax 61 3 9761 7965 Email info holinger com au Web www holinger com au 6 SPEED SEQUENTIAL GEARBOX Foreword The Holinger GTR is a sequential shift dog change gearbox designed for use in the R32 and R33 Nissan Skyline GTR and is suitable for all types of racing The gearbox is fitted with 6 forward gears and a reverse gear and shifting is performed via the original gear lever These transmissions are used with great success in cars with more than 1000hp in drag racing applications Features e The gearbox is designed to bolt directly to the Nissan RB Series engine at the front and standard Nissan R32 R33 transfer case at the rear e The gearbox is fitted with 6 forward gears and a reverse gear It is available with a 1 1 6th gear or with an overdrive 6th gear e All gears are removable from shafts with an extensive range of ratios available e Gear engagement is performed by non synchronised face dogs e Gear change is performed by using the standard Nissan gear lever and mechanism e The gear lever is pulled back for up changes and pushed forward for down changes e Neutral is selected from 1st gear position by moving the gear lever to the left and forward e Reverse is selected from the neutral position by pushing the gear lever forward From reverse gear neutral is selected
4. the reverse gear The Layshaft Bolt can be secured only with Lock Wire Tighten to 35 Ibs ft 50 N m NOTE Ensure that the Gear and Washer are placed in a way that allows the Lock Wire to be installed so that it is in TENSION if the Nut Bolt try to loosen Insert Roll Pins into the components requiring them Install the Reverse Idler Gear Lever and Rod End Ensure sealant is placed under Blackened Washer retaining the Reverse Lever Ensure Loctite 243 Blue is used on the bolt securing the Reverse Idler Spindle HOLINGER ENGINEERING 15 Fit the detent balls and springs then the Blackened Plates Seal with an appropriate sealant Fit the Pawls Springs and Camshaft Shim gt NOTE If installing a new Camshaft or Bearing the Shim underneath it may need to be adjusted Please contact Holinger directly to receive proper instruction on how to calculate the required thickness HOLINGER 16 ENGINEERING Insert the plungers into the rear of the Gearbox and seal the Black Plugs with Loctite 243 blue NOTE The Plunger on the Left Hand Side of the picture is sprung loaded Before the Loctite sets adjust the Sprung loaded Plug on the LHS of the pictures so that the neutral Latch just clears the Camshaft when the gear Change Rod is turned Clockwise to it s extremity Use feeler gauges if necessary and set the clearance to about 0 020 0 5mm a F
5. the Bearing End Float HOLINGER ENGINEERING 12 By using a Dial Indicator under the Main and Layshafts then applying an appropriate amount of force to move them up and down you can check the End Float t f moa The correct End Float setting for the GTR gearbox is Mainshaft 0 000 Layshaft 0 000 You may need to install wider shims to achieve this in a used Gearbox Once the correct End Float has been achieved you can remove the Bellhousing NOTE If you haven t already install the M8 Cap Screws that secure the Maincase and Sandwich Plate together INSTALL THESE CAP SCREWS HOLINGER 13 ENGINEERING Install the Gasket then the 1 and 2 Gears Spacers Sleeves along with the Selector Ring Hub and Rod Fork Also install the spring spacers and rod guide if necessary Now install the Rear Case Whilst installing the Rear Case the Gear Lever Rod must be connected to the Intermediate Rod by the use of the Rod Connector then the Neutral Actuator must slide over the connector The Striker must also be placed onto the Neutral Latch Rod whilst sliding the Rear Case Forward HOLINGER ENGINEERING 14 Secure the case with M8 Nuts and Washers The Reverse Gears can now be fitted to the Main and Layshafts and the nut bolt tightened The Mainshaft Nut can be secured with Loctite 263 red Tighten to 110 Ibs ft 150 N m Lock wire the nut to
6. ING Holinger Engineering has been designing and manufacturing high precision components for motor racing for decades Specialising in transmissions we manufacture a range of gearboxes and associated products from stand alone bespoke designs right through to gear sets for existing production cars Our gearboxes can be found in a wide range of international classes from GT racing right through to cross country rallying We supply several categories with control gearboxes as well as featuring heavily in open classes Some of our customers include Porsche Ford GM Ralliart Lamborghini Aston Martin and BMW plus many other private teams and racers Our products have survived some of the toughest endurance events in the world including the Le Mans Spa and Nurburgring 24 hour races the Bathurst 1000 and the Dakar Rally WHY CHOOSE HOLINGER Product Longevity Holinger Racing Transmissions are truly world class ultra reliable and user friendly We have many customers that have enjoyed years of reliable service from their Holinger gearboxes many of which have done so after enduring prolonged frustration and on going cost from inferior brands Ease of maintenance All of our gearboxes are designed to be easily worked on with regular workshop tools So servicing can be easily performed wherever and whenever the need arises Parts backup Holinger prides itself in producing gearboxes with a very lon
7. ated on the left hand side of the gearbox can also be used as an oil level check hole The oil level may change after running and should be re checked to ensure it is correct The gear oil should be inspected regularly to quickly evaluate the gearbox condition If oil condition looks overly metallic in appearance further inspection of the gearbox should be conducted HOLINGER 4 ENGINEERING If you do not have an assembly drawing of the GTR gearbox please contact Holinger Engineering to obtain one DISASSEMBLY NOTE The first thing to do before commencing any work on the Holinger GTR Gearbox is to place it in the Neutral gear position The Gearbox Bellhousing needs to be removed to expose the camshaft mechanism before any other work can be carried out Begin by removing the 4 x M12 nuts Washers Then remove the Detent plunger and Spring which is located on the upper left side of the Bellhousing under the black plug Then remove the Potentiometer its Drive Adaptor and Spring Finally the 6 x M8 Bolts Washers HOLINGER 5 ENGINEERING Lightly tap the Bellhousing away from the gearbox and remove it to expose the Camshaft mechanism and front Bearings Knock the Rollpins out from the 3 4 and Reverse Cam Followers and remove them from the selector rods You can now also remove the Circlip Washer Spring from the Neutral Lockout Latch Remove the Camshaft by pulling it away from the rest of the gearbo
8. by pulling the gear lever back and 1st is selected by pulling the gear lever back again e This system prevents neutral or reverse being accidentally selected when in the forward gear pattern e A gear position sensor is supplied for interfacing with an electronic dash display Alternatively a stand alone gear indicator display is available for cars not fitted with an electronic dash e Case hardened nickel chrome steel is used for all gears and shafts e The selector forks are aluminium bronze e Casings are sandcast Aluminium alloy heat treated to T6 specifications e Clutch splines are normally 1 1 8 x 26 24 48DP 30 deg P A but can be ordered with standard Nissan splines e The gearbox weight is 46kgs 102lbs HOLINGER 1 ENGINEERING CONTENTS CHANGIN O GEAR ereraa E E E E N N 3 MAINSHAFT LAYSHAFT BEARING END FLOAT ccccccccsssccccccsceseccccescusecsseeeucecseeseessecsseueuscecsseueuncesseeuuucesseeuenscsss 4 EEN Cho T 4 LUBRICATION SEE SEE 4 eee 5 RER EMIGI SEES ES DEER DE SEE T E E E E E E 11 CFR 19 HOLINGER 2 ENGINEERING CHANGING GEARS Changing gears with a Holinger GTR is performed via the standard Nissan Gear Lever Shifting between gears is achieved by moving the gear lever forward a
9. e onto a fixture supported vertically in a vice or similar Insert the Mainshaft assembly into the Sandwich Plate along with the 3 4 Rod Fork Insert the Reverse Selector Rod into the Sandwich Plate and align the Reverse Selector Rod Guide with the 5th 6th rod hole Now Place the 5 6 Selector Ring Rod into the assembly Install the Layshaft HOLINGER 11 ENGINEERING If the Spiral Actuator was removed previously it is easiest to install that and the pawl carrier now v 9 ae ka 21 Place a new Gasket onto the Sandwich Plate then lower the Maincase over the assembly Lightly tap it home with a soft hammer ensuring it goes on square and even onto the locating Dowels NOTE The Bearing Inner Races for both the Input Shaft and Layshaft should be tapped forward slightly from their original location after disassembly This allows you to reset the Bearing Endfloat correctly during re assembly Clamp the Sandwich Plate and Maincase together in at least 6 evenly spaced places and install the Endfloat Shims above the Input and Layshaft bearings Now you will need to install the Bellhousing purely as a Bearing Setting aid so this should be done without the use of sealant and without all the final parts Tighten the 6 inner M8 bolts on the Bellhousing so that it is flush with the Maincase NOTE Make sure you tighten the bolts gradually to ensure the bearings are clamped evenly Now you can check
10. g service life and we will always continue to support our classic gearboxes and kits This means that our customers have the peace of mind that they can always source genuine Holinger parts We have supplied reliable winning transmissions to many categories and classes around the world Some of our most recent projects include V8 Supercars Australia 2008 Current Control Transmission Porsche Cup 2005 Current Global Control Transmission International FIA GT Championships with victories in 2011 The Dakar Rally including the T1 class victory in 2009 The Australasian Safari 1st Outright in 2008 2009 2010 and 2011 Australian Rally Championship 1st Outright 2011 Australian Tarmac Rally Championship 1st Outright 2010 ALMS American Le Mans Series plus many others HOLINGER ENGINEERING
11. nce and then forward once repeatedly You may need to turn the input shaft a small amount initially but should be able to simply go back and forward when the dogs are aligned Wind the Plug deeper into the Bellhousing until you cannot change gears smoothly Find the point where shifting is still smooth and wind the plug back one full turn The plunger depth is now set Shift back and forward between all the gears to shift from 1st to neutral rotate the gear change rod all the way clockwise and pull back including reverse Shifting should be positive smooth and consistent throughout all the gears Finally place the gearbox in 3rd gear and install the Gear Position Potentiometer into the end of the Camshaft Roughly align the dot on the potentiometers spindle with the red wire in its body Plug in the dash mounted gear indicator and make sure it has power Shift through all the gears and check that the display is correct HOLINGER 18 ENGINEERING O ml x N N N N N N a 1562 1 555 ara 1465 1207 1251 1 946 1202 1298 0 2 3 1 548 1 531 1 474 1 417 1 407 1 353 1 299 1 204 1 242 1 190 na 28 1510 f 146s 1407 1 507 1 349 1 29 1182 5 N X N a N X N sj N N R b r bar N N a BY ejeje 1 285 M S LAY SHAFT GEAR INPUT SHAFT GEAR L S GEAR RATI ENGINEERING HOLINGER HOLINGER ENGINEER
12. nd backward in a straight line One movement in either direction corresponds to one gear change in sequence from Reverse Neutral 1st 2nd 3rd 4th 5th 6th and back To shift up a gear simply pull back firmly on the gear lever until it stops then release it allowing it to spring back to the central home position To shift down a gear simply push forward firmly on the gear lever until it stops then release it allowing it to spring back to the central home position To avoid selecting Neutral or Reverse at an unwanted time a Lock Out system has been incorporated To shift from 1st Gear into Neutral push the gear lever all the way to the left and then push forward once From this position the driver can select Reverse Gear with a single down change or 1st gear with a single up change as per normal HOLINGER 3 ENGINEERING MAINSHAFT LAYSHAFT BEARING END FLOAT 0 000 0 00mm TORQUE SETTINGS Mainshaft Nut 110lbs ft 150 N m Layshaft Nut 45 Ibs ft 60 N m Layshaft Bolt 35 Ibs ft 48 N m Drain and Filler plugs 60 Ibs ft 80 N m Front Cover bolts M8 Nuts 20 Ibs ft 27 N m M6 capscrews 12 Ibs ft 16 N m M5 capscrews 7 bs ft 9 5 N m LUBRICATION The extreme pressure additives in Limited Slip Differential oil have proven to aid gear life We recommend fully synthetic LSD oil with an API GL5 or higher rating and heavier viscosity range typically 85w 140 75w 90 is also acceptable The Oil Filler Plug loc
13. x NOTE Be careful not to lose the Pawls Springs when doing this HOLINGER 6 ENGINEERING After removing the Camshaft Shim Pawls Springs turn your attention to the Rear of the gearbox Select either 3 or 4 gear by moving the selector rod protruding from the front of the gearbox and simultaneously select Reverse gear by moving the other protruding rod This locks the gearboxes shafts together allowing the rear nut bolt to be removed Cut the lock wire on both the Mainshaft Nut and Layshaft Bolt then remove them Remove the Cast Aluminium Cover from the top of the Rear case then knock out the Roll Pins from Gear Change Rod Neutral Latch Striker and Reverse Rod End Now Remove the Reverse Lever Reverse Idler Gear and Spindle lt 7 HOLINGER 7 ENGINEERING The rest of the components in the Rear Case can now be removed along with the M8 Nuts Washers between the Main and Rear Cases Now also remove the Blackened Plates from the top and side of the gearbox NOTE The plates located on the sandwich plate will release Detent Springs Balls Be Careful not to lose them Lightly tap the Rear Case backwards with a soft hammer separating it from the Sandwich Plate NOTE If possible try to prevent the Gasket from tearing Remove 1 and 2 Gears Spacers Sleeves along with the Selector Ring Hub and Rod Fork HOLINGER 8 ENGINEERING You will now need to remove the Spiral Actuator Pin and Rollers
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