MAINTENANCE SERVICING OF HEWLAND FT 200, FG 400, …

1 MAINTENANCE SERVICING OFHEWLAND FT 200, FG 400, FGA & FGBTRANSAXLE GEARBOX UNITSHEWLANDENGINEERING LTDWALTHAM ROAD, WHITE WALTHAMMAIDENHEAD, BERKSHIRE, SL6 3 LRTEL: +44 (0) 1628 827600 FAX: +44 (0) 1628 829706-mail: UNIT- FT& the Gear Train the Selector CASE & DIFFERENTIAL COMPARTMENT - FT200 Differential & Drive - Outboard Drive - Inboard CASE & DIFFERENTIAL COMPARTMENT- FG400,FGA& & Final Drive - FG400 Side Plates for Outboard Drive - FG400 Side Plates for Inboard Drive - FGA ..SETTING-UPCROWN WHEEL& Pinion of HEWLAND Setting Gauge to Check Pinion Pinion of FG400 HEWLAND Setting Guage to Check Pinion Pinion of Pre-load of Differential - FT200, FGA & FGB..Page3444458888899991818181818171717 171731313131313132 Adjusting the Pump Removal & GEAR POSITIONS FOR GEARBOXES WITH ROTATINGTOP GEAR THRUST Gear Positions in Main Gear Positions with Selector Fork Unit FT200, FG400 & FGA.

2 Main Case & Differential Compartment - FT200..MainCase-FG400&FGA ..Gearbox Components - FGB..Differential & Final Drive - FT200 - Outboard BrakesDifferential & Final Drive - FT200 - Inboard Brakes .Differential & Final Drive - FG400 - Outboard BrakesDifferential & Final Drive - FG400 - Inboard BrakesDifferential & Final Drive - FGA ..Differential Assembly- FGB & DGB ..Alternative Differential - FGA ..Oil Pump ..Oil Pump- FT& FG ..INSET ILLUSTRATIONSH ewland Forksetting Dial Gauge to Measure Pinion Depth Setting Gear Position in Main Case/Selector Fork ,FG400,FGA & FGB transaxle GEARBOX UNITSGENERAL NOTES ONMAINTENANCE AND OVERHAULOnly genuine HEWLAND spares should be used asreplacements. These are manufactured in our ownworkshops to the fine tolerances necessary, andrigorously inspected and nuts, circlips, oil seals and gaskets should alwaysbe used on SETTINGSP inion Nut ( ).

3 115 ft/lbsLayshaft Nut ( ) .. _ 80 ft/lbsCrownwheel Bolts .. _ ..75 ft/lbsAll 5/16 in. UNF Nuts.. _ _ .. 20 ft/lbsWhen warming the casings, keep the blow lampmoving. Test with a spot of moisture, which willbounce off at correct temperature. Do not Weight (approximate)Oil CapacityType of OilFT 200FG 400 FGAFGB90 Ibs110 Ibs110 Ibs112 litres2 litres2litres2 litresSAE 80 or90 SAE 80 or90 SAE 80or90 SAE 80or90 Notes: Oil capacity given for transmission without oil cooler GEARBOX UNIT-FT & FGREMOVING THE UNIT Refer to //lustration AEnd the UNF Nyloc nuts (1) and washers(2) securing the end cover. Take off cover the split pins from the castellated pinionand layshaft the heads of the two outside selector rods,thus engaging the gears. This locks the gear boxby engaging 2 the pinion nut, (left hand thread) andslacken off the layshaft nut, (conventional righthand thread),Now withdraw the two outside selector rods, todisengage the the bearing carrier securing nuts andwashers (5/i6 UNF).

4 2. Using a plastic mallet, tap the bearing carrier andremove 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 slideoff the gearbox unit is now completely re-fit, assemble in reverse order to GEAR RATIOSWhen changing a gear ratio, take off the slackenedlayshaft nut and remove the layshaft from the bearingcarrier. Gears are exchanged in pairs - one from thelayshaft and one from the pinion shaft. Each gear isetched with two sets of is essential that gears should be correctly pairedaccording to these TRAIN hubs, clutch rings andgears. Wash andinspect for wear and cracks, particularly to theclutch Examine forks for heavy or uneven wear, andtest for excessive play between forks and If forks are not to be dismantled, check thatself-locking nuts are tight.

5 Continue disassemblyas 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 housingand withdraw selector finger (35).(2) Slacken and remove UNC Allen cap screw(5/16 in).(3) Slacken and remove UNF Nyloc nutinside housing (5/16 in) (51). gasket from bearing remove forks, remove nut (50). Remove allthree sets and lift off forks (47,46,48).Slacken and remove all three cap screws (40) andtake out the top selector rod springs and balls(38 & 39). Then take out the three selector rods,one at a time, collecting the bottom balls the UNC cap screw (3/8 in.) and pushout the locking slugs (41).Inspect pinion and layshaft tail bearings and re-new if necessary. To remove, warm up surroundarea. Bearings are located by cap screws (13).

6 Re-assemble in reverse order to above, noting replacing bottom balls and springs, set upto correct height. About one-third of the ballsshould be exposed. Continue by inserting lockingslugs and selector rods, then top balls and hub replaced should be identical in lengthwith the original. If replacing all hubs, or mainbearing carrier, check that overall length ofpinion assembly has not been altered. Clearanceis essential to avoid overheating and seizure, buttoo much clearance will cause excessive wear.(See Setting the Selector Forks-page 5, para 4)THE GEARBOX UNIT (continued)SETTING UP THE SELECTOR FORKSE xtreme accuracy in setting up is imperative toensure that gears engage freely, and to avoid unevenor excessive wear. The use of a HEWLAND ForksettingJig is strongly recommended. Designed specificallyfor FT/FG T will save costly setting-up time andvastly reduce the possibility of error.

7 (Fig. 1) that when two layshaft gears run together,their chamfered sides must face each other (seediagram A).Warm the bearing carrier and drop in the piniontail bearing as described the jig in a vice. Slide the hubs with topgear and thrust washer, on to the dummy the bearing carrier to the jig, usingtemporary the pinion nut. Then check for correctclearance on top gear. (.008 in. to .010 in.). (ForFGB see page 31)Remove from jig. Fit selector forks to rodstogether with nuts and up the hubs, gears and clutch rings, andslide them back on to the setting the forks individually. Correct positioningrequires that:(a)The clutch ring should be centred on its hub,between the two gears.(b)The clutch ring should engage fully witheither 1 HEWLAND Forksetting Jig(c)When fully engaged with either gear thereshould still be in.

8 Clearance betweenthe gear and clutch-ring faces.(d)lf clutch-ring is over engaged it could resultin gears overheating and seizing up or causeexcessive wear on selector Tighten all three selector rods using new nuts andtabs, at the same time, make sure that the selectorrod heads are correctly aligned, and that there isclearance between them (but not From up surrounding area and fit layshaftbearing. Build up the complete layshaft assemblywith gears, spacers and thrust washer. Replace inbearing the complete assembly back into the jig. Re-check all clearances. Test all movements. Whensatisfied, remove the assembly from jig and boltit into the gearbox, using a jointing the nyloc nuts around the bearingcarrier. Replace nuts on pinion, layshaft andtighten to the correct torque (See note).)

9 Put insplit the selector finger housing and selectorfinger, renewing gasket (6). Fit new gasket (4)and replace the end : The correct torque is 115 ft/lbs for pinionnut, and 80 ft/lbs for UNIT PARTS LISTI llus. 5/16 in. UNF NylocFT 201336 Washer 5/16 in. Chamfered flatFT 202736 End Cover - StandardFT 2041 Gasket, End CoverFT 2601 Selector Finger HousingFT 2031 Gasket, Selector Finger HousingFT 2611 Nut, Layshaft ( )FT 2361 Split PinFT 23012 Bearing, LayshaftFT 23431 StudFT 20267 Screw, Bearing RetainingFT 22932 Bearing CarrierFT 2021 ScrewFT 20262 SpringFT 20341 BallFT 20331 PlungerFT 20301 Spring,FT 20321 PlugFT 20351 Thrust WasherFT 23451 SpacerFT 23461 Layshaft (see ratio chart)FT 2341 BearingFT 22912 First and Reverse Sliding GearFT 2311 Hub Front (FT only)FT 2261 Hub Front (Length 3 l/l6 in.)FG 2261 Hub Front (Length 2 15/16 in.)

10 FGA2261 Needle BearingFT 22615 Clutch Ring (FT only)FT 2322 Illus. No. Ring (FG/FGA)DG 2322A29 Hub Centre (FT only)FT 2271A 2 9 Hub Centre (FG/FGA)FG 2271A30 Hub Rear (FT only)FT 2281A30 Hub Rear (FG/FGA)FG 2281A3 1 Inner Track 5th GearFT 2291A32 Thrust WasherFT 22941A33 StudFT 20251A34 Nut, Pinion ( )FT 2301A35 Selector FingerFT 2521A36 BushFT 20362A37 0 RingFT 20371A38 SpringFT 20226A39 BallFT 202 16A40 ScrewFT 20233A4 1 PlungerFT 20242A42 Screw (not illus.)FT 20311A43 Selector Rod 2461A44 Selector Rod 2ndI3rdFT 2471A45 Selector Rod 4thl5thFT 2481A 4 6 Selector Fork 2491A47 Selector Fork 2ndl3rdFT 2501 A48 Selector Fork 4th/5thFT 2511A50 NutFT 24623A51 ScrewFT20311 1A52 SpacerFT20310 1A53 PlateFT 20301A54 ScrewFT 20394A55 Spacer (various sizes)FT 24633 THE MAIN CASE & DIFFERENTIAL COMPARTMENT-FT 200 Removal and replacement of units and assemblies.