GP3 2013 Hewland Gearbox MLI User Manual Issue 15 Dated 22 01 2013

SERVICING INSTRUCTIONS AND
ILLUSTRATED PARTS LIST FOR MLI GEARBOX
HEWLAND ENGINEERING LTD

WALTHAM ROAD, WHITE WALTHAM,
MAIDENHEAD,BERKSHIRE,
SL6 3LR,ENGLAND
TELEPHONE: +44 (0)1628 827600
FAX: +44 (0) 1628 829706
e-mail: sales@hewland.com
www.hewland.com
Issue 15 - 22nd January 2013 1
CONTENTS
Page Page
Technical Specification 4 Differential Assembly 26
Recommended Torque Settings 5 Differential Unit Sub Assembly 28
General Notes 6 Selector Rack Assembly 30
Differential Bearing Preload 7 Input Shaft Assembly 34
Pinion Shaft Setting 8 Fork and Barrel Assembly 36
Crownwheel Backlash Setting 9 Selector Fork Sub Assembly 40
Sequential Barrel Setting 10 Selector Barrel Sub Assembly 42
Gearbox Assembly 11 Gear Cluster Assembly: Integral 2nd Gear Option 44
Powerflow Differential 13 Gear Cluster Assembly: Loose 2nd Gear Option 48
Differential Setting 14 Cluster Assembly: Pinion shaft 54
Illustrated Parts List 15 Pinion Bearing Sub Assembly 56
Casings and Associated Parts 16 Gearbox Tooling 58
Oil Spray Sub Assembly 24 Common Part Locations 60
Amendments 61
ILLUSTRATIONS
Page
Fig.1 Differential Bearing Preload 7 Fig.16 Fork and Barrel Assembly 39
Fig.2 Pinion Shaft Setting 8 Fig.17 Selector Fork Sub-Assembly 41
Fig.3 Crownwheel Backlash Setting 9 Fig.18 Selector Barrel Sub Assembly 43
Fig.4 Sequential Barrel Setting 10 Fig.19 Gear Cluster Assembly:

Integral 2nd Gear Option 45&47
Fig.5 Powerflow Differential 15
Fig.20 Gear Cluster Assembly:
Fig.6 Differential Settings 14 Loose 2nd Gear Option 49&51
Fig.7 Casings & Associated Parts 17&19 Fig.21 Cluster Assembly: Pinion shaft 53
Fig.8 Casings & Associated Parts 21&23 Fig.22 Pinion Bearing Sub Assembly 55
Fig.9 Oil Spray Sub Assembly 25 Fig.23 Gearbox Tooling 57
Fig.10 Differential Assembly 27
Fig.11 Differential Unit Sub Assembly 29
Fig.12 Selector Rack Assembly 31
Fig.13 Selector Rack Assembly 33
Fig.14 Input Shaft Assembly 35
Fig.15 Fork and Barrel Assembly 37

TECHNICAL SPECIFICATION
The MLI gearbox is a longitudinal unit, designed for mid-engined, rear wheel drive cars. The unit is produced with six forward gears, reverse,
and a powerflow differential. It is also available with a complete Hewland semi-automatic system
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 main shaft, and then on to 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 (to Hewland specification) 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 MLI-200 is a high tech racing longitudinal unit which achieves the maximum effective use of power, in conjunction
with extremely stiff suspension, rear impact structure and damper mountings.
The MLI gearbox is equipped with a 250 micron filter on the scavenge side of the oil system and an integral 60 micron in-line filter fitted to the
pressure side.
Note:- It is highly recommended that both oil temperature and pressure are monitored with alarms set at 115°C & 5barG respectively
1st to 6th gear ratios from 3.083:1 to 0.857:1

Final drive ratios 8/35, 9/35, 10:31 & 11/31
Weight 57Kg Including Bell housing

Oil type SAE 80 or 90
Oil quantity 1.75 litres Not Including cooler or external pipe work.
Oil Temperature (in operation) 100°C (recommended) 120°C (Max) - measured at gearbox outlet (pre-cooler)
Maximum torque 320 lbs.ft (430 Nm)

RECOMMENDED FITTING TORQUES
General nut and bolt torque settings:-
RECOMMENDED TIGHTENING RECOMMENDED TIGHTENING TORQUES RECOMMENDED TIGHTENING TORQUES

TORQUES FOR METRIC COARSE FOR UNIFIED FINE SERIES BOLTS CLASS FOR UNIFIED COARSE SERIES BOLTS
SERIES BOLTS CLASS 12.9 12.9 CLASS 12.9
THREAD (Nm) (lbs.ins) (lbs.ft) THREAD (Nm) (lbs.ins) (lbs.ft) THREAD (Nm) (lbs.ins) (lbs.ft)
M5 6.7 59 4.9 1/4 14.2 126 10.5 1/4 12.5 110 9.2
M6 11.2 99 8.3 5/16 28.4 252 21.0 5/16 25.6 227 18.9
M8 27.3 242 20.2 3/8 52.2 462 38.5 3/8 46.0 407 33.9
M10 53.9 477 39.8 7/16 82.5 731.0 60.9
RECOMMENDED TIGHTENING TORQUES FOR METRIC

COARSE SERIES K-NUTS
FITTING TO EN16T STUDS
THREAD
(Nm) (lbs.ins) (lbs.ft)
M5 8.4 75 6.2
M6 12.7 112 9.3
M8 27.0 239 19.9
M10 x 1.50 40.0 354 29.5
M10 x 1.25 50.0 443 36.9
Specific nut and bolt torque settings:-
(Where Specific nut and bolt details are a similar size to General nut and bolt details, the tightening torques
listed in this section must be adhered to for these components.)
Pinion shaft nut tightening torque = 120 lbs.ft (163 Nm)

Crownwheel bolt tightening torque = 75 lbs.ft (100 Nm) (Lockwire must also be applied to these bolts.)

GENERAL NOTES
a) Read these instructions carefully and with reference to the illustrations.
b) Before dismantling the gearbox, see that a clean tray is available, in which to place the parts.
c) Thoroughly clean and inspect all parts before reassembly. Discard any worn or damaged components and replace
with new ones.
d) Use only genuine Hewland parts, Supplied by GP3 motorsport as replacements. These are manufactured in our workshops
to the fine tolerances necessary and are rigorously inspected.
e) Always ensure that locknuts, and oil seals are in good condition when reassembling.
f) All studs and screws must be Loctited or wirelocked in position, unless stated otherwise
g) Bearing Replacement :-
Bearings 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.
NB. 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 seatings without delay, thus eliminating the need to reheat. At the correct
temperature, fitting the bearings should present no difficulty.
During cooling, or when the casings have cooled, it is advisable to once more lightly press the bearings to ensure that
they are correctly seated.
h) Oil:
Fill the gearbox through the oil filler hole on top of the maincase. The oil will find it's own level within the gearbox.
NB. 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 (37) as a guide, fit the outer races
of bearings (33) 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 (37) 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 Differential Assembly page for
part references.
FIGURE 1

PINION HEIGHT SETTINGS
Press the pinion head bearing assembly (20) onto the pinion
shaft (46) Heat the maincase as described on page 6. Along
with the nominal shim pack (82) Insert the pinion shaft and
bearing assembly into its location bore in the maincase. Fix
into place using screws (106) and washer (70). Assemble
the spacers and hubs (112), (21), (72), (71) & (111) onto the
pinion shaft. Fit bearing (11) and the pinion shaft nut (127).
Using special tool H3007A001 (Tooling page Item 1) tighten
the nut to the torque specified on page 5.
Measure the distance from the pinion head to the maincase

split face (crownwheel axis to mounting face) this distance
should be equal to the dimension indicated on the pinion
shaft label minus the pinion head height . If the dimension
differs from the stated value. Adjustment can be made by
adding or removing shim (82) behind the bearing housing FIGURE 2
(20)
Important Note:-
It is imperative to check the selector barrel setting NB. It is not correct practice to replace a pinion shaft without
after changing or resetting a pinion shaft or checking the setting distance, even if the old and new shafts have
pinion head bearing. the same recorded setting distance.
It is also good practice to renew the pinion head bearing if the

pinion shaft is being replaced.
CROWNWHEEL & PINION BACKLASH SETTING
Requires special tool No. H3007A002
With the pinion shaft (46), differential assembly (125), Rear cover (81)
and sideplate fitted (66), and the correct diff bearing shims ascertained,
the actual backlash can be measured by means of a dial test indicator
against the relevant crownwheel & pinion ratio mark etched in the face
of tool SK-1913.
Be sure to take at least 6 backlash readings, turning the crownwheel

30-45 degrees between each reading (this is to ensure that any
variation due to manufacturing tolerances are taken into account). The
backlash variation from manufacture will be logged on the gear data
card supplied with each crownwheel & pinion set.
The correct minimum backlash figure should be 0.005” (0.13mm) taken

at the tightest point of gear mesh. If the measured backlash is incorrect,
rectify it by removing some shims (37) from behind one diff bearing, and
inserting the equivalent amount of shim behind the other, thus moving
the diff across in the maincase.
NB. Generally 0.001” of crownwheel axial adjustment equates to

0.0008” modification in gear set backlash.
Do not add or discard any shims, as to do so will affect the

differential bearing preload.
NB. Dummy bearings can be used to ease the shim change during the
setting procedures. However, before fitting the actual differential
bearings, it is important to compare their width with that of the dummy
bearings and compensate the shim thicknesses for any difference.
FIGURE 3
SEQUENTIAL FORK SETTING
Requires special tool H3007A003 (see tooling page)
The MLI is fork set by moving the hubs along the pinion shaft by means of a spacer.
This fork setting procedure MUST be carried out each time the pinion head bearing is replaced or re-shimmed.
a/ Assemble the entire ratchet, barrel and detent assembly into the maincase (see fork and barrel assembly for reference).
b/ With the pinion shaft fitted and set (as described on page 8). Slide the fork setting spacer (21), hubs, spacers (112), (72), (71)
& (111), clutch rings (47), selector forks (23) reverse pinion (73), pinion gears (135) and bearing (11) onto the pinion shaft
securing in place with the pinion shaft nut (127) tightened to the torque specified on page 5
c/ Engage the selector fork pins with the relevant barrel tracks and slide the selector rail (120) through the forks and on to
engage with its location bore in the maincase.
d/ Rotate the barrel to the neutral position and fit special tool SK-2359
Remove plugs (94) from the dog sighting holes in the maincase.
Measure and record the dog gap either side of each visible
clutch ring, any differences between the measured
dimensions must be averaged out by adjusting / replacing the
fork setting spacer (21).
Note:-
It is not possible (or necessary) to adjust
each fork individually.
Issue 15 - 22nd January 2013 FIGURE 4 10

GEARBOX ASSEMBLY
A) It is assumed that all bearings, oil seals, studs, oil jets, and dowels are already fitted into their casings.
B) Slide the reverse idler top hat bush (40) into place in the maincase (79), then push it in as far as it will go. Slide the second
reverse idler top hat bush (29) into place, then pull it towards the rear of the maincase. Press the bearing (52) into the reverse
idler gear (28), slide the sleeve (41) into the bearing, and position the gear between the bushes.
Push the reverse idler top hat bush (29) towards the rear of the maincase, fit the screw (102) , and lockwire.
C) Press the dowel (30) into the maincase, and secure the detent arm (92), trunion (45), and spring (93) into the maincase using
screw (58) and washer (52).
D) Position the pawl (113) in the slot in the selector rack (42), and press pin (27) into place ensuring that it does not protrude
outside the rack outer diameter, and moves freely. Slide the washers (43), spring (115), and sleeve (44) onto the rack and
secure them with circlip (16). This spring has a limited effective life, therefore periodic replacement is recommended. It is also
advisable never to re-use the circlip (16).
E) Fit the quad ring seal (91) carefully into the seal carrier (123), then assemble it onto the maincase using screws (108)
ensuring o-ring (90) is fitted. Fit the spring carrier (122), into the maincase, oil the rack liberally and slide it in, ensure that it
travels back and forth without any stiction. Whilst holding the detent arm against its spring using a pair pliers feed the barrel
(22) into the maincase and secure with the cir-clip (25). It may be necessary to lift the pawl up so as to let the barrel pass
underneath it.
F) Slide the plunger (114), spring (1) and washer (32) into the rack and secure with circlip (15), then fit rack cover (121) and
o-ring (90), using screws (108). NB. If the gearbox has not yet been fork set, then delay this step, as it easier to push the
pawl up if it has not yet been fitted with its return spring.
G) Assemble the bell crank (110), bearings (14), spacer (109), and washers (61) into the maincase with the bellcrank bracket
(65) and secure with screws (104) & (108) fitted with washers (61). Ensure that the selector operates smoothly in both
directions, and self returns to its normal position.

H) Fit the clutch shaft retainer (64) lip seal (62) into the bell housing and retain using cir-clip (17).
The gear cluster can now be loaded into the maincase, (this is assuming the pinion shaft, and pinion bearing have been set
as described on page 8). pinion gears, spacers, hubs, bearings and clutchrings can be slide onto it. It is necessary to fit the
relevant selector forks in conjunction with their clutchring, locating the selector fork pin into the barrel track, once all four forks
are correctly located with their clutch ring, and the barrel, then the selector rail (120) can be slid through all of the forks and
into the maincase. Secure the assembly with nut (127) tightened to the specified torque (page 5) locking ring (84) & cir-clip
(38) The layshaft, input gears, and spacers can now also be assembled into the maincase.
NB The pinion gears may need rotating in order to allow the input gears to pass and mesh correctly.
I) Fit the gear cluster oil spray rail (19).
J) The bellhousing can now be fitted with barrel bearing (5) shaft bearings (11) & (12) locking washer (133) and screw (98). Fit
o-ring cord (128) into its groove. This can now be assembled together with the maincase.
K) Presuming the differential bearing preload and crownwheel & pinion backlash has been set (pages 7 & 9) the differential and
sideplate assembly may now be fitted to the maincase.
L) Ensuring o-ring cord (128) is fitted correctly to the rear cover (81) fit together with the maincase. Slide the oil pump driver (74)
into its spline in the layshaft followed by the oil pump rotors (124) o-ring (89) and oil pump cover (67).
M) Fit all ancillary parts, oil filters, pinion oil spray, breather and all oil fittings etc.

POWERFLOW DIFFERENTIAL
This powerflow differential unit is designed with versatility as its major asset. Many factors will contribute to the settings required. A
car with good traction and low power, may require a completely different arrangement to that of a car with poor traction and high
power.There are 10 friction plates within the unit (4 splined to the diff casing, and 6 splined to the side bevel gears). Slip limiting is
dependant on the friction resistance between these plates, and is affected by clamping the plates together. Four factors contribute
to the total friction torque between the plates :-
1) The side bevel gears thrust apart to clamp the plates as
they transmit the driving power. This is a feature of the gear
geometry, and is not adjustable.
2) The side ring gear ramp angles have an effect on how much
of the transmitted torque is converted into sideways (clamping)
force onto the plates. For example, on the drive side of the ring
gear, 45 degrees transmits less sideways force than 30
degrees. Likewise on the coast side of the ring gear, an 80
degree angle will transmit little or no clamping force onto the
plates, whereas a 45 degree angle will transmit a much greater
force. The side rings gear are available with many different
drive/coast ramp angle combinations.
3) The second adjustable factor is how tightly the plate stack is
compressed on assembly (known as static preload). The
preload torque is measured between the side bevel gears, by
holding one side bevel gear stationary, and measuring the
torque required to turn the other. NB. Figure 6 shows a belle-
ville spring fitted to the plate stack, that can be used to maintain
static preload during the “running in” period.
4) The final adjustment is simply to re-order the plate stack so
as to change the number of relatively rotating faces. The
diagram shows the stack setup with the maximum 12 working
FIGURE 5
faces. Standard stack may be shuffled to give
as few as 2 working faces.
DIFFERENTIAL SETTINGS
Percentage Rating Ramp Angle No. of Friction Surfaces

4 80 2
7 60 2
8 80 4
11 45 2
13 80 6
15 60 4
17 80 8
21 80 10
22 60 6
22 45 4
30 60 8
33 45 6
37 60 10
43 45 8
45 60 12
54 45 10
65 45 12
This table is intended as a quick reference guide to

percentage lock various setting permutations.
FIGURE 6

ILLUSTRATED PARTS
LIST

01A CASINGS & ASSOCIATED PARTS
Item Barcode Description Qty Price Item Barcode Description Qty Price
6 *HCOM00001*
*HCOM00001*
ADAPTOR 1 € 6.50 67 *H3001A067*
*H3001A067*
OIL PUMP COVER 1 € 81.56
7 *HCOM00002*
*HCOM00002*
DOWTY WASHER 1 € 2.50 68 *H3001A068*
*H3001A068*
BRACKET TRIGGER
SENSOR
2 € 36.59
8 *HCOM00003*
*HCOM00003*
IN-LINE FILTER 1 € 85.97 74 *H3001A074*
*H3001A074*
OIL PUMP DRIVE 1 € 161.46
18 *H3001A018*
*H3001A018*
SPRAY RAIL ASSEMBLY 1 € 84.95 79 *H3001A079*
*H3001A079*
MAINCASE - DRESSED 1 € 1,580.00
26 *HCOM00004*
*HCOM00004*
RING DOWEL 4 € 2.64 80 *H3001A380*
*H3001A380*
BELLHOUSING - DRESSED 1 € 1,506.96
31 *H3001A031*
*H3001A031*
STUD 6 € 6.12 81 *H3001A081*
*H3001A081*
REAR COVER - DRESSED 1 € 1,019.61
53 *HCOM00071*
*HCOM00071*
MAGNETIC PLUG 1 € 49.41 85 *HCOM00010*
*HCOM00010*
KAYNUT 13 € 0.98
54 *HCOM00005*
*HCOM00005*
BANJO JOINT 1 € 14.19 86 *HCOM00011*
*HCOM00011*
KAYNUT 11 € 0.79
55 *HCOM00006*
*HCOM00006*
SEALING WASHER 2 € 0.47 87 *HCOM00012*
*HCOM00012*
K-NUT 4 € 1.68
56 *HCOM00007*
*HCOM00007*
BANJO BOLT 1 € 1.27 88 *HCOM00013*
*HCOM00013*
O-RING 1 € 0.22
57 *HCOM00008*
*HCOM00008*
DOWTY WASHER 2 € 0.36 89 *H3001A089*
*H3001A089*
O-RING 1 € 1.05
60 *H3001A060*
*H3001A060*
DOWEL 2 € 0.50 94 *HCOM00014*
*HCOM00014*
PLUG 3 € 11.29
61 *HCOM00009*
*HCOM00009*
WASHER 10 € 0.08 95 *H3001A095*
*H3001A095*
BLANKING PLUG 1 € 6.54
66 *H3001A066*
*H3001A066*
SIDE COVER 1 € 103.93 96 *H3001A096*
*H3001A096*
SOCKET SET SCREW 3 € 0.07

FIGURE

97 *H3001A097*
*H3001A097*
SOCKET CAP SCREW 2 € 0.16 138 *H3001A138*
*H3001A138*
STUD 2 € 10.10
100 *H3001A100*
*H3001A100*
*H3001A139*
SOCKET CAP SCREW 1 € 1.23
101 *HCOM00015*
*HCOM00015*
SOCKET SET SCREW 1 € 1.43 140 *H3001A140*
*H3001A140*
103 *HCOM00016*
*HCOM00016*
*H3001A141*
ACTUATOR BRACKET 1 € 82.72
107 *H3001A107*
*H3001A107*
SOCKET CAP SCREW 8 € 3.89 142.1 *H3003A143*
*H3003A143*
SHIM WASHER 0.076MM 0 € 0.44
116 *H3001A116*
*H3001A116*
STUD 4 € 6.38 142.2 *H3003A144*
*H3003A144*
117 *H3001A117*
*H3001A117*
STUD 11 € 5.49 142.3 *H3003A145*
*H3003A145*
119 *H3001A119*
*H3001A119*
OIL FILTER 1 € 95.87 142.4 *H3003A146*
*H3003A146*
124 *H3001A124*
*H3001A124*
OIL PUMP ROTORS 1 € 226.75 144 *H3001A147*
*H3001A147*
O-RING 1 € 5.68
126 *H3001A126*
*H3001A126*
O-RING 1 € 0.89
128 *HCOM00017*
*HCOM00017*
SEALING STRIP 2 € 13.42
130 *HCOM00018*
*HCOM00018*
DOWTY WASHER 3 € 0.55
131 *H3001A131*
*H3001A131*
WASHER 4 € 0.26
132 *H3001A132*
*H3001A132*
WASHER 13 € 0.02

FIGURE 7

6 *HCOM00001*
*HCOM00001*
ADAPTOR 1 € 6.50 67 *H3001A067*
*H3001A067*
OIL PUMP COVER 1 € 81.56
7 *HCOM00002*
*HCOM00002*
DOWTY WASHER 1 € 2.50 68 *H3001A068*
*H3001A068*
BRACKET TRIGGER SENSOR 2 € 36.59
8 *HCOM00003*
*HCOM00003*
IN-LINE FILTER 1 € 85.97 74 *H3001A074*
*H3001A074*
OIL PUMP DRIVE 1 € 161.46
18 *H3001A018*
*H3001A018*
SPRAY RAIL ASSEMBLY 1 € 84.95 79 *H3001A079*
*H3001A079*
MAINCASE - DRESSED 1 € 1,580.00
26 *HCOM00004*
*HCOM00004*
RING DOWEL 4 € 2.64 80 *H3001A380*
*H3001A380*
BELLHOUSING - DRESSED 1 € 1,506.96
31 *H3001A031*
*H3001A031*
STUD 6 € 6.12 81 *H3001A081*
*H3001A081*
REAR COVER - DRESSED 1 € 1,019.61
53 *HCOM00071*
*HCOM00071*
MAGNETIC PLUG 1 € 49.41 85 *HCOM00010*
*HCOM00010*
KAYNUT 13 € 0.98
54 *HCOM00005*
*HCOM00005*
BANJO JOINT 1 € 14.19 86 *HCOM00011*
*HCOM00011*
KAYNUT 11 € 0.79
55 *HCOM00006*
*HCOM00006*
SEALING WASHER 2 € 0.47 87 *HCOM00012*
*HCOM00012*
K-NUT 4 € 1.68
56 *HCOM00007*
*HCOM00007*
BANJO BOLT 1 € 1.27 88 *HCOM00013*
*HCOM00013*
O-RING 1 € 0.22
57 *HCOM00008*
*HCOM00008*
DOWTY WASHER 2 € 0.36 89 *H3001A089*
*H3001A089*
O-RING 1 € 1.05
60 *H3001A060*
*H3001A060*
DOWEL 2 € 0.50 94 *HCOM00014*
*HCOM00014*
PLUG 3 € 11.29
61 *HCOM00009*
*HCOM00009*
WASHER 10 € 0.08 95 *H3001A095*
*H3001A095*
BLANKING PLUG 1 € 6.54
66 *H3001A066*
*H3001A066*
SIDE COVER 1 € 103.93 96 *H3001A096*
*H3001A096*
SOCKET SET SCREW 3 € 0.07

01A CASINGS & ASSOCIATED
Rotary Potentiometer
not Hewland Supply
FIGURE 8

97 *H3001A097*
*H3001A097*
*H3001A138*
STUD 2 € 10.10
100 *H3001A100*
*H3001A100*
*H3001A139*
101 *HCOM00015*
*HCOM00015*
SOCKET SET SCREW 1 € 1.43 140 *H3001A140*
*H3001A140*
103 *HCOM00016*
*HCOM00016*
*H3001A141*
ACTUATOR BRACKET 1 € 82.72
107 *H3001A107*
*H3001A107*
SOCKET CAP SCREW 8 € 3.89 142.1 *H3003A143*
*H3003A143*
116 *H3001A116*
*H3001A116*
STUD 4 € 6.38 142.2 *H3003A144*
*H3003A144*
117 *H3001A117*
*H3001A117*
STUD 11 € 5.49 142.3 *H3003A145*
*H3003A145*
119 *H3001A119*
*H3001A119*
OIL FILTER 1 € 95.87 142.4 *H3003A146*
*H3003A146*
124 *H3001A124*
*H3001A124*
OIL PUMP ROTORS 1 € 226.75 144 *H3001A147*
*H3001A147*
O-RING 1 € 5.68
126 *H3001A126*
*H3001A126*
O-RING 1 € 0.89
128 *HCOM00017*
*HCOM00017*
SEALING STRIP 2 € 13.42
130 *HCOM00018*
*HCOM00018*
DOWTY WASHER 3 € 0.55
131 *H3001A131*
*H3001A131*
WASHER 4 € 0.26
132 *H3001A132*
*H3001A132*
WASHER 13 € 0.02

01A CASINGS & ASSOCIATED
Rotary Potentiometer
not Hewland Supply
FIGURE 8

01B - OIL SPRAY SUB ASSEMBLY
Item Barcode Description Qty Price
161 *HCOM00019* O-RING 2 € 0.13

*HCOM00019*
162 *H3001B003* PLUG 1 € 6.70

*H3001B003*

01B - OIL SPRAY SUB ASSEMBLY
FIGURE 9

02A DIFFERENTIAL ASSEMBLY
24 *H3002A024*
*H3002A024*
CIR-CLIP 2 € 0.49 66 *H3001A066* SIDE COVER 1 € 103.93
*H3001A066*
33 *HCOM00020*
*HCOM00020*
TAPER ROLLER BEARING 2 € 9.82 69 *H3002A069* TRIPOD OUTER JOINT 2 € 306.63
*H3002A069*
34 *H3002A034*
*H3002A034*
L/H SIDEPLATE SPACER 1 € 26.28 83 *H3002A083* SIDEPLATE SPACER 1 € 31.14
*H3002A083*
35 *H3002A035*
*H3002A035*
BALL BEARING 2 € 5.57 107 *H3001A107* SOCKET CAP SCREW 8 € 3.89
*H3001A107*
36 *H3002A036*
*H3002A036*
LIP SEAL 2 € 2.27 125 *H3002A125*
*H3002A125*
TPT DIFF ASSEMBLY 1 € 1,603.75
37.1 *HCOM00021*
*HCOM00021*
SHIM (0.076mm) 0 € 0.69 126 *H3001A126*
*H3001A126*
O-RING 1 € 0.89
37.2 *HCOM00022*
*HCOM00022*
SHIM (0.127mm) 0 € 0.69 129 *H3002A129*
*H3002A129*
CROWN WHEEL BOLT 10 € 1.51
37.3 *HCOM00023*
*HCOM00023*
SHIM (0.203mm) 0 € 0.69
37.4 *HCOM00024*
*HCOM00024*
SHIM (0.254mm) 0 € 0.69
37.5 *HCOM00025*
*HCOM00025*
SHIM (0.381mm) 0 € 0.69
37.6 *HCOM00026*
*HCOM00026*
SHIM (0.508mm) 0 € 0.69
37.7 *HCOM00027*
*HCOM00027*
SHIM (0.635mm) 0 € 0.69
46 *H3002A046*
*H3002A046*
CROWN WHEEL & PINION
ASSEMBLY (11:31)
1 € 1,545.67
FIGURE 9
46 *H3002A346*
*H3002A346*
ASSEMBLY (10:35)
1 € 2,401.77

02A DIFFERENTIAL ASSEMBLY
FIGURE 10

02B - DIFFERENTIAL UNIT SUB ASSEMBLY
143 *HCOM00029*
*HCOM00029*
SIDE BEVEL GEAR 2 € 149.35 152 *H3002B005*
*H3002B005*
145 *HCOM00030*
*HCOM00030*
DISC SPRING 1 € 48.04 153 *H3002B010*
*H3002B010*
DIFF CASE 1 € 444.43
146.1 *HCOM00072*
*HCOM00072*
PRELOAD SPACER 3.94mm 0 € 46.06 154 *H3002B011*
*H3002B011*
DIFF END PLATE 1 € 93.43
146.2 *HCOM00035*
*HCOM00035*
PRELOAD SPACER
2.41/2.29mm
0 € 46.06
146.3 *HCOM00036*
*HCOM00036*
PRELOAD SPACER
3.05/2.92mm
0 € 46.06
146.4 *HCOM00037*
*HCOM00037*
PRELOAD SPACER 5.97mm 0 € 46.06
146.5 *HCOM00038*
*HCOM00038*
PRELOAD SPACER
4.78/4.65mm
0 € 46.06
146.6 *HCOM00039*
*HCOM00039*
PRELOAD SPACER
5.54/5.41mm
0 € 46.06
147 *HCOM00028*
*HCOM00028*
PRELOAD SPRING CARRIER 1 € 97.13
148 *HCOM00032*
*HCOM00032*
PLANET DIFF. GEAR 3 € 51.96
149.1 *HCOM00040*
*HCOM00040*
SIDE RING GEARS 20 x 80 1 € 441.19
149.2 *HCOM00033*
*HCOM00033*
SIDE RING GEARS 45x60 0 € 441.19
150 *HCOM00034*
*HCOM00034*
CORE PLATE 6 € 5.24
151 *HCOM00031*
*HCOM00031*
OUTER DRIVE CLUTCH
PLATE
4 € 5.24

02B - DIFFERENTIAL UNIT SUB ASSEMBLY
RAMP DIRECTION
FIGURE 11

03A SELECTOR RACK ASSEMBLY
1 *HCOM00041*
*HCOM00041*
COMPRESSION SPRING 1 € 0.69 108 *HCOM00047*
*HCOM00047*
14 *HCOM00042*
*HCOM00042*
BALL BEARING 2 € 2.55 109 *H3003A109*
*H3003A109*
SPACER TUBE 1 € 19.01
15 *HCOM00043*
*HCOM00043*
CIRCLIP 1 € 0.31 110 *H3003A110*
*H3003A110*
BELLCRANK 1 € 133.22
16 *HCOM00044*
*HCOM00044*
CIRCLIP 1 € 0.31 113 *HCOM00048*
*HCOM00048*
PAWL 1 € 102.94
27 *H3003A027*
*H3003A027*
DOWEL 1 € 12.24 114 *HCOM00049*
*HCOM00049*
PLUNGER 1 € 30.82
32 *H3003A032*
*H3003A032*
WASHER 1 € 0.02 115 *HCOM00050*
*HCOM00050*
COMPRESSION SPRING 1 € 2.97
42 *H3003A042*
*H3003A042*
SELECTOR RACK 1 € 97.61 121 *H3003A121*
*H3003A121*
RACK END COVER 1 € 44.96
43 *HCOM00045*
*HCOM00045*
SELECTOR RACK WASHER 2 € 8.79 122 *H3003A122*
*H3003A122*
RACK SPACER 1 € 23.59
44 *HCOM00046*
*HCOM00046*
SLEEVE 1 € 20.57 123 *H3003A123*
*H3003A123*
RACK END SEAL HOUSING 1 € 35.03
61 *HCOM00009*
*HCOM00009*
WASHER 10 € 0.08 142.1 *H3003A143*
*H3003A143*
65 *H3003A065*
*H3003A065*
BRACKET - BELLCRANK 1 € 61.54 142.2 *H3003A144*
*H3003A144*
90 *H3003A090*
*H3003A090*
O-RING 2 € 0.30 142.3 *H3003A145*
*H3003A145*
91 *H3003A091*
*H3003A091*
QUAD RING 1 € 1.75 142.4 *H3003A146*
*H3003A146*
104 *H3003A104*
*H3003A104*

FIGURE 12

1 *HCOM00041*
*HCOM00041*
COMPRESSION SPRING 1 € 0.69 108 *HCOM00047*
*HCOM00047*
14 *HCOM00042*
*HCOM00042*
BALL BEARING 2 € 2.55 109 *H3003A109*
*H3003A109*
SPACER TUBE 1 € 19.01
15 *HCOM00043*
*HCOM00043*
CIRCLIP 1 € 0.31 110 *H3003A110*
*H3003A110*
BELLCRANK 1 € 133.22
16 *HCOM00044*
*HCOM00044*
CIRCLIP 1 € 0.31 113 *HCOM00048*
*HCOM00048*
PAWL 1 € 102.94
27 *H3003A027*
*H3003A027*
DOWEL 1 € 12.24 114 *HCOM00049*
*HCOM00049*
PLUNGER 1 € 30.82
32 *H3003A032*
*H3003A032*
WASHER 1 € 0.02 115 *HCOM00050*
*HCOM00050*
COMPRESSION SPRING 1 € 2.97
42 *H3003A042*
*H3003A042*
SELECTOR RACK 1 € 97.61 121 *H3003A121*
*H3003A121*
RACK END COVER 1 € 44.96
43 *HCOM00045*
*HCOM00045*
SELECTOR RACK WASHER 2 € 8.79 122 *H3003A122*
*H3003A122*
RACK SPACER 1 € 23.59
44 *HCOM00046*
*HCOM00046*
SLEEVE 1 € 20.57 123 *H3003A123*
*H3003A123*
RACK END SEAL HOUSING 1 € 35.03
61 *HCOM00009*
*HCOM00009*
WASHER 10 € 0.08 142.1 *H3003A143*
*H3003A143*
65 *H3003A065*
*H3003A065*
BRACKET - BELLCRANK 1 € 61.54 142.2 *H3003A144*
*H3003A144*
90 *H3003A090*
*H3003A090*
O-RING 2 € 0.30 142.3 *H3003A145*
*H3003A145*
91 *H3003A091*
*H3003A091*
QUAD RING 1 € 1.75 142.4 *H3003A146*
*H3003A146*
104 *H3003A104*
*H3003A104*

FIGURE 13

04A INPUT SHAFT ASSEMBLY
17 *HCOM00051*
*HCOM00051*
CIRCLIP 1 € 0.85
59 *H3004A059*
*H3004A059*
62 *H3004A062*
*H3004A062*
LIP SEAL 1 € 5.96
64 *H3004A064*
*H3004A064*
SHAFT RETAINER 1 € 35.09
75 *H3004A375*
*H3004A375*
CLUTCH SHAFT 1 € 269.27
76 *H3004A076*
*H3004A076*
SLAVE CYLINDER ADAPTOR 1 € 95.72
77 *H3004A077*
*H3004A077*
SENSOR MOUNTING PLATE 1 € 30.95
86 *HCOM00011*
*HCOM00011*
KAYNUT 11 € 0.79
99 *H3004A099*
*H3004A099*
105 *H3004A105*
*H3004A105*
137 *HCOM00070*
*HCOM00070*
COUNTERSUNK SCREW 2 € 2.50

04A INPUT SHAFT ASSEMBLY
137
137
FIGURE 14

05A FORK AND BARREL ASSEMBLY
5 *H3005A005*
*H3005A005*
NEEDLE ROLLER BEARING 1 € 3.28 78 *H3005A078*
*H3005A078*
QUILL SHAFT - GEAR
SENSOR
1 € 34.64
10 *H3005A010*
*H3005A010*
BALL BEARING 1 € 1.62 92 *HCOM00057*
*HCOM00057*
DRUM STOPPER 1 € 9.36
13 *HCOM00052*
*HCOM00052*
*HCOM00058*
COIL SPRING 1 € 1.98
22 *H3005A022*
*H3005A022*
SELECTOR BARREL ASSY 1 € 294.09 120 *H3005A120*
*H3005A120*
SELECTOR RAIL 1 € 90.49
23 *H3005A023*
*H3005A023*
SELECTOR FORK
ASSEMBLY
3 € 122.42 134 *H3005A134*
*H3005A134*
OLDHAM COUPLING 1 € 22.32
173 *H3005A173*
*H3005A173*
SELECTOR FORK ASSY 1 € 123.76
25 *H3005A025*
*H3005A025*
CIR-CLIP 1 € 0.36
30 *HCOM00053*
*HCOM00053*
DOWEL 1 € 0.30
39 *H3005A039*
*H3005A039*
BEARING RETAINING PLATE 1 € 23.44
45 *HCOM00054*
*HCOM00054*
SPRING TRUNION 1 € 10.96
52 *HCOM00055*
*HCOM00055*
DRUM WASHER 1 € 1.22
58 *HCOM00056*
*HCOM00056*
59 *H3004A059*
*H3004A059*
63 *H3005A063*
*H3005A063*
LIP SEAL 1 € 1.82

FIGURE 15

5 *H3005A005*
*H3005A005*
*H3005A078*
QUILL SHAFT - GEAR
SENSOR
1 € 34.64
10 *H3005A010*
*H3005A010*
*HCOM00057*
DRUM STOPPER 1 € 9.36
13 *HCOM00052*
*HCOM00052*
*HCOM00058*
COIL SPRING 1 € 1.98
22 *H3005A022*
*H3005A022*
SELECTOR BARREL ASSY 1 € 294.09 120 *H3005A120*
*H3005A120*
SELECTOR RAIL 1 € 90.49
23 *H3005A023*
*H3005A023*
SELECTOR FORK ASSEMBLY 3 € 122.42 134 *H3005A134*
*H3005A134*
OLDHAM COUPLING 1 € 22.32
173 *H3005A173*
*H3005A173*
SELECTOR FORK ASSY 1 € 123.76
25 *H3005A025*
*H3005A025*
CIR-CLIP 1 € 0.36
30 *HCOM00053*
*HCOM00053*
DOWEL 1 € 0.30
39 *H3005A039*
*H3005A039*
BEARING RETAINING PLATE 1 € 23.44
45 *HCOM00054*
*HCOM00054*
SPRING TRUNION 1 € 10.96
52 *HCOM00055*
*HCOM00055*
DRUM WASHER 1 € 1.22
58 *HCOM00056*
*HCOM00056*
59 *H3004A059*
*H3004A059*
63 *H3005A063*
*H3005A063*
LIP SEAL 1 € 1.82


FIGURE 16
05B - SELECTOR FORK SUB ASSEMBLY
159 *HCOM00059* ROLL PIN 1 € 2.50

*HCOM00059*
160 *HCOM00060* SELECTOR FORK PIN 1 € 20.59

*HCOM00060*

05B - SELECTOR FORK SUB ASSEMBLY
FIGURE 17

05C - SELECTOR BARREL SUB ASSEMBLY
163 *HCOM00073* BARREL PIN 8 € 3.43

*HCOM00073*
164 *HCOM00061* GEAR SENSOR DRIVE 1 € 18.88

*HCOM00061*

05C - SELECTOR BARREL SUB ASSEMBLY
FIGURE 18

06A GEAR CLUSTER ASSEMBLY
INTEGRAL 2ND GEAR OPTION
2 *HCOM00062* NEEDLE ROLLER BEARING 7 € 19.25 28 *H3006A028*

*H3006A028*
REVERSE IDLER 1 € 68.67
*HCOM00062*
3 *H3006A003* LAYSHAFT SPACER 1 € 36.73 29 *H3006A029*

*H3006A029*
REVERSE IDLER SPIGOT 1 € 25.19
*H3006A003*
4 *H3006A004* DISC SPRING 1 € 24.52

38 *HCOM00065*
*HCOM00065*
CIRCLIP 1 € 0.33
*H3006A004*
9 *H3006A009* ROLLER BEARING 1 € 13.87

40 *H3006A040*
*H3006A040*
*H3006A009*
41 *H3006A041* SLEEVE 1 € 19.23
11 *HCOM00063* ROLLER BEARING 1 € 35.31 *H3006A041*
*HCOM00063*
46 *H3002A046* CROW N W HEEL & PINION
ASSEMBLY (11:31)
1 € 1,545.67
12 *H3006A012*
*H3006A012*
ROLLER BEARING 1 € 16.86 *H3002A046*
CROW N W HEEL & PINION

46 *H3002A346* ASSEMBLY (10:35)
1 € 2,401.77
19 *H3006A019* SPRAY RAIL 1 € 103.23 *H3002A346*
*H3006A019*
47 *H3006A047* CLUTCH RING 4 € 157.41
20 *H3006A020* PINION BEARING ASSEMBLY 1 € 173.83
*H3006A047*
*H3006A020*
48 *H3006A048* HUBBED RATIO SET 1 € 297.32
21.1 *H3006A021* FORK SETTING SPACER
(2.667mm)
0 € 52.47
*H3006A048*
*H3006A021* 49 *H3006A049*
*H3006A049*
LAYSHAFT SET (INTEGRAL
2ND)
1 € 765.15
21.2 *H3006A022*
*H3006A022*
FORK SETTING SPACER
(2.794mm)
0 € 52.47
51 *HCOM00066* NEEDLE ROLLER BEARING 1 € 9.14
*HCOM00066*
21.3 *H3006A023*
*H3006A023*
FORK SETTING SPACER
(2.921mm)
0 € 52.47
70 *H3006A070* CLAMP PLATE 1 € 29.95
*H3006A070*
21.4 *H3006A024*
*H3006A024*
FORK SETTING SPACER
(3.048mm)
0 € 52.47
71 *H3006A071* HUB 3 € 150.82
*H3006A071*
21.5 *H3006A025*
*H3006A025*
FORK SETTING SPACER
(3.175mm)
0 € 52.47 72 *H3006A072* HUB - REVERSE 1 € 111.83
*H3006A072*
21.6 *H3006A026*
*H3006A026*
FORK SETTING SPACER
(3.302mm)
0 € 52.47 73 *H3006A073*
*H3006A073*
REVERSE PINION GEAR 1 € 124.96

FIGURE 19

2 *HCOM00062* NEEDLE ROLLER BEARING 7 € 19.25 28 *H3006A028*

*H3006A028*
*HCOM00062*
3 *H3006A003* LAYSHAFT SPACER 1 € 36.73 29 *H3006A029*

*H3006A029*
*H3006A003*
4 *H3006A004* DISC SPRING 1 € 24.52

38 *HCOM00065*
*HCOM00065*
CIRCLIP 1 € 0.33
*H3006A004*
9 *H3006A009* ROLLER BEARING 1 € 13.87

40 *H3006A040*
*H3006A040*
*H3006A009*
41 *H3006A041* SLEEVE 1 € 19.23
11 *HCOM00063* ROLLER BEARING 1 € 35.31 *H3006A041*
*HCOM00063*
1 € 1,545.67
12 *H3006A012*
*H3006A012*
ROLLER BEARING 1 € 16.86 *H3002A046*
ASSEMBLY (11:31)

ASSEMBLY (10:35)
1 € 2,401.77
19 *H3006A019* SPRAY RAIL 1 € 103.23 *H3002A346*
*H3006A019*
47 *H3006A047* CLUTCH RING 4 € 157.41
20 *H3006A020* PINION BEARING ASSEMBLY 1 € 173.83
*H3006A047*
*H3006A020*
48 *H3006A048* HUBBED RATIO SET 1 € 297.32
21.1 *H3006A021* FORK SETTING SPACER
0 € 52.47
*H3006A048*
*H3006A021*
(2.667mm)
49 *H3006A049*
*H3006A049*
LAYSHAFT SET (INTEGRAL
2ND)
1 € 765.15
21.2 *H3006A022*
*H3006A022*
FORK SETTING SPACER
(2.794mm)
0 € 52.47
51 *HCOM00066* NEEDLE ROLLER BEARING 1 € 9.14
*HCOM00066*
21.3 *H3006A023*
*H3006A023*
FORK SETTING SPACER
(2.921mm)
0 € 52.47
70 *H3006A070* CLAMP PLATE 1 € 29.95
*H3006A070*
21.4 *H3006A024*
*H3006A024*
FORK SETTING SPACER
(3.048mm)
0 € 52.47
71 *H3006A071* HUB 3 € 150.82
*H3006A071*
21.5 *H3006A025*
*H3006A025*
FORK SETTING SPACER
(3.175mm)
0 € 52.47 72 *H3006A072* HUB - REVERSE 1 € 111.83
*H3006A072*
21.6 *H3006A026*
*H3006A026*
FORK SETTING SPACER
(3.302mm)
0 € 52.47 73 *H3006A073*
*H3006A073*

FIGURE 19

82 *H3006A082*
*H3006A082*
PINION BEARING SHIM
(PEELABLE)
1 € 21.33 50.1 *H30101629*
*H30101629*
2ND - 6TH RATIO PAIR 16:29 1 € 297.15
84 *HCOM00067*
*HCOM00067*
LOCKING RING 1 € 101.32 50.2 *H30101826*
*H30101826*
2ND - 6TH RATIO PAIR 18:26 1 € 297.15
98 *H3006A098*
*H3006A098*
COUNTERSUNK SET SCREW 1 € 0.12 50.3 *H30102025*
*H30102025*
2ND - 6TH RATIO PAIR 20:25 1 € 297.15
102 *H3006A102*
*H3006A102*
SOCKET CAP SCREW 1 € 7.92 50.4 *H30101923*
*H30101923*
2ND - 6TH RATIO PAIR 19:23 1 € 297.15
106 *H3006A106*
*H3006A106*
*H30102226*
2ND - 6TH RATIO PAIR 22:26 1 € 297.15
111 *H3006A111*
*H3006A111*
SPACER 1 € 24.73 50.6 *H30102831*
*H30102831*
2ND - 6TH RATIO PAIR 28:31 1 € 297.15
112 *H3006A112*
*H3006A112*
HUB SPACER 1 € 10.05 50.7 *H30102224*
*H30102224*
2ND - 6TH RATIO PAIR 22:24 1 € 297.15
118 *H3006A118*
*H3006A118*
BEARING INNER TRACK 1 € 56.94 50.8 *H30102728*
*H30102728*
2ND - 6TH RATIO PAIR 27:28 1 € 297.15
127 *H3006A127*
*H3006A127*
SHAFT NUT 1 € 62.06 50.9 *H30102424*
*H30102424*
2ND - 6TH RATIO PAIR 24:24 1 € 297.15
133 *H3006A133*
*H3006A133*
WASHER 1 € 19.47 50.11 *H30102524*
*H30102524*
2ND - 6TH RATIO PAIR 25:24 1 € 297.15
136 *H3006A136*
*H3006A136*
LAYSHAFT SPACER 0 € 58.32 50.12 *H30102624*
*H30102624*
2ND - 6TH RATIO PAIR 26:24 1 € 297.15
50.13 *H30102724*
*H30102724*
2ND - 6TH RATIO PAIR 27:24 1 € 297.15
50.14 *H30102824*
*H30102824*
2ND - 6TH RATIO PAIR 28:24 1 € 297.15

FIGURE 19

06A CLUSTER ASSEMBLY
LOOSE 2ND GEAR OPTION
2 *HCOM00062*
*HCOM00062*
*H3006A028*
3 *H3006A003*
*H3006A003*
LAYSHAFT SPACER 1 € 36.73 29 *H3006A029*
*H3006A029*
4 *H3006A004*
*H3006A004*
DISC SPRING 1 € 24.52 38 *HCOM00065*
*HCOM00065*
CIRCLIP 1 € 0.33
9 *H3006A009*
*H3006A009*
ROLLER BEARING 1 € 13.87 40 *H3006A040*
*H3006A040*
11 *HCOM00063*
*HCOM00063*
ROLLER BEARING 1 € 35.31 41 *H3006A041*
*H3006A041*
SLEEVE 1 € 19.23
12 *H3006A012* ROLLER BEARING 1 € 16.86 46 *H3002A046*

*H3002A046*
ASSEMBLY (11:31)
1 € 1,545.67
*H3006A012*
19 *H3006A019*
*H3006A019*
SPRAY RAIL 1 € 103.23 46 *H3002A346* CROWN WHEEL & PINION
ASSEMBLY (10:35)
1 € 2,401.77
*H3002A346*
20 *H3006A020*
*H3006A020*
PINION BEARING ASSEMBLY 1 € 173.83 47 *H3006A047* CLUTCH RING 4 € 157.41
*H3006A047*
21.1 *H3006A021*
*H3006A021*
FORK SETTING SPACER
(2.667mm)
0 € 52.47 48 *H3006A048* HUBBED RATIO SET 0 € 297.32
*H3006A048*
21.2 *H3006A022*
*H3006A022*
FORK SETTING SPACER
(2.794mm)
0 € 52.47 51 *HCOM00066*
*HCOM00066*
NEEDLE ROLLER BEARING 1 € 9.14
21.3 *H3006A023*
*H3006A023*
FORK SETTING SPACER
(2.921mm)
0 € 52.47 70 *H3006A070*
*H3006A070*
CLAMP PLATE 1 € 29.95
21.4 *H3006A024*
*H3006A024*
FORK SETTING SPACER
(3.048mm)
0 € 52.47 71 *H3006A071*
*H3006A071*
HUB 3 € 150.82
21.5 *H3006A025*
*H3006A025*
FORK SETTING SPACER
(3.175mm)
0 € 52.47 72 *H3006A072*
*H3006A072*
HUB - REVERSE 1 € 111.83
21.6 *H3006A026*
*H3006A026*
FORK SETTING SPACER
(3.302mm)
0 € 52.47 73 *H3006A073*
*H3006A073*

FIGURE 20

82 *H3006A082*
*H3006A082*
PINION BEARING SHIM
(PEELABLE)
1 € 21.33 50.3 *H30102025*
*H30102025*
2ND - 6TH RATIO PAIR 20:25 1 € 297.15
84 *HCOM00067*
*HCOM00067*
LOCKING RING 1 € 101.32 50.4 *H30101923*
*H30101923*
2ND - 6TH RATIO PAIR 19:23 1 € 297.15
98 *H3006A098*
*H3006A098*
COUNTERSUNK SET SCREW 1 € 0.12 50.5 *H30102226*
*H30102226*
2ND - 6TH RATIO PAIR 22:26 1 € 297.15
102 *H3006A102*
*H3006A102*
*H30102831*
2ND - 6TH RATIO PAIR 28:31 1 € 297.15
106 *H3006A106*
*H3006A106*
*H30102224*
2ND - 6TH RATIO PAIR 22:24 1 € 297.15
111 *H3006A111*
*H3006A111*
SPACER 1 € 24.73 50.8 *H30102728*
*H30102728*
2ND - 6TH RATIO PAIR 27:28 1 € 297.15
112 *H3006A112*
*H3006A112*
HUB SPACER 1 € 10.05 50.9 *H30102424*
*H30102424*
2ND - 6TH RATIO PAIR 24:24 1 € 297.15
118 *H3006A118*
*H3006A118*
BEARING INNER TRACK 1 € 56.94 50.11 *H30102524*
*H30102524*
2ND - 6TH RATIO PAIR 25:24 1 € 297.15
127 *H3006A127*
*H3006A127*
SHAFT NUT 1 € 62.06 50.12 *H30102624*
*H30102624*
2ND - 6TH RATIO PAIR 26:24 1 € 297.15
133 *H3006A133*
*H3006A133*
WASHER 1 € 19.47 50.13 *H30102724*
*H30102724*
2ND - 6TH RATIO PAIR 27:24 1 € 297.15
136 *H3006A136*
*H3006A136*
LAYSHAFT SPACER 1 € 58.32 50.14 *H30102824*
*H30102824*
2ND - 6TH RATIO PAIR 28:24 1 € 297.15
50.1 *H30101629*
*H30101629*
2ND - 6TH RATIO PAIR 16:29 1 € 297.15 135.1 *H30101435*
*H30101435*
LAYSHAFT INT 1ST RATIO
14:35
1 € 611.10
50.2 *H30101826*
*H30101826*
2ND - 6TH RATIO PAIR 18:26 1 € 297.15 135.2 *H30201435*
*H30201435*
LAYSHAFT INT 1ST RATIO
WIDE 14:35
1 € 682.50

FIGURE 20

PINION SHAFT
20 *H3006A020*
*H3006A020*
PINION BEARING ASSEMBLY 1 € 173.83
46 *H3002A046*
*H3002A046*
ASSEMBLY (11:31)
1 € 1,545.67
46 *H3002A346*
*H3002A346*
ASSEMBLY (10:35)
1 € 2,401.77
82 *H3006A082*
*H3006A082*
PINION BEARING SHIM
(PEELABLE)
1 € 21.33

PINION SHAFT
FIGURE 21

06B - PINION BEARING SUB ASSEMBLY
155 *H3006B001*
*H3006B001*
SPACER 1 € 39.57
156 *H3006B002*
*H3006B002*
PINION HEAD BEARING
HOUSING
1 € 111.49
157 *H3006B003*
*H3006B003*
TAPER ROLLER BEARING 1 € 14.52
158 *H3006B004*
*H3006B004*
TAPER ROLLER BEARING 1 € 13.03

06B - PINION BEARING SUB ASSEMBLY
FIGURE 22

07A GEARBOX TOOLING
165 *HCOM00064*
*HCOM00064*
SOCKET ONLY (SEPERATE
PART)
1 € 130.11
166 *HCOM00074*
*HCOM00074*
REACTION BAR SPANNER 1 € 310.45
167 *H3007A002*
*H3007A002*
NMT PINION TOOL 1 € 153.46
168 *H3007A003*
*H3007A003*
FORK SETTING FIXTURE
ASSY
1 € 262.33
169 *H3007A004*
*H3007A004*
DIFF HOLDING POST 1 € 149.53
170 *HCOM00068*
*HCOM00068*
SPACER 1 € 20.59
171 *HCOM00069*
*HCOM00069*
DIFF PRELOAD TOOL - 32
SPLINE (SHORT)
1 € 96.08
172 *H3007A007*
*H3007A007*
DUMMY BEARING 2 € 102.31

07A GEARBOX TOOLING
FIGURE 23

Common Part Locations
Part Number Item Pages Part Number Item Pages Part Number Item Pages
HCOM00001 6 16‐17 HCOM00026 37.6 26‐27 HCOM00051 17 34‐35
HCOM00002 7 16‐17 HCOM00027 37.7 26‐27 HCOM00052 13 36‐37
HCOM00003 8 16‐17 HCOM00028 147 28‐29 HCOM00053 30 36‐37
HCOM00004 26 16‐17 HCOM00029 143 28‐29 HCOM00054 45 36‐37
HCOM00005 54 16‐17 HCOM00030 145 28‐29 HCOM00055 52 36‐37
HCOM00006 55 16‐17 HCOM00031 151 28‐29 HCOM00056 58 36‐37
HCOM00007 56 16‐17 HCOM00032 148 28‐29 HCOM00057 92 36‐37
HCOM00008 57 16‐17 HCOM00033 149.2 28‐29 HCOM00058 93 36‐37
HCOM00009 61 16‐17 HCOM00034 150 28‐29 HCOM00059 159 40‐41
HCOM00010 85 16‐17 HCOM00035 146.2 28‐29 HCOM00060 160 40‐41
HCOM00011 86 16‐17 HCOM00036 146.3 28‐29 HCOM00061 164 42‐43
HCOM00012 87 16‐17 HCOM00037 146.4 28‐29 HCOM00062 2 44‐45
HCOM00013 88 16‐17 HCOM00038 146.5 28‐29 HCOM00063 11 44‐45
HCOM00014 94 16‐17 HCOM00039 146.6 28‐29 HCOM00064 165 56‐57
HCOM00015 101 18‐19 HCOM00040 149.1 28‐29 HCOM00065 38 44‐45
HCOM00016 103 18‐19 HCOM00041 1 28‐29 HCOM00066 51 44‐45
HCOM00017 128 18‐19 HCOM00042 14 28‐29 HCOM00067 84 48‐49
HCOM00018 130 18‐19 HCOM00043 15 28‐29 HCOM00068 170 56‐57
HCOM00019 161 24‐25 HCOM00044 16 28‐29 HCOM00069 171 56‐57
HCOM00020 33 26‐27 HCOM00045 43 28‐29 HCOM00070 137 34‐35
HCOM00021 37.1 26‐27 HCOM00046 44 28‐29 HCOM00071 53 16‐17
HCOM00022 37.2 26‐27 HCOM00047 108 28‐29 HCOM00072 146.1 28‐29
HCOM00023 37.3 26‐27 HCOM00048 113 28‐29 HCOM00073 163 42‐43
HCOM00024 37.4 26‐27 HCOM00049 114 28‐29 HCOM00074 166 56‐57
HCOM00025 37.5 26‐27 HCOM00050 115 28‐29

AMENDMENTS
Issue 1: First Issue

Issue 7: Hewland part Numbers added to Parts Lists
Issue 8: Parts lists and drawings updated
Issue 10: Parts Lists Updated
Issue 11: Prices Updated
Issue 13: Barcode Format Altered
Issue 14: Illustration corrected (page 37)

Notes:-

Hewland Part References

Item Part Number Description Qty Item Part Number Description Qty
1 102-260-9 COMPRESSION SPRING 1 35 FGC-205-3 BALL BEARING 2
2 104-226-2 NEEDLE ROLLER BEARING 7 36 FGC-205-4 LIP SEAL 2
3 104-234-4 LAYSHAFT SPACER 1 37.1 FGC-206-1-003 SHIM (0.076mm) 0
4 105-234-8 DISC SPRING 1 37.2 FGC-206-1-005 SHIM (0.127mm) 0
5 105-260-6 NEEDLE ROLLER BEARING 1 37.3 FGC-206-1-008 SHIM (0.203mm) 0
6 306-06-M14D ADAPTOR 1 37.4 FGC-206-1-010 SHIM (0.254mm) 0
7 400-868-4490-41 DOWTY WASHER 1 37.5 FGC-206-1-015 SHIM (0.381mm) 0
8 7710E-020-060 IN-LINE FILTER 1 37.6 FGC-206-1-020 SHIM (0.508mm) 0
9 BEA-001 ROLLER BEARING 1 37.7 FGC-206-1-025 SHIM (0.635mm) 0
10 BEA-052 BALL BEARING 1 38 FT-219-1A CIRCLIP 1
11 BEA-079 ROLLER BEARING 1 39 FTR-202-2 BEARING RETAINING PLATE 1
12 BEA-093 ROLLER BEARING 1 40 FTR-237-1 REVERSE IDLER SPIGOT 1
13 BEA-141 BALL BEARING 1 41 FTR-237-2 SLEEVE 1
14 BEA-162 BALL BEARING 2 42 FTR-260-3 SELECTOR RACK 1
15 CIR-082 CIRCLIP 1 43 FTR-260-4 SELECTOR RACK WASHER 2
16 CIR-084 CIRCLIP 1 44 FTR-260-5 SLEEVE 1
17 CIR-185 CIRCLIP 1 45 FTR-260-8 SPRING TRUNION 1
18 CPK-201-1 SPRAY RAIL ASSEMBLY 1 46 GP3-221-11:31 CROWN WHEEL & PINION (11:31) 1
19 CPK-201-2 SPRAY RAIL 1 46 GP3-221-10:35 CROWN WHEEL & PINION (10:35) 1
20 CPK-223 PINION BEARING ASSEMBLY 1 47 GP3-232 CLUTCH RING 4
21.1 CPK-229-1-105 FORK SETTING SPACER (2.667mm) 0 48 GP3-RATIO-HUB HUBBED RATIO SET 1
21.2 CPK-229-1-110 FORK SETTING SPACER (2.794mm) 0 49 GP3-RATIO-RATIO LAYSHAFT SET (INTEGRAL 2ND) 1
21.3 CPK-229-1-115 FORK SETTING SPACER (2.921mm) 0 50 GP3-RATIO-STD RATIO SET 3
21.4 CPK-229-1-120 FORK SETTING SPACER (3.048mm) 0 51 HC-237-2 NEEDLE ROLLER BEARING 1
21.5 CPK-229-1-125 FORK SETTING SPACER (3.175mm) 0 52 HP-M-7039 DRUM WASHER 1
21.6 CPK-229-1-130 FORK SETTING SPACER (3.302mm) 0 53 HP-M-9004 MAGNETIC PLUG 1
22 CPK-260 SELECTOR BARREL ASSY 1 54 HP-M-9037 BANJO JOINT 1
23 CST-250-C SELECTOR FORK ASSEMBLY 4 55 HP-M-9038 SEALING WASHER 2
24 DG-219-1A CIR-CLIP 2 56 HP-M-9039 BANJO BOLT 1
25 DGB-239-0 CIR-CLIP 1 57 HP-M-9042 DOWTY WASHER 2
26 DOW-030 RING DOWEL 4 58 HP-M-9054 SOCKET CAP SCREW 1
27 DOW-063 DOWEL 1 59 HP-N-9006 SOCKET CAP SCREW 5
28 EGT-237-1 REVERSE IDLER 1 60 LD-201-5 DOWEL 2
29 EGT-237-2 REVERSE IDLER SPIGOT 1 61 LD-202-9 WASHER 10
30 F3A-202-9A DOWEL 1 62 LIP-094 LIP SEAL 1
31 STU-120 STUD 6 63 LIP-096 LIP SEAL 1
32 F3D-236-1 WASHER 1 64 LSF-201-4 SHAFT RETAINER 1
33 FGC-205-1 TAPER ROLLER BEARING 2 65 MLI-201-1 BRACKET - BELLCRANK 1
34 FGC-205-2A L/H SIDEPLATE SPACER 1 66 MLI-205 SIDE COVER 1

Item Part Number Description Qty Item Part Number Description Qty
67 MLI-208-1 OIL PUMP COVER 1 106 SCR-343 SOCKET CAP SCREW 5
68 MLI-208-2 BRACKET TRIGGER SENSOR 2 107 SGT-202-12 SOCKET CAP SCREW 8
69 MLI-218 TRIPOD OUTER JOINT 2 108 SGT-244-13 SOCKET CAP SCREW 8
70 MLI-223-1 CLAMP PLATE 1 109 SHL-260-2 SPACER TUBE 1
71 MLI-226 HUB 3 110 SHL-260-4 BELLCRANK 1
72 MLI-228 HUB - REVERSE 1 111 SPA-012 SPACER 1
73 MLI-231 REVERSE PINION GEAR 1 112 SPA-052 HUB SPACER 1
74 MLI-234-1 OIL PUMP DRIVE 1 113 SPH1077-M3 PAWL 1
75 MLI-239-2 CLUTCH SHAFT 1 114 SPH1078-M3 PLUNGER 1
76 MLI-244 SLAVE CYLINDER ADAPTOR 1 115 SPR-130 COMPRESSION SPRING 1
77 MLI-244-1 SENSOR MOUNTING PLATE 1 116 STU-038 STUD 4
78 MLI-260-1 QUILL SHAFT - GEAR SENSOR 1 117 STU-039 STUD 11
79 MLI-301 MAINCASE - DRESSED 1 118 TE-234-2 BEARING INNER TRACK 1
80 MLI-307-B BELLHOUSING - DRESSED 1 119 TE-266 OIL FILTER 1
81 MLI-308 REAR COVER - DRESSED 1 120 TLS-246 SELECTOR RAIL 1
82 NLT-223-2 PINION BEARING SHIM (PEELABLE) 1 121 TMT-260-5 RACK END COVER 1
83 NMT-205-2A SIDEPLATE SPACER 1 122 TMT-260-6 RACK SPACER 1
84 NMT-230-1 LOCKING RING 1 123 TMT-260-7 RACK END SEAL HOUSING 1
85 NUT-004 KAYNUT 13 124 TMT-265-1 OIL PUMP ROTORS 1
86 NUT-005 KAYNUT 11 125 TPT-212 TPT DIFF ASSEMBLY 1
87 NUT-008 K-NUT 4 126 TR-100-AC O-RING 1
88 ORI-027 O-RING 1 127 TSHD-230 SHAFT NUT 1
89 ORI-065 O-RING 1 128 VG-201-9 SEALING STRIP 2
90 ORI-118 O-RING 2 129 VG-221-1C CROWN WHEEL BOLT 10
91 ORI-227 QUAD RING 1 130 WSH-010 DOWTY WASHER 3
92 PCT-260-2 DRUM STOPPER 1 131 WSH-027 WASHER 4
93 PCT-260-3 COIL SPRING 1 132 WSH-028 WASHER 13
94 PLU-030 PLUG 3 133 WSH-051 WASHER 1
95 PLU-048 BLANKING PLUG 1 134 ZH147-01 OLDHAM COUPLING 1
96 SCR-002 SOCKET SET SCREW 3 135.1 GP3-14:35-INT LAYSHAFT INT 1ST RATIO 14:35 0
97 SCR-012 SOCKET CAP SCREW 2 136 TE-234-1 LAYSHAFT SPACER 0
98 SCR-023 COUNTERSUNK SET SCREW 1 137 HP-M-9031 COUNTERSUNK SCREW 2
99 SCR-049 SOCKET CAP SCREW 3 138 STU-102 STUD 2
100 SCR-092 SOCKET CAP SCREW 4 139 SCR-068 SOCKET CAP SCREW 1
101 SCR-107 SOCKET SET SCREW 1 140 SCR-069 SOCKET CAP SCREW 2
102 SCR-117 SOCKET CAP SCREW 1 141 MLI-208-3 ACTUATOR BRACKET 1
103 SCR-129 SOCKET CAP SCREW 3 142.1 WSH-067 SHIM WASHER 0.076MM 0
Item Part Number Description Qty
142.4 WSH-067 SHIM WASHER 0.508MM 0
143 HP-N-2041-H SIDE BEVEL GEAR 2
144 ORI-153 O-RING 1
145 SPR-150 DISC SPRING 1
146.1 TPT-213-3 PRELOAD SPACER 3.94mm 0
146.2 TPT-213-3A PRELOAD SPACER 2.41/2.29mm 0
146.3 TPT-213-3B PRELOAD SPACER 3.05/2.92mm 0
146.4 TPT-213-3C PRELOAD SPACER 5.97mm 0
146.5 TPT-213-3D PRELOAD SPACER 4.78/4.65mm 0
146.6 TPT-213-3E PRELOAD SPACER 5.54/5.41mm 0
147 TPT-213-3SP PRELOAD SPRING CARRIER 1
148 TPT-213-5AH PLANET DIFF. GEAR 3
149.1 TPT-213-7-20X80 SIDE RING GEARS 20 x 80 1
149.2 TPT-213-7-45X60 SIDE RING GEARS 45x60 0
150 TPT-213-8 CORE PLATE 6
151 TPT-213-10 OUTER DRIVE CLUTCH PLATE 4
152 TPT-213-12 SOCKET CAP SCREW 6
153 TPTS-213 DIFF CASE 1
154 TPTS-214 DIFF END PLATE 1
155 CPK-223-1 SPACER 1
156 CPK-223-A PINION HEAD BEARING HOUSING 1
157 VG-222-1A TAPER ROLLER BEARING 1
158 VG-222-1B TAPER ROLLER BEARING 1
159 RM-265-16 ROLL PIN 1
160 TLS-250-1 SELECTOR FORK PIN 1
161 ORI-001 O-RING 2
162 PLU-054 PLUG 1
163 DOW-033 BARREL PIN 8
164 DTR-260-1A GEAR SENSOR DRIVE 1
165 SK-1452-A SOCKET ONLY (SEPERATE PART) 1
166 SK-1452-B REACTION BAR SPANNER 1
167 SK-1913 NMT PINION TOOL 1
168 SK-2359 FORK SETTING FIXTURE ASSY 1
169 SK-838-A DIFF HOLDING POST 1
170 SK-838-B SPACER 1
171 SK-838-C DIFF PRELOAD TOOL - 32 SPLINE 1
172 SK-119-FGC DUMMY BEARING 2
173 MLI-250-A SELECTOR FORK ASSY 1

GP3 2013 Hewland Gearbox MLI User Manual Issue 15 Dated 22 01 2013

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GP3 2013 Hewland Gearbox MLI User Manual Issue 15 Dated 22 01 2013

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SERVICING INSTRUCTIONS AND

ILLUSTRATED PARTS LIST FOR MLI GEARBOX

HEWLAND ENGINEERING LTD

Technical Specification 4 Differential Assembly 26

Recommended Torque Settings 5 Differential Unit Sub Assembly 28

General Notes 6 Selector Rack Assembly 30

Differential Bearing Preload 7 Input Shaft Assembly 34

Pinion Shaft Setting 8 Fork and Barrel Assembly 36

Crownwheel Backlash Setting 9 Selector Fork Sub Assembly 40

Sequential Barrel Setting 10 Selector Barrel Sub Assembly 42

Gearbox Assembly 11 Gear Cluster Assembly: Integral 2nd Gear Option 44

Powerflow Differential 13 Gear Cluster Assembly: Loose 2nd Gear Option 48

Differential Setting 14 Cluster Assembly: Pinion shaft 54

Illustrated Parts List 15 Pinion Bearing Sub Assembly 56

Casings and Associated Parts 16 Gearbox Tooling 58

Oil Spray Sub Assembly 24 Common Part Locations 60

Fig.1 Differential Bearing Preload 7 Fig.16 Fork and Barrel Assembly 39

Fig.2 Pinion Shaft Setting 8 Fig.17 Selector Fork Sub-Assembly 41

Fig.3 Crownwheel Backlash Setting 9 Fig.18 Selector Barrel Sub Assembly 43

Fig.4 Sequential Barrel Setting 10 Fig.19 Gear Cluster Assembly:

Fig.9 Oil Spray Sub Assembly 25 Fig.23 Gearbox Tooling 57

Fig.10 Differential Assembly 27

Fig.11 Differential Unit Sub Assembly 29

Fig.12 Selector Rack Assembly 31

Fig.13 Selector Rack Assembly 33

Fig.14 Input Shaft Assembly 35

Fig.15 Fork and Barrel Assembly 37

1st to 6th gear ratios from 3.083:1 to 0.857:1

Weight 57Kg Including Bell housing

Issue 15 - 22nd January 2013 4

General nut and bolt torque settings:-

RECOMMENDED TIGHTENING RECOMMENDED TIGHTENING TORQUES RECOMMENDED TIGHTENING TORQUES

RECOMMENDED TIGHTENING TORQUES FOR METRIC

Specific nut and bolt torque settings:-

Pinion shaft nut tightening torque = 120 lbs.ft (163 Nm)

Issue 15 - 22nd January 2013 5

a) Read these instructions carefully and with reference to the illustrations.

Issue 15 - 22nd January 2013 6

Issue 15 - 22nd January 2013 7

Measure the distance from the pinion head to the maincase

It is also good practice to renew the pinion head bearing if the

Requires special tool No. H3007A002

Be sure to take at least 6 backlash readings, turning the crownwheel

The correct minimum backlash figure should be 0.005” (0.13mm) taken

NB. Generally 0.001” of crownwheel axial adjustment equates to

Do not add or discard any shims, as to do so will affect the

Requires special tool H3007A003 (see tooling page)

Issue 15 - 22nd January 2013 FIGURE 4 10

Issue 15 - 22nd January 2013 11

I) Fit the gear cluster oil spray rail (19).

Issue 15 - 22nd January 2013 12

Percentage Rating Ramp Angle No. of Friction Surfaces

This table is intended as a quick reference guide to

Issue 15 - 22nd January 2013 14

Issue 15 - 22nd January 2013 15

Issue 15 - 22nd January 2013 16

Issue 15 - 22nd January 2013 17

Issue 15 - 22nd January 2013 18

Issue 15 - 22nd January 2013 19

Issue 15 - 22nd January 2013 20

Issue 15 - 22nd January 2013 21

Issue 15 - 22nd January 2013 22

Issue 15 - 22nd January 2013 23

Item Barcode Description Qty Price

161 HCOM00019 O-RING 2 € 0.13

162 H3001B003 PLUG 1 € 6.70

159 HCOM00059 ROLL PIN 1 € 2.50

160 HCOM00060 SELECTOR FORK PIN 1 € 20.59

163 HCOM00073 BARREL PIN 8 € 3.43

164 HCOM00061 GEAR SENSOR DRIVE 1 € 18.88

2 HCOM00062 NEEDLE ROLLER BEARING 7 € 19.25 28 H3006A028

3 H3006A003 LAYSHAFT SPACER 1 € 36.73 29 H3006A029

4 H3006A004 DISC SPRING 1 € 24.52

9 H3006A009 ROLLER BEARING 1 € 13.87

2 HCOM00062 NEEDLE ROLLER BEARING 7 € 19.25 28 H3006A028

3 H3006A003 LAYSHAFT SPACER 1 € 36.73 29 H3006A029

4 H3006A004 DISC SPRING 1 € 24.52

9 H3006A009 ROLLER BEARING 1 € 13.87

46 H3002A346 CROW N W HEEL & PINION

12 H3006A012 ROLLER BEARING 1 € 16.86 46 H3002A046