Gearbox Manual DG350 2017 - drenth-gearboxes.com · Gearbox Manual DG350 – Revision: 009 Pole Position In Gearboxes 1.3. Oil System A gerotor internal-gear pump is standard in the

Gearbox Manual DG350

2017

2

Gearbox Manual DG350 – Revision: 009

Pole Position

In Gearboxes

Warning Please be aware that information in this manual may be inaccurate, incomplete or contain typographical errors. The content of this manual is subject to

change without notice and should, therefore, be used for informational purposes only. Consequently, replacement parts must always by ordered according

to the part number engraved on the part.

If you find information in this manual that is incorrect or incomplete, we would appreciate your comments and suggestions.

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Contents Warning ............................................................................................................................................................................................................................................. 2

Contents ............................................................................................................................................................................................................................................ 3

1. Technical Specifications................................................................................................................................................................................................................. 5

1.1. General Specifications ............................................................................................................................................................................................................ 6

1.2. General Dimensions ................................................................................................................................................................................................................ 7

1.2.1. Ford T9 – Short Version.................................................................................................................................................................................................... 7

1.2.2. Toyota GT86 ..................................................................................................................................................................................................................... 8

1.2.3. Ford T9 - Direct Replacement .......................................................................................................................................................................................... 9

1.2.4. BMW .............................................................................................................................................................................................................................. 10

1.3. Oil System ............................................................................................................................................................................................................................. 11

2. Gearbox Assembly ....................................................................................................................................................................................................................... 12

2.1. General Instruction Notes..................................................................................................................................................................................................... 13

2.2. Bearing Assembly .................................................................................................................................................................................................................. 14

2.3. Gearbox Assembly Ford T9 ................................................................................................................................................................................................... 16

2.4. Gearbox Assembly Toyota GT86 ........................................................................................................................................................................................... 54

2.5. Gearbox Assembly BMW E30 ............................................................................................................................................................................................... 58

2.6. Gearbox Assembly Opel ........................................................................................................................................................................................................ 60

2.7. Rotary Sensor ........................................................................................................................................................................................................................ 62

3. Accessories .................................................................................................................................................................................................................................. 65

3.1. Bellhousings / Adaptor Plates ............................................................................................................................................................................................... 66

3.2. Gearbox Brackets .................................................................................................................................................................................................................. 68

3.3. Gear Lever ............................................................................................................................................................................................................................. 69

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3.4. DMS Gear Lever .................................................................................................................................................................................................................... 71

3.5. Gear lever Brackets ............................................................................................................................................................................................................... 73

3.6. Gear Indicator ....................................................................................................................................................................................................................... 74

3.7. Display Unit ........................................................................................................................................................................................................................... 75

3.8. Switchbox .............................................................................................................................................................................................................................. 76

3.9. Oil Breather Catchtank ......................................................................................................................................................................................................... 77

4. Assembly Tooling ......................................................................................................................................................................................................................... 78

5. Contact Information .................................................................................................................................................................................................................... 81

5.1. Contact Details ...................................................................................................................................................................................................................... 82

Appendix A: Technical Bulletin ........................................................................................................................................................................................................ 83

Appendix B: Amendments ............................................................................................................................................................................................................... 85

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1. Technical Specifications

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1.1. General Specifications

DG350

Application Circuit, Hill Climb & Rally

Type 6-Speed Sequential

Torque rating 350 Nm

Weight (dry weight) 27.5 kg

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1.2. General Dimensions

1.2.1. Ford T9 – Short Version

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1.2.2. Toyota GT86

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1.2.3. Ford T9 - Direct Replacement

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1.2.4. BMW

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1.3. Oil System A gerotor internal-gear pump is standard in the DG350. The oil pump is used to feed oil to the bearings, gears, dog rings and drop gears. The oil can be fed

to an external oil cooler from the oil-out port and returned to the gearbox using the oil-in port. On the right and left side of the main housing an M12x1.50

thread is provided to mount oil temperature and pressure sensors. On top of the gearbox a D-06 adaptor is mounted which needs to be connected to an oil

catch tank or has to be replaced with a breather.

Oil Type Motul 75W140 Gear Competition

Oil Quantity 1.1 litres (excluding external oil lines & oil cooler)

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2. Gearbox Assembly

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2.1. General Instruction Notes The following information is intended for mechanics to (dis)assemble the gearbox. This is illustrated using exploded views including the corresponding Bill Of

Materials (BOM). Specific notes related to the (dis)assembly of a part are shown in the notes column of the BOM. For more details on the bearing

installation see §2.2 Bearing Assembly.

Please read the manual and make sure all parts are present before starting to assemble. Also ensure that all parts are clean and undamaged. It is

recommended to replace nuts, seals and circlips after removal. Only genuine Drenth Gearboxes parts should be used when overhauling the gearbox.

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2.2. Bearing Assembly To reduce the risk of bearing or casing damage, heat mounting is used to install or remove bearings. Drenth Gearboxes highly recommend to use an oven to

ensure an even heat distribution. Casings should not be heated above 130°C. Fit the bearings promptly after removing the casing from the oven to avoid

extra heating cycles being required.

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POS Part Number Description QTY NOTE

1 37-13-0326 Plain Bearing 1

2 37-13-0016 Endcover Sliding Joint 1

3 37-02-0509 Ball Bearing 1

4 39-08-0471 Roller Bearing 1


6 37-02-0023 Circlip 2

7 37-13-0311 Circlip 2 Supersedes: 37-08-0029

8 37-13-0010 Main Housing 1

9 38-03-0034 Roller Bearing 1 Without Inner Ring. Supersedes: 39-08-0465 & 44-09-0313

10 39-08-0470 Roller Bearing 1 Without Inner Ring. Supersedes: 44-09-0312

11 37-08-0020 Ball Bearing 1


13 37-13-0015 Constant Housing 1


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2.3. Gearbox Assembly Ford T9

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1 37-02-0324 Nut M24 1 Torque: 30Nm. Use Loctite 243

2 37-02-0325 Seal M24 1

3 37-08-0109 K-Nut M6 1

4 37-02-0319 Washer M6 1

5 39-08-0057 Cup 2

6 37-02-0322 Spring 1

7 37-13-0091 Selector Rod 1

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2 37-08-0026 Ratch 2

3 37-08-0027 Spring 2

4 37-08-0024 Ratchet Carrier 1

5 37-02-0314 Bolt M4 2

6 39-08-0036 Selector Plate 1

7 35-01-0334 Dowel 2

8 37-02-0352 Washer M10 2


10 37-13-0092 Selector Lever 1

11 37-02-0351 Spacer 1

12 37-13-0306 K-Nut M10 1

13 37-13-0093 Bolt M10 1

14 37-02-0473 End Cap D-06 1 Supersedes: 44-09-0384

15 37-02-0460 Adaptor D-06xM14 1

16 37-02-0458 Multiseal M14 1

17 37-13-0315 End Cap 1

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1 37-02-0465 Bolt M6 4

2 37-02-0337 Washer M6 4 Supersedes: 37-07-0049

3 37-02-0452 Cover Inputshaft 1

4 37-02-0466 Oil Seal 1

5 37-02-0103 O-Ring 1

6 37-12-0304 Circlip 1 Supersedes: 35-01-0066 & 37-13-0304

7 37-12-0302 Inner Ring 1

8 37-12-0302 Inner Ring 1

9 37-13-0501 Constant Gear 24 - (25) 1 Depending on gear ratio

10 37-13-0252 Input Shaft - Ford T9 1

11 37-13-0308 Needle Bearing 1

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1 37-12-0079 Sliding Gear Reverse 1

2 37-13-0096 Selector Fork Reverse Gear 1

3 37-13-0072 Hub Reverse Gear 1

4 37-13-0052 Dog Gear (14)-32 1 Depending on gear ratio

5 24-04-0034 Needle Bearing 1 Supersedes: 10-97-0193

6 37-02-0185 Dog Ring 1

7 37-02-0520 Selector Fork 1

9 37-13-0071 Hub 1st Gear 1

10 37-13-0066 Outputshaft Sliding Joint 1

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1 37-13-0042 Layshaft 14 - (32) 1 Depending on gear ratio

2 37-13-0076 Spacer 1

3 37-13-0502 Constant Gear (24) - 25 1 Depending on gear ratio

4 37-13-0075 Spacer 1



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1 37-02-0310 Conveyer Rotary Sensor 1 Make sure that the marks are aligned

2 37-13-0094 Selector Drum 6th Gear 1:1 1

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1 37-13-0161 Stud M8 2

2 37-13-0189 Stud M10 4

3 37-13-0162 Stud M8 2

4 37-02-0022 Positioning Bush 2

5 44-09-0372 Seal M12 1

6 37-13-0324 Oil Plug M12 1

7 37-02-0019 Oil Plug M24 - Magnetic 1

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1 37-08-0091 Bolt M8 1 Torque 40Nm. Use Loctite 270

2 37-13-0080 Spacer Idler Gear Reverse 1

3 37-12-0080 Idler Gear Reverse 1

4 37-12-0306 Needle Bearing 1

5 37-13-0062 Shaft Idler Gear Reverse 1

6 37-13-0077 Inner Track 1

7 37-13-0162 Stud M8 2

8 37-13-0161 Stud M8 10

9 37-02-0022 Positioning Bush 2

10 37-02-0325 Seal M24 1

11 37-02-0032 Oil Plug M24 1

12 44-09-0372 Seal M12 1

13 37-13-0324 Oil Plug M12 1

14 37-13-0307 Bolt M8 1

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1 37-13-0097 Selector Shaft 1

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2 37-02-0014 D-Cord 1

3 37-13-0010 Main Housing 1

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1 37-08-0108 K-Nut M8 12

2 44-09-0344 Washer M8 12

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1 37-13-0679 Splined Gear 18 - (28) 1 Depending on gear ratio

2 37-13-0680 Dog Gear (18) - 28 1 Depending on gear ratio


4 37-02-0185 Dog Ring 1


6 37-13-0073 Hub 2nd-5th Gear 1

7 37-13-0076 Spacer 1



10 37-13-0081 Inner Track 1

11 37-13-0078 Spacer 1

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4 37-02-0185 Dog Ring 1


6 37-13-0073 Hub 2nd-5th Gear 1

7 37-13-0076 Spacer 1



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2 37-02-0194 Retainer Cap 1

3 37-02-0193 Nut M32 1

4 37-13-0082 Spacer 1


6 37-13-0074 Spacer 1



9 37-13-0079 Spacer 1

10 37-13-0310 Dowel 1

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1 37-13-0095 Shaft Selector Fork 1

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1 37-13-0329 Circlip 1

2 37-13-0157 Cover Oilpomp 1

3 37-13-0156 Oil Pomp Outer Rotor 1

4 37-13-0155 Oil Pomp Inner Rotor 1


6 44-09-0324 Dowel 1

7 37-02-0314 Bolt M4 2

8 37-13-0151 Cover Oilfilter 1

9 37-13-0152 Filter Oilpomp 1


11 37-13-0323 Seal M8 1

12 37-12-0311 Spring 1

13 37-12-0310 Ball 1

14 37-13-0316 Set Screw M8 1

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1 37-13-0913 Seal Plug Sliding Joint 1 Used for (dis) assembly of 37-13-0325

2 37-13-0325 Oil Seal 1

4 37-02-0326 Oil Seal 1

5 37-13-0316 Set Screw M8 1

6 44-09-0630 Set Screw M5 1

7 37-13-0341 Set Screw M10 1

8 37-02-0458 Multiseal M14 2

9 37-12-0317 Set Screw M3 1

10 37-02-0460 Adaptor D-06xM14 1


12 37-12-0315 O-Ring 1

13 37-12-0153 Adaptor D-06 1

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1 37-08-0108 K-Nut M8 4

2 44-09-0344 Washer M8 4

3 44-09-0345 Washer M10 4

4 37-08-0112 K-Nut M10 4

5 37-02-0014 D-Cord 1

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1 37-08-0045 Positioning Pin 1

2 37-02-0331 Spring 1

3 37-02-0036 Seal M14 1

4 37-08-0188 Nut M14x1.5 1

5 37-08-0189 Guide Cable 1

6 37-02-0342 Inner Cable 1

7 37-02-0343 Outer Cable 1

8 37-02-0344 Cover Outer Cable 1

9 37-02-0346 Lock Screw 1

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1 37-02-0440 Tab Housing 1

2 35-01-0414 Fitbolt M5 1

3 37-13-0165 Shift Fork 1

4 44-09-0348 Washer M5 1

5 44-09-0346 K-Nut M5 1

6 25-03-0011 Rotary Sensor 1 See chapter: Rotary Sensor

7 37-02-0311 O-Ring 1

8 37-02-0315 Washer M4 2

9 37-02-0312 Bolt M4 2 Supersedes: 35-01-0319

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2.4. Gearbox Assembly Toyota GT86

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1 37-13-0193 Dust Cap 1

2 37-13-0331 Oil Seal 1


4 37-02-0326 Oil Seal 1


6 37-02-0315 Washer M4 2

7 25-03-0011 Rotary Sensor 1 See chapter: Rotary Sensor

8 37-02-0440 Tab Housing 1

9 37-12-0315 O-Ring 1

10 37-13-0342 Fitbolt M6 1

11 37-02-0428 Washer 2

12 37-13-0344 Ball Bearing 2

13 37-13-0103 Selector Lever 1

14 37-13-0190 Washer 1


16 37-08-0109 K-Nut M6 1

17 37-13-0104 Selector Shaft 1

18 37-13-0067 Outputshaft Sliding Joint 1

19 37-02-0458 Multiseal M14 2

20 37-02-0460 Adaptor D-06xM14 1


22 37-12-0153 Adaptor D-06 1

23 37-13-0341 Set Screw M10 1

24 37-12-0317 Set Screw M3 1

25 44-09-0630 Set Screw M5 1

28 37-13-0316 Set Screw M8 1

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1 37-02-0465 Bolt M6 4


3 37-02-0452 Cover Inputshaft 1

4 37-02-0466 Oil Seal 1

5 37-02-0103 O-Ring 1


7 37-12-0302 Inner Ring 1

8 37-12-0302 Inner Ring 1

9 37-13-0501 Constant Gear 24 - (25) 1 Depending on gear ratio

10 37-13-0255 Input Shaft - Totota GT86 OEM 1

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2.5. Gearbox Assembly BMW E30

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1 37-13-0178 Centering Pin 1

2 37-13-0031 Output Flange 1


4 37-02-0194 Retainer Cap 1

5 37-02-0193 Nut M32 1

6 37-02-0190 Oil Seal 1

7 37-02-0326 Oil Seal 1

8 37-13-0341 Set Screw M10 1

9 37-13-0316 Set Screw M8 1

10 37-02-0458 Multiseal M14 2

11 37-02-0460 Adaptor D-06xM14 1


13 37-12-0153 Adaptor D-06 1


15 37-13-0063 Outputshaft 1

16 37-13-0013 Endcover 1

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2.6. Gearbox Assembly Opel

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1 37-13-0174 Adaptor Plate Opel 1


3 37-02-0466 Oil Seal 1


6 37-02-0103 O-Ring 1



9 35-01-0482 Stud M12 4

10 37-03-0005 Locking Nut M12 4

11 37-13-0253 Input Shaft - Opel 1

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2.7. Rotary Sensor

The gearboxes come with a Penny & Giles SRH280DP rotary sensor. The rotary sensor signal is used to show the engaged gear on the Drenth Display Unit /

Drenth Gear Indicator or any other display. For correct gear indication, it is necessary that rotary sensor is properly connected and calibrated. Information

related to the wiring of the sensor is shown in the table below.

Cable Colour Description

Red + 5 V Supply

Yellow Output 1

White Output 2

Black 0 V Supply (GND)

Depending on the type of gearbox, Output 1 or Output 2 is used. The table below shows which output is used for the different types of gearboxes:

Gearbox Type Output Cable Colour

DG350 Output 2 White

DG350 Direct Replacement Output 1 Yellow




DGT250 Output 2 White

DGT350 Output 2 White

Mitsubishi Lancer Evolution VI-IX Output 1 Yellow

Mitsubishi Lancer Evolution X Output 1 Yellow

MPG Output 1 White

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The connection diagrams when using output 1 or output 2 are shown below:

Please note that the above information does not apply to other sensors!

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3. Accessories

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3.1. Bellhousings / Adaptor Plates Drenth Gearboxes offers a variety of removable bellhousings and adaptor plates to mount the DG400 into different vehicles. In addition, bellhousings and

adaptor plates for customer specific applications can be developed, produced and supplied


1 37-03-0037 Assembly Bellhouse DG400 - BMW M3 S54 1

2 37-03-0100 Assembly Bellhouse DG400 - Honda S2000 1

3 37-12-0926 Assembly Bellhouse DG350 - Toyota GT86 1

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Part Number Description QTY NOTE

37-13-0925 Assembly Adaptor Plate Opel - DG350 1

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3.2. Gearbox Brackets The Drenth gearbox brackets are designed to mount the DG400 using the existing chassis mounting points of the specific vehicle. Please note that these

brackets can only be used in vehicles where the chassis mounting points and/or the position of the engine have not been modified.


1 37-13-0194 Assembly Bracket Gearbox Toyota GT86 1

2 37-13-0202 Assembly Bracket Gearbox 1

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3.3. Gear Lever Drenth Gearboxes offers a one-piece aluminium gear lever which, in combination with shift rods or a push/pull cable, can be used on any Drenth sequential

gearbox to change gear. Several gearbox and chassis mounted brackets are available for mounting the gear lever at the desired position.

In order to suit a variety of applications, the gear lever comes in two different lengths:

• 260 mm • 360 mm

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1 25-03-0052 Assembly Gearlever Long / Short Stud 1 2 25-03-0053 Assembly Gearlever Long / Inter Stud 1 3 25-03-0054 Assembly Gearlever Long / Long Stud 1 4 37-02-0650 Assembly Gearlever Short / Short Stud 1

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3.4. DMS Gear Lever Drenth Gearboxes offers a one-piece DMS aluminium gear lever with integrated electronics which, in combination with shift rods or a push/pull cable, can

be used on any Drenth sequential gearbox to change gear. The analogue output signal of the gear lever electronics can be used to configure the ignition cut

enabling flat-shifting. An optional Switchbox is used to convert the analogue signal when a digital output signal for programming the ignition cut is required.

The DMS gear lever can also be used to program down shift throttle blip if the car is equipped with drive-by-wire. In addition, several gearbox and chassis

mounted brackets are available for mounting the gear lever at the desired position.

In order to suit a variety of applications, the gear lever comes in two different lengths:

• 260 mm • 360 mm

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1 25-03-0055 Assembly Gearlever Short / Short Stud 1 Avalaible in Alu & Black

2 25-03-0056 Assembly Gearlever Long / Inter Stud 1 Avalaible in Alu & Black

3 25-03-0057 Assembly Gearlever Long / Long Stud 1 Avalaible in Alu & Black

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3.5. Gear lever Brackets Drenth Gearboxes offers various types of gear lever brackets for mounting the (DMS) gear lever in the car. There can be chosen between two types of

brackets, namely gearbox mounted gear lever brackets and tunnel mounted gear lever brackets.


1 37-13-0180 Assembly Bracket Gearlever DG350 - Toyota 1 OEM GT86 Replacement

2 37-13-0199 Assembly Bracket Gearlever DG350 - Ford T9 1 OEM Replacement

3 37-13-0205 Assembly Bracket Gearlever 1 T9 Short Version

4 37-13-0206 Assembly Bracket Gearlever 1 Universal

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3.6. Gear Indicator Designed to work seamlessly with every Drenth sequential gearbox, the gear indicator uses the rotary sensor signal to show the selected gear. Using the

supplied software, it is possible to show up to 8 forward gears as well as neutral and reverse on the display with integrated light sensor. In addition, the gear

indicator features an option to control the reversing light.

Features:

- Gear indication

- Reverse light

- Automatic calibration


1 25-03-0065 Gear Indicator 1

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3.7. Display Unit Designed to work seamlessly with every Drenth sequential gearbox, the display unit uses the rotary sensor signal to show the selected gear. Using the

supplied software, it is possible to show up to 8 forward gears as well as neutral and reverse on the display with integrated light sensor. In addition, the

display unit features an adjustable shift light and an option to control throttle blip or the reversing light. In combination with the DMS gear lever, the display

unit can be used for flat-shifting which allows the user to set the cut time for each gear separately. This is also possible when using any other load cell,

Switchbox or switch.

Features:

• Gear indication • Shift light • Flat-shifting • Down shift throttle blip / Reverse light • Automatic calibration

• DMS Gear Lever calibration


1 25-03-0066 Display Unit 1

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3.8. Switchbox The Drenth Gearboxes Switchbox is an analog-to-digital converter which is used in combination with the Drenth Display Unit or a programmable ECU to

enable flat-shifting. When a digital output signal is required for setting the ignition cut the Switchbox is used to convert the analogue signal. Because the

Switchbox is equipped with two potentiometers, the upshift and downshift threshold levels can be adjusted as desired.

Features:

• Adjustable downshift threshold voltage

• Adjustable upshift threshold voltage


1 25-03-0060 Switchbox DMS Gearlever 1

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3.9. Oil Breather Catchtank Drenth Gearboxes recommends the use of an Oil Breather Catch Tank for breathing the gearbox. Therefore Drenth Gearboxes offers a universal catch tank

which can be used with any gearbox. The set includes the breather catch tank, oil hose and the necessary adaptors.


1 25-03-0200 Assembly Oil Breather Catchtank 1

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4. Assembly Tooling

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Optionally, Drenth Gearboxes provide tools which are used for assembling and disassembling the DG350. The tools listed below make it possible to perform

maintenance on the DG350:

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1 37-13-0900 Assembly Workbench Stand DG350 1 Used for (dis) assembly of 37-13-0002 / 0004 / 0007

2 37-13-0901 Tool Shaft Selector Fork 1 Used for (dis) assembly of 37-13-0095 / 0099

3 37-13-0907 Tool Plain Bearing 1 Used for (dis) assembly of 37-13-0321


6 37-13-0909 Tool Outputshaft lock 1 Used for (dis) assembly of 37-13-0064

7 37-13-0910 Tool Oil Seal 1 Used for (dis) assembly of 37-13-0305

8 37-13-0911 Tool Outputshaft Lock 1 Used for (dis) assembly of 37-13-0066 / 0068


10 37-13-0914 Tool Outputshaft lock 1 Used for (dis) assembly of 37-13-0067

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5. Contact Information

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5.1. Contact Details Drenth Motorsport Gearboxes

Fleuweweg 10

7468 AG Enter

The Netherlands

www.drenth-gearboxes.com

Spare Parts: +31 (0)547 38 26 96 [email protected]

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Appendix A: Technical Bulletin

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Appendix B: Amendments

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Date Page Modification 18-10-2017 1st Issue of completely revised manual

26-06-2018 70 Added chapter 4.1 Bellhousings

28-06-2018 71 Added Adaptor Plates to chapter 4.1

18-07-2018 10 Changed oil type to Motul 75W140 Gear Competition

16-10-2018 61 & 62 Added BMW E30 New Type

22-10-2018 80 Added Assembly Bracket Gearlever Universal

07-02-2019 10 Added dimension drawing BMW

15-07-2019 24-25 & 30-31 Position spacer 37.13.0077 changed from page 24 to page 30

14-10-2019 69 Position Rotary Sensor added

25-06-2020 - Manual converted to Illustrator

T +31 (0)547 38 26 96 E [email protected] W www.drenth-gearboxes.com

Documents

Gearbox Manual DG350 2017 - drenth-gearboxes.com · Gearbox Manual DG350 – Revision: 009 Pole Position In Gearboxes 1.3. Oil System A gerotor internal-gear pump is standard in the