Elite TXL200 5S User manual

FULLY ILLUSTRATED INSTRUCTION MANUAL
INCLUDING PARTS LIST
UK Office US Office
Elite Racing Transmissions UK Elite Racing Transmissions US
Gear Works 8444 Capricorn Way No. 10
Salem Street San Diego
Etruria California 92126
Stoke-on-Trent USA
ST1 5PR
www.eliteracingtransmissios.com www.elitetransmissions.com
Tel [phone] Tel [phone]
Fax [phone] Fax As Above
Email [email protected] Email [email protected]
Table of Contents
Technical Specifications Actuator Assembly
Diagram Parts List Instructions
General Notes Bearing Carrier Assembly
Diagram Parts List Instructions
Pinion Setting Section Gearbox Case Assembly
Diagram Parts List
Differential Preload Section Free Differential Assembly
Diagram Parts List Instructions
CWP Backlash Section LSD Differential Assembly
Diagram Parts List Instructions
Sequential Barrel Section Cam & Pawl Differential Assembly
Diagram Parts List Instructions
ALL PARTS, INFORMATION AND ILLUSTRATIONS CONTAINED WITHIN THIS PUBLICATION ARE COPYRIGHT OF ELITE
DESIGN & MANUFACTURING LTD., GEAR WORKS, SALEM STREET, ETRURIA, STOKE-ON-TRENT, ST1 5PR.
COPIES OF THE MANUAL CANNOT BE PRODUCED OR DISTRIBUTED WITHOUT THE WRITTEN PERMISSION OF ELITE
DESIGN & MANUFACTURING LTD.

TECHNICAL SPECIFICATIONS
TXL-200 5S
The TXL200-5S is a transaxle gearbox design for use in single seat / mid engine rear wheel
drive race cars. The gearbox has 5 forward gears and 1 reverse gear which are selected by
the use of a sequential mechanism.
The gear pattern is:
5/R . R . N . 1 . 2 . 3 . 4 . 5
The 5/R position is only used to aid the tightening of the pinion shaft and layshaft nuts. This
position must NOT be used whist the gearbox is in operation as it will cause a catastrophic
failure.
The drive from the power plant is transmitted to the gearbox layshaft via a custom input
shaft (varied to application). This is then transmitted via gears to the pinion shaft and into
the differential. Various differentials are available for the TXL200-5S including LSD, Cam
and Pawl and Free Diff.
Gear change is carried out through the actuator assembly to the sequential drum which then
moves a dog ring to engage each gear in turn in the above sequence. Reverse uses a sliding
gear to select in replacement of the dog ring system.
When coming down the gearbox a manually operated lock-out exists to stop the gearbox
hitting neutral and spiking the engine.
The gearbox case is manufactured from high grade cast aluminum. All gears in the gearbox
are manufactured from case hardening high grade material.
Lubrication in the gearbox is achieved by a simple splash system and retained within the
gearbox using oil seals
FOR ANY GUIDANCE OR QUESTIONS CALL US ON 01782 280136
The TXL200-5S gearbox is designed to be a fully stressed integral component within the
vehicles chassis with points provided for mounting of rear suspension.
Maximum Gearbox Operating Torque 200 lbs/ft
(This is application dependant; advice is
available by contacting Elite)
Gearbox Oil Type Fully synthetic gear oil
(Millers 75W90 is recommended)
Oil Quantity 1.5ltrs normal road tracks & 1.75ltrs oval tracks
(Capacity to filler on gearbox = 1.75litres)
CWP Backlash Setting 0.10 / 0.15 mm
Gearbox Dry Weight 36kg (including input shaft)

TORQUE SETTINGS
TXL-200 5S
Find below the torque settings for nuts and bolts:
Pinion Nut 150-180 LBS.FT
Layshaft Nut 150-180 LBS.FT
Crownwheel Bolts 80 LBS.FT
Pinion Bearing Nut 180 LBS.FT
Pinion Bearing Bolts 25 LBS.FT
Bearing Carrier Nuts 25 LBS.FT
Sideplate Nuts 25 LBS.FT
CAUTION: OVERTIGHTENING OF THE NUTS AND BOLTS MAY LEAD TO DAMAGE WITHIN THE GEARBOX

GENERAL NOTES
TXL-200 5S
All instructions and illustrations within this manual are created to
aid successful gearbox management. These should be read
carefully and adhered to in all instances to avoid damage to the
gearbox
›Before youdismantle the gearbox, ensure you have a clean tray available to place
parts.
›Before thegearbox is reassembled ensure all the parts which are to be reassembled
are fully cleaned and inspected for any problems such as excessive wear or fractures. Any
part which is thought to be damaged must be replaced with new components. If advice is
required on part please Contact Elite.
›Use onlygenuine Elite Racing Transmissions Parts in the TXL200-5S. Use of any parts
supplied by a third party cannot be guaranteed to be of the quality expected by the
customer of parts which are manufactured by Elite Racing Transmissions.
›Ensure allLocknuts, O’Rings and oil seals are replaced each time the gearbox is fully
stripped and rebuilt.
›The pinionand layshaft nut Torque Settings are to be checked on a regular basis. A
recommended checking interval of the above is prior to each race meeting or test day. All
other torque settings need to be checked every three race meetings/test days. This is
good practice as the wear within the gearbox can be monitored on a regular basis.
›On reassemblyof bearing in the gearbox lubricate with a small amount of oil. Never
run the gearbox after reassembly without doing this as the bearings will run dry until the
oil is circulated and cause damage which will reduce the life.
›Fill theoil to the desired level outline in the Technical Specifications section using a
measuring jug. Never overfill the gearbox as this will cause damage by the components
overheating and power loss within the transmission.
›Wear on the fork pins must be carefully monitored. Elite recommend changing fork
pins once least once a season. Failure of the fork pins causes a catastrophic failure of
the gearbox.

PINION SETTING
TXL-200 5S
Crownwheel and Pinions are supplied by Elite Racing Transmissions in matched sets and
these are identified by the numbers etched onto each set.
To make set-up simpler there is a pinion setting jig available from Elite Racing
Transmissions, Part Number ERT-TO-01.
TO FIT A NEW CROWNWHEEL AND PINION PROCEED AS FOLLOWS:-
›Press the pinion bearing onto the shaft; it is always advisable to fit a new pinion bearing
with a new pinion.
›Screw the pinion bearing nut onto the pinion shaft and tighten to between150-180lbs.ft.
There are special tools available from Elite to simplify this task; these are part numbers
ERT-TO-02 and ERT-TO-03.
›Select a shim and fit over the bearing, the old shim is a good starting point.
›Warm up the maincase to approximately 115°C and slide in the shaft, bearing and shims
from the differential side of the maincase. Secure the assembly into the maincase using
the Pinion Bearing Retaining Ring (ERT-IN-011), the washer (ERT-IN-012) and six bolts
(ERT-ST-010).
›When the maincase has cooled down fit the pinion setting jig onto the sideplate studs
and secure with four nuts.
›Using feeler gauges measure the gap between the jig and the ground end of the pinion
shaft.
›Establish the change of shim required to set the pinion at the correct depth and warm up
the case. Remove the pinion shaft and repeat steps 4 to 6 until the pinion shaft is in the
correct position.
›Following final assembly ensure that the six pinion bearing bolts are tightened to 25
lbs.ft.

DIFFERENTIAL PRELOAD SETTING
TXL-200 5S
Following the Pinion Setting to the correct height the next operation is to set the Differential
bearing preload. Special Dummy Bearing outer cones are available from Elite to Speed up
this operation, Part Number ERT-TO-004.
FOLLOW PROCEDURE BELOW TO SET THE DIFFERENTIAL BEARING PRELOAD
›Fit the assembled Differential unit to the gearbox followed by the left hand sideplate
assembly. Bolt the sideplate securely to the maincase.
›To measure the bearing pre-load, slowly undo the sideplate nuts. Using feeler gauges
measure the gap between the maincase and the sideplate. When there is no longer any
load on the sideplate nuts there is no preload on the differential bearings. To change the
preload, change the preload shims between the outer bearing cones and the sideplate.
The proper preload is set when the gap between the maincase and sideplate is 0.15 to
0.20mm.
›Next the CWP Backlash must be set. Do not yet replace the dummy bearing cones with
the correct parts.

CWP BACKLASH SETTING
TXL-200 5S
Following setting the Differential Preload Setting it is necessary to set the correct backlash
for the Crownwheel and Pinion.
FOLLOW PROCEDURE BELOW TO SET THE CWP BACKLASH
›Fit the differential to the gearbox and fit the left hand sideplate, fasten securely ensuring
that the differential is free to turn whilst tightening the nuts.
›When all of the nuts are fastened fit the front hub and the two rearmost hubs to the
pinion shaft, fit a spacer, ERT-TO-005, to the shaft and tighten up the pinion shaft nut to
approx. 15lb/ft.
›It is now possible to fit a Dial Test Indicator (DTI) to the rearmost maincase studs and fit
the pointer onto the rear most hub spline. By rotating the pinion shaft gently by hand the
backlash can be measured.
›The amount of backlash required is 0.1 to 0.15mm, if this has been achieved then
further adjustments need not be made, otherwise continue.
›Adjustment is made to the backlash by moving the diff preload shims from one sideplate
to the other, at this point no shims should be added or removed or this will alter the
Differential Preload. To increase the backlash shims should be moved from the left to the
right and vice versa to decrease the backlash.
›Measurements should be taken at various positions around the pinion shaft to average
out the effects of any manufacturing tolerances.
›If you still have the dummy bearing cones fitted replace them now with correct parts and
install the differential and sideplate.

SEQUENTIAL BARREL SETTING
TXL-200 5S
Fork setting on the EVD sequential transaxle is achieved by means of one shim on the
Selector Barrel.
TO DETERMINE THE THICKNESS FOR THIS SHIM PROCEED AS FOLLOWS
›Assemble front & middle hubs onto the pinion shaft and stand gearbox upright on its
front face.
›Using a caliper/vernier and straight edge measure the distance from the rear face of the
gearbox to the top of the rearmost hub.
›Make a note of this height and add 25.7mm to it. Note this number down.
›Stand the bearing carrier on its back face with the barrel fitted to the bearing (with no
shim fitted). Measure from the bearing carrier front face to the bottom of the middle
neutral track position. Add 3.5mm to this figure.
›Subtract the track position size from the hub position figure. This size is the size of the
shim required.
›Fit this shim to the selector barrel and fit to the bearing carrier, tighten up the selector
barrel nut to 50lbs.ft.
›The selector forks can now be slid over the barrel and located with the fork pin (ERT-IN-
020) and circlip (ERT-ST-040).
IT MUST BE NOTED THAT IF THE FORK PIN CIRCLIP IS REMOVED ON
REFITTING THEN A NEW CIRCLIP MUST BE USED.
AFTER INSTALLATION ENSURE THAT CIRCLIP IS SAT PROPERLY IN GROOVE.

ACTUATOR ASSEMBLY
ERT90303
FIG 1
ACTUATOR ASSEMBLY
ERT90303
01
02
03 04
05
06
07
08
09
10 11
12
13 14 15
16
17
19
20
20
21
22
23 18

ACTUATOR SUB ASSEMBLY PARTS LIST
ERT90303
Ref Part No Description Qty
1 ERT40822 ACTUATOR RING DOWEL 1
2 ERT-ST-033 BEARING 1
3 ERT40816 RATCHET OUTPUT 1
4 ERT60967 BEARING 1
5 ERT40818 RATCHET SPACER 1
6 ERT40817-RH ACTUATOR PAWL RH 1
7 ERT80297 SPRING-ACTUATOR PAWL 2
8 ERT40815 ACTUATOR INPUT 1
9 ERT40817-LH ACTUATOR PAWL LH 1
10 ERT40814 STOP
/
GUIDE PLATE 1
11 ERT60966 BEARING 1
12 ERT40282 ACTUATOR BODY 1
13 ERT-ST-032 COUNTERSUNK SETSCREW 2
14 ERT-ST-008 ACTUATOR TORSION SPRING 1
15 ERT40820 ACTUATOR LEVER 1
16 ERT-ST-042 COUNTERSUNK SETSCREW 2
17 ERT80056 CAPHEAD SETSCREW 1
18 ERT40298 TORSION SPRING STOP 1
19 ERT40280 NEUTRAL
/
REVERSE PLUNGER 1
20 ERT-ST-013 DETENT SPRING 2
21 ERT40281 CABLE LINK BOLT 1
22 ERT-ST-041 GRUB SCREW 1
23 ERT-ST-008 DETENT SPRING 1

ACTUATOR BUILD PROCEDURE
TXL-200 5S
›Fit stop guide plate (10) into the actuator body (12) using the setscrews (13). Ensure the
guide plate goes into the bore square and use Loctite 648 and activator 7471.
›Fit the springs (07) and pawls (06, 09) to the ratchet input (08).
›Take the above assembly and fit the spacer (05) and bearing (04) to their respective
diameters.
›Assemble the above to the ratchet output (03) and locate the bearing in the diameter.
›Take bearing (11) and fit this onto the journal on the ratchet input side of the assembly.
›Slide the assembly into the housing locating the bearing in the bearing bore.
›Fit the output bearing (02) into the housing ensuring the bearing sits square.
›Fit the ball (23), spring (20) and grubscrew (22) to the front side bore.
›Fit the plunger (19), spring (20) and cap (21) into rear side bore.
›Fit the adjustable stop (18), using capscrews (16, 17).
›Fit the torsion spring (14) to lever (15) and key to actuator input (assy). Push lever assy
onto the input of the actuator ensuring the assembly does not push the bearing out of the
body. Fix with capscrew (16).
›Adjust stop and caps to achieve correct feel on all springs ensuring the re-cock action of
the actuator is equal each way. Fit ring dowel (01) and check operation.
FIG 4
ACTUATOR SECTION
FIG 3
ACTUATOR BUILD

BEARING CARRIER ASSEMBLY
TXL-200 5S
FIG 5
BEARING CARRIER ASSEMBLY
ERT90333

BEARING CARRIER ASSEMBLY
TOP SHAFT
FIG 5a
BEARING CARRIER ASSEMBLY
TOP SHAFT
2433
15
12
33
23
22
33
11
14
20
17
13
26
3315
12
33
25

BEARING CARRIER ASSEMBLY
BOTTOM SHAFT
FIG 5b
BEARING CARRIER ASSEMBLY
BOTTOM SHAFT
19
27
18
21
26
16
25
24
23
22

BEARING CARRIER ASSEMBLY
SELECTION
FIG 5c
BEARING CARRIER ASSEMBLY
SELECTION
42
39
06
50
29
08
10
43
08
10
08
10
43
43

BEARING CARRIER ASSEMBLY
ANCILLARY ITEMS
FIG 5d
BEARING CARRIER ASSEMBLY
ANCILLARY ITEMS
02 46 45
31
31
35 48
04
47
01
05
44
52
53 54
03
48
49

BEARING CARRIER SUB ASSEMBLY PARTS LIST
ERT90333
Ref Part No Description Qty
1 ERT10800 BEARING CARRIER 5 SPEED 1
2 ERT10801 BELLCRANK DROPLINK 1
3 ERT10802 DROPLINK PIN 2
4 ERT10803 BELLCRANK 1
5 ERT40804 BELLCRANK BRACKET 1
6 ERT40805 BARREL BEARING RETAINER 1
7 ERT40806 BEARING ANTI.ROT. PLATE 1
8 ERT30828 SELECTOR FORK 1ST/REV 1
9 ERT30829 SELECTOR FORK 2
10 ERT30830 FORK PIN 3
11 ERT30831 FRONT HUB 5 SPEED 1
12 ERT30832 SYMMETRICAL HUB 2
13 ERT-03-020 INNER TRACK / THRUST WASHER 1
14 ERT30833 1ST/REV SLIDING GEAR 1
15 ERT30834 DOG RING 5 DOG STAGGERED 3
16 ERT30835 LAYSHAFT SPACER 1
17 ERT-IN-027 PINION SHAFT REAR BEARING 1
18 ERT-IN-028 LAYSHAFT REAR BEARING 1
19 ERT31366 INPUT SHAFT NUT 1
20 ERT-03-016 PINION SHAFT NUT 1
21 ERT30836 LAYSHAFT REAR SPACER 1
22 VARIOUS 1ST GEAR SET 1
23 VARIOUS 2ND GEAR SET 1
24 VARIOUS GEAR SET 1
25 VARIOUS GEAR SET 1
26 VARIOUS GEAR SET 1
27 ERT30837 LAYSHAFT BEARING CUP 1
28 ERT-GC-010 A.H BARREL SHIM 1
29 ERT40819 SELECTOR BARREL 1
30 ERT41387 BEARING SPACER 2
31 ERT40840 END CAP 2
32 ERT-ST-014 BOLT 1
33 ERT-ST-015 NEEDLE ROLLER BEARING RATIOS 5
34 ERT-ST-017 WASHER 6MM 1
35 ERT-ST-018 NUT 6MM 1
36 ERT-ST-029 O.RING 1
37 ERT-ST-030 O.RING 1
38 ERT-ST-031 BOLT 3
39 ERT-ST-037 CONTROL BEARING 1
40 ERT-ST-036 BEARING 1
41 ERT-ST-038 CIRCLIP INTERNAL 1
42 ERT-ST-039 BARREL NUT 1
43 ERT60307 CIRCLIP FORK PIN 3
44 ERT-ST-042 C'SUNK BOLT 2
45 ERT-ST-043 BOLT 1
46 ERT-ST-044 SPHERICAL BEARING 2
47 ERT-ST-045 CIRCLIP EXTERNAL 1
48 ERT-ST-046 BEARING SEALED 2
49 ERT-ST-047 BOLT 1
50 ERT-ST-048 BOLT 3
51 ERT-ST-049 O.RING 2
52 ERT-ST-050 5MM STUD 4
53 ERT-ST-051 5MM WASHER 4
54 ERT-ST-052 5MM NUT 4

BEARING CARRIER BUILD PROCEDURE
TXL-200 5S
›Put bearing carrier on back faces
›Build output gears & hubs onto top shaft in order: 5th / 4th Hubs, 3rd / 2nd Hub, 1st / Rev
Hub
›Ensure all dogs rings are sited correctly within the fork
›Build layshaft gears and spacers in order: 5th Gear, Spacer, 4th Gear, 3rd Gear, 2nd Gear
(Shouldered Gear)
›Offer layshaft through gears and locate in bearing on the lower part of the bearing carrier
›Screw nut finger tight onto layshaft. Cupping the output shaft gear, offer the bearing
carrier into the maincase assembly. Rotate the output shaft gears to ensure the splines
line up
›When bearing carrier is fully located on maincase use locknuts and fully secure the
bearing carrier to the maincase
›Put the gearbox into the S/R position and tighten the layshaft and pinion shaft nut
›Replace rear covers and secure using canscrews. Take gearbox out of S/R position
before testing
IF PROBLEMS OCCUR IN THE SELECTION AND BARREL SYSTEM CONTACT ELITE RACING TRANSMISSIONS
ELITE DO NOT RECOMMEND INTERFERENCE WITH THE SELECTION SYSTEM
FIG 15
BEARING CARRIER
BUILD
FIG 15
BEARING CARRIER
SECTION

GEARCASE ASSEMBLY
TXL-200 5S