Contents
1. Summary of Lubricants and Greases.................................................................. 4
2. Operating requirements ...................................................................................... 5
3. Specification........................................................................................................ 7
3.1. General Items .............................................................................................. 7
3.2. Standard Options (no cost) .......................................................................... 9
3.3. Optional Extras (cost options)...................................................................... 9
3.4. Excluded Items ............................................................................................ 9
4. Gearbox Operation............................................................................................ 10
4.1. Gearchange Description ............................................................................ 10
4.2. Oil System.................................................................................................. 10
4.2.1. Description............................................................................................ 10
4.2.2. Dedicated Oil Feeds ............................................................................. 11
4.2.3. Sensors ................................................................................................ 11
4.2.4. Filtration and Magnets .......................................................................... 11
4.2.5. Setup/Running Conditions.................................................................... 11
4.3. Gear Cluster............................................................................................... 12
4.3.1. Reverse Gear ....................................................................................... 13
4.4. Differential.................................................................................................. 14
4.4.1. Description............................................................................................ 14
4.4.2. Ramp Angles ........................................................................................ 15
4.4.3. Number of Friction Faces ..................................................................... 15
4.4.4. Positive Preload.................................................................................... 15
4.4.5. Differential Test Rig .............................................................................. 15
5. Gearbox Assembly and Maintenance ............................................................... 16
5.1. General Assembly Notes ........................................................................... 16
5.1.1. Torque Settings .................................................................................... 17
5.2. Cluster Setup ............................................................................................. 18
5.2.1. Ratio Change Procedure ...................................................................... 18
5.2.2. Selector Barrel Setup ........................................................................... 19
5.3. Differential Setup ....................................................................................... 21
5.4. Spiral Bevel Gear Assembly ...................................................................... 21
5.5. Lifing Chart................................................................................................. 21
6. General Information .......................................................................................... 23
6.1. Customer Support...................................................................................... 23
6.1.1. Gearbox & Parts Supply ....................................................................... 23
6.1.2. Training/Servicing................................................................................. 23
6.1.3. Contacts ............................................................................................... 24
7. Appendix A – Non Standard Tightening Torques.............................................. 25
8. Appendix B – Dog Damage Sheet .................................................................... 26
9. Appendix C – Example Bevel Setting Sheet ..................................................... 27
10. Appendix D – Electrical Component Data Sheets .......................................... 28
10.1. Bosch Temperature Sensor NTC M12-L.................................................... 28
11. Appendix E – Oil Pumps and Flow ................................................................. 29
11.1. Oil Pump Pressure and Flow Rates ........................................................... 29
12. Appendix F – Differential Characteristics........................................................ 30
