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Elite TXL200 5S Manual

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Summary of Contents for Elite TXL200 5S

  • Page 2 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.

  • Page 3: Technical Specifications

    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 &...

  • Page 4: Torque Settings

    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...

  • Page 5: General Notes

    Elite. › Use only genuine 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.
  • Page 6 › 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.
  • Page 7 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 ›...
  • Page 8 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.
  • Page 9 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.

  • Page 10: Actuator Assembly

    ACTUATOR ASSEMBLY ERT90303 FIG 1 ACTUATOR ASSEMBLY ERT90303...
  • Page 11 ACTUATOR SUB ASSEMBLY PARTS LIST ERT90303 Part No Description ERT40822 ACTUATOR RING DOWEL ERT-ST-033 BEARING ERT40816 RATCHET OUTPUT ERT60967 BEARING ERT40818 RATCHET SPACER ERT40817-RH ACTUATOR PAWL RH ERT80297 SPRING-ACTUATOR PAWL ERT40815 ACTUATOR INPUT ERT40817-LH ACTUATOR PAWL LH ERT40814 STOP/GUIDE PLATE ERT60966 BEARING ERT40282...
  • Page 12 ACTUATOR BUILD PROCEDURE TXL-200 5S FIG 3 FIG 4 ACTUATOR BUILD ACTUATOR SECTION › 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. ›...
  • Page 13 BEARING CARRIER ASSEMBLY TXL-200 5S FIG 5 BEARING CARRIER ASSEMBLY ERT90333...
  • Page 14 BEARING CARRIER ASSEMBLY TOP SHAFT FIG 5a BEARING CARRIER ASSEMBLY TOP SHAFT...
  • Page 15 BEARING CARRIER ASSEMBLY BOTTOM SHAFT FIG 5b BEARING CARRIER ASSEMBLY BOTTOM SHAFT...
  • Page 16 BEARING CARRIER ASSEMBLY SELECTION FIG 5c BEARING CARRIER ASSEMBLY SELECTION...
  • Page 17 BEARING CARRIER ASSEMBLY ANCILLARY ITEMS FIG 5d BEARING CARRIER ASSEMBLY ANCILLARY ITEMS...
  • Page 18 BEARING CARRIER SUB ASSEMBLY PARTS LIST ERT90333 Part No Description ERT10800 BEARING CARRIER 5 SPEED ERT10801 BELLCRANK DROPLINK ERT10802 DROPLINK PIN ERT10803 BELLCRANK ERT40804 BELLCRANK BRACKET ERT40805 BARREL BEARING RETAINER ERT40806 BEARING ANTI.ROT. PLATE ERT30828 SELECTOR FORK 1ST/REV ERT30829 SELECTOR FORK ERT30830 FORK PIN ERT30831...
  • Page 19 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...

  • Page 20: Gearcase Assembly

    GEARCASE ASSEMBLY TXL-200 5S...
  • Page 21 GEARCASE ASSEMBLY PARTS LIST TXL-200 5S Part No Description ERT10838 ALUNIMIUM MAINCASE ERT80054 MAINCASE STUD ERT30300 PINION SHAFT - 12/(33) ERT-IN-009 PINION BEARING ERT-IN-010 A-H PINION BEARING SHIM ERT31361 PINION BEARING RETAINING RING ERT31362 BOLT RING WASHER ERT30825 REVERSE IDLER SPIGOT ERT31360 REVERSE IDLER GEAR ERT31363...
  • Page 22 FREE DIFFERENTIAL ASSEMBLY ERT90328 FIG 13 FREE DIFFERENTIAL ASSEMBLY ERT90328...
  • Page 23 FREE DIFFERENTIAL SUB ASSEMBLY PARTS LIST ERT90328 Part No Description ERT20807 FREE DIFFERENTIAL BODY ERT-02-003 FREE DIFFERENTIAL END CAP ERT20808 CROSS PIN ERT-02-012 SIDE GEAR ERT-02-013 PLANET GEAR ERT-03-031 CROWNWHEEL BOLT ERT-ST-053 CIRCLIP . EXTERNAL ERT-ST-054 LARGE COATED WASHER ERT-ST-055 SMALL CONICAL WASHER...
  • Page 24 FREE DIFFERENTIAL BUILD PROCEDURE TXL-200 5S FIG 15 FIG 16 FREE DIFF BUILD FREE DIFF SECTION › Take the body and crownwheel assy (1) and place the bearing nose down onto a clean work top. › Place the large coated washer (8) and place this onto the side gear (4) and offer this into the body.
  • Page 25 LIMITED SLIP DIFFERENTIAL ASSEMBLY ERT90308 FIG 17 LSD ASSEMBLY ERT90308...
  • Page 26 LIMITED SLIP DIFFERENTIAL SUB ASSEMBLY PARTS LIST ERT90309 Part No Description ERT-02-017 LIMITED SLIP DIFFERENTIAL HOUSING ERT-02-018 LIMITED SLIP DIFFERENTIAL END CAP ERT-02-024 LIMITED SLIP DIFFERENTIAL PLANET GEAR ERT-02-025 LIMITED SLIP DIFFERNETIAL SIDE GEAR ERT-02-026 DOG PLATE ERT-02-027 SPLINED PLATE ERT-02-047 RAMP ELEMENT 80 DEG / 80 DEG 2 OPTIONAL...
  • Page 27 LIMITED SLIP DIFFERENTIAL BUILD PROCEDURE TXL-200 5S FIG 19 FIG 20 LSD BUILD LSD SECTION › Place the LSD housing (1) so that the bearing diameter is face down on the bench (main hole upwards). › Put the side gear (4) into the LH ramp element (various) and build 2 dog plates (5) and 2 splined plates (6) in the order shown on the exploded diagram (17).
  • Page 28 CAM AND PAWL DIFFERENTIAL ASSEMBLY ERT90331 FIG 21 CAM & PAWL DIFFERENTIAL ASSEMBLY ERT90331...
  • Page 29 CAM AND PAWL SUB ASSEMBLY PARTS LIST ERT90331 Part No Description ERT-02-006 INNER CAM TRACK ERT-02-007 OUTER CAM TRACK ERT-02-008 PLUNGER CARRIER ERT-02-009 OUTER HOUSING ERT-02-010 PLUNGER ERT31367 CROWNWHEEL BOLT...
  • Page 30 CAM & PAWL DIFFERENTIAL BUILD PROCEDURE TXL-200 5S FIG 23 FIG 24 CAM & PAWL CAM & PAWL BUILD SECTION › Place the differential plunger carrier (3) onto a clean surface bearing diameter down. › Take the inner cam track (1) and place this in the centre of the plunger slots. ›...