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SADEV ST90-17 CUPRA TCR Technical Manual

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Technical manual
Gearbox
ST90-17 CUPRA TCR
Version: 11/03/2024

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Summary of Contents for SADEV ST90-17 CUPRA TCR

  • Page 1 Technical manual Gearbox ST90-17 CUPRA TCR Version: 11/03/2024...

  • Page 2: Table Of Contents

    Reassembly of the pinion ......................................29 Reassembling the rear housing ....................................31 SERVICE PLANNIG ........................................32 SERVICE PLANNIG ........................................33 SADEV factory rebuild ........................................35 Personal revision ........................................... 35 GEARBOX LOG BOOK ......................................... 36 EXPLODED VIEWS ........................................37 Primary geartrain ........................................... 37 Secondary geartrain ........................................
  • Page 3 a Selector axle section........................................41 Differential ............................................. 42 a Main housing ..........................................43 b Main housing ..........................................44 c Drive housing + closing flange ....................................45 d Rear housing ..........................................46 Lubrication ............................................ 47 Clutch bearing A.P......................................... 48 Hydraulic hose ..........................................49 Drive shaft .............................................

  • Page 4: General Details

    1. GENERAL DETAILS The kit SADEV transmission ST90-17 CUPRA sequential is composed of 6 front speed + 1 reverse gear. The weight of the complete gearbox is 36kg. The kit includes: Self-locking differential Quick release» system to remove the differential cassette.

  • Page 5: Differential Set-Up

    2. DIFFERENTIAL SET-UP The differential is a self-locking type, with 6 frictions faces on each side and pressure plates with ramps, acting either for driving or braking phasis. The running clearance in the differential = 0.1 ± 0.05mm. The preload may be adjusted by tightening / untightening the preload nut (internal or external) or by changing the springs. (16 small springs and 16 big springs).

  • Page 6: Principle Of Differential Preload Adjustment On The Car

    3. PRINCIPLE OF DIFFERENTIAL PRELOAD ADJUSTMENT ON THE CAR: It is important to note that the lock nut is made by "clicks" (32 "clicks" per revolution). Then, it is therefore to stop on a "click" to be sure of the good lock nut desired position. Using a hexagonal socket, press and turn the knob to change the preload of the self-locking device: More preload = Turning clockwise Less preload = Turning ant-clockwise...

  • Page 7: Lubrication

    When the gearbox is removed, seal correctly all the openings, to prevent any water getting into the gearbox. GEARBOX TEMPERATURE: SADEV recommends use in operation between 100°C - 110°C above this temperature, the life of the gearbox parts may be affected.

  • Page 8: Sensors

    5. SENSORS CONTACTLESS ANGLE SENSOR FOR BARREL: +0.5V to +4.5V Calibration tables SENSOR: F0089072 Gears voltage (V) 0.633 1.167 1.70 Nota Bene: Sensor adjusted in our factory = 2.767V ±0.05 in 3 gear 2.223 2.767 A: +5Vdc 3.30 B: Ground 3.833 C: Output signal terminal (0.5V to 4.5V) (±...

  • Page 9: Gear Shifting

    GEAR SHIFTING GRID: R-N-1-2-3-4-5-6 SELECTOR SHAFT THROW: 18mm From Reverse gear to Neutral From Neutral to 1 Each gear from 1 to 6 REVERSE GEAR LOCKING SYSTEM: From N to 1rst => push the button on the lock rod (on the steering wheel or on the gear level) From N to R =>...

  • Page 10: Special Tools

    6. SPECIAL TOOLS PICTURE PART NUMBER NAME FOUT9055110 Slot socket FOUT9045200 Secondary nut socket FOUT9053024 X2 31-splines assembled socket...
  • Page 11 PICTURE PART NUMBER NAME FOUT9067003 Preload tool Screwing socket (M13x100) FOUT9046013 manual selector...
  • Page 12 PICTURE PART NUMBER NAME Selector axle clamping sleeve FOUT9046006 "only paddle shift" FOUT9046001 Selector axle actuator "Only paddle shift"...

  • Page 13: Information About Disassembly

    7. INFORMATION ABOUT DISASSEMBLY 1) Before any intervention Unless otherwise stated, all interventions are done with gearbox in neutral, drained and disassembled of the car. Arrange you a clean and large enough surface to put parts during disassebly. It is very important to mark the mounting direction of each part during disassembly. When they were run in a direction of rotation, reuse them in the opposite direction may cause premature damage.

  • Page 14: Information About Disassembly

    8. Information about disassembly 1) Visual inspection dog clutch Use the dog inspection caps located on the cluster housing. Remove the bolt (M5 CHC), the cap and check the dogs. Be careful with O-ring. The screws are tightened to 10 Nm. and glued with Loctite 222.

  • Page 15: Retractable Clutch Shaft

    2) Retractable clutch shaft. PURPOSE: To facilitate the disassembly of the gearbox on the car. 1. Remove the closing plate from the primary line (1 M6X12 screw) 2. Using an inertia extractor (M8 male tip) retract the clutch shaft about 60mm.

  • Page 16: Disassembly The Geartrains

    3) Disassembly the geartrains 1. Unscrew the 9 M8x30 screws and gently remove the rear housing. 2. Remove the fork axis so as to release the pin from the barrel forks. 3. Remove the primary and secondary lines simultaneously.

  • Page 17: Disassembly The Selector

    4) Disassembly the selector 1. Remove the complete indexer, as well as the dual pin rock pusher. 2. Remove the barrel. 3. Unscrew the 2 M7X16 screws and remove the control flange. 4. Using the tool FOUT9046006 loosen the M7 nut. 5.

  • Page 18: Disassembly The Piston

    5) Disassembly the piston 1. Unscrew the 3 M6 X18 screws and remove the closing flange. 2. Remove the piston, then with an extractor remove the sleeve and o’rings assembly. 3. Check all parts and reassemble with the KITREVPDBVSLR82142 (See KIT page 33)
  • Page 19 Disassembly the differential 1. Extract the output shaft. 2. Remove the M6 x1 2 screw, flange lock, and make a clockwise rotation of the differential closing flange so as to release the lugs. 3. Remove the closing flange assembly. 4. CAUTION: Play with the preload tool to avoid tooth-to-tooth contact when extracting the differential case. 5.

  • Page 20: Disassembly The Differential Closing Housing " Crown

    6) Disassembly the differential closing housing « crown » 1. Remove the 3 retaining screws « Quick release » 2. Remove the preload tool holder assembly. 3. Remove the 7 M8 x35 screws and the 4 M12x50 screws, gently remove the differential closing housing. 4.

  • Page 21: Disassembly Of The Pump And Drive Mechanism

    7) Disassembly of the pump and drive mechanism 1. Remove the 5 M6x16 screws and remove the pump cover. 2. Remove the entire pump mechanism. 3. Remove the 2 pump seals. 4. Clean the entire mechanism and change the parts if necessary. Disassembly pump drive wheel 1.

  • Page 22: Extraction Of The Different Bearings

    8) Extraction of the different bearings For the rear housing the barrel bearing "61907" can be removed without heating. To remove 2 NU207 bearings, heat to 80 ° C if necessary and then using an extractor remove them. CAUTION: Behind the bearings of the primary, secondary and barrel, sometimes washers may be present. Clean and reposition them identically before any reassembly of the bearings.
  • Page 23 For the main housing, the barrel bearing "61905" can be removed without heating. The bearing of the NU305 primary line, the outer ring NJ208 and the needle bearing HK2016, heat to 80 ° C if necessary and then using an extractor remove them. The bearing NU1007, remove the 2 screws M6x100 heat and extract the bearing.

  • Page 24: Reassembly Of Bearings

    9) Reassembly of bearings When reassembling, lightly lubricate bearings, needle cages with gearbox oil. Reposition the different bearings of the main housing as well as those of the rear housing. Reassembly of the pump and drive mechanism Reposition the drive wheel of the pump, then the stopper with the 2 stop screws and the 2 nuts M8x125 "glued to the loctite243 and tightened to the torque of 35N.m.

  • Page 25: Reassembly Of The Rear Housing And Crown

    Reassembly of the rear housing and crown 1. Replace the snap ring, bearing and double lip seal. 2. Replace the 0101054 bearing and the crown bearing assembly. 3. Change the main housing o’ring. 4. Reposition the differential housing gently on the main housing with the 4 M12x50 screws glued to loctite 222 tightened to 75N.m torque, and 7 M8x35 screws glued to loctite 222 and tightened to 25N.m.(D) 5.

  • Page 26: Reassembly Of The Differential

    Reassembly of the differential 1. Once the differential case is serviced and the internal parts of the differential changed if necessary. 2. Reposition the differential case in its compartment. CAUTION: Play with the preload tool to avoid tooth-to-tooth contact when repositioning the cassette. 3.

  • Page 27: Reassembling The Selection

    Reassembling the selection 1. Replace the output shaft. 2. After replacing the various seals of the Control Axis Sealing Kit. 3. Replace the sleeve assembly in the main housing. 4. The piston. 5. The piston closing plate equipped with the anti-extrusion ring and its o’ring "M6 screws glued to loctite 222 and torque 15 N.m."...
  • Page 28 1. After changing the defective parts of the control axis, reposition the control axis 2. Using the FOUT9046005 tool screw the M7 nut onto the stud of the control axis "nut glued to loctite 243 and tightened to 25N.m".do not forget the piston spacer. 3.

  • Page 29: Reassembly Of The Pinion

    Reassembly of the pinion 1. Reassemble the secondary with the reverse gear fork. 2. Reassemble the 1-2 and 3-4 gear forks. 3. Mount the primary line, then the 5-6 forks. 4. Reposition the barrel.
  • Page 30 5. Align the dogs ring with the fingers "axial play" through the dog traps to position the fork fingers in the tracks of the barrel. 6. Reposition the fork axis.

  • Page 31: Reassembling The Rear Housing

    Reassembling the rear housing 1. Reposition the 3 dog traps. 2. After changing the rear housing bearings and the "0201110 Ø200X3" seal of the main housing. 3. Reassemble the rear housing on the main housing with the 9 M8X30 screws glued to loctite 222 and tightened to 25 N.m. 4.

  • Page 32: Service Plannig

    9. SERVICE PLANNIG The service plan of the gearbox is based on SADEV experiences. The information given about service plan can be updated in the near future. ELEMENT PART NUMBER ACTION FREQUENCY 800-1000 km, its depends on that you use the Complete rebuilding in order to check all the gears.

  • Page 33: Service Plannig

    SERVICE PLANNIG PART NUMBER DESCRIPTION Attribution PART NUMBER KITREVST901702 DESCRIPTION Attribution KITREVST901702 9907079 Seeger SB37 Snap ring Primary line Ø 10 x 2 O’ring 0201135 Lubrication Ø 17 x 2 Viton O’ring Primary line 0202075 0203055 Ø 10 x 14 x 3 Lip seal Lubrication Primary line F9046602...
  • Page 34 PART NUMBER DESCRIPTION Attribution PART NUMBER KITRLTST901702 DESCRIPTION Attribution KITREVST821402 0105045 47 x 52 x 17 Needle bearing Secondary line Ø 20 x 2 O’ring 0202019 Selector semi-auto 0106027 HK 50/20 Bearing Secondary line Selector semi-auto Ø 29,87 x 1,78 O’ring 0202020 F9067310 Ø...

  • Page 35: Sadev Factory Rebuild

    1) SADEV factory rebuild • The gearboxes are delivered plumbed and numbered. • SADEV will adopt a careful attitude when receiving a gearbox without any ‘SADEV ‘seals. This will also be valid if the gearbox shows minor or major damages.

  • Page 36: Gearbox Log Book

    INFORMATIONS CLIENT / CUSTOMER DETAILS INFORMATIONS PRODUIT / INFORMATION OF RETURN PRODUCT Type de produit Nom client Type of product Customer's name Ex: SL924 ,SP03, Paddle shift… N° de Produit N° Téléphone Phone nb Product Serial Number Discipline Email Application Fonctionnement avec Peal Pour les limiteurs de couple Working with PEAL system...

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