Table of Contents
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SERVICING INSTRUCTIONS AND ILLUSTRATED
PARTS LIST FOR THE FTR FAMILY OF HEWLAND
GEARBOXES, COVERING FTR, FTRS, FTRL, JFR &
LJS UNITS.
HEWLAND ENGINEERING LTD
WALTHAM ROAD, WHITE WALTHAM,
MAIDENHEAD, BERKSHIRE,
SL6 3LR, ENGLAND
TELEPHONE: +44 (0)1628 827600
Last Updated 23rd March 2009
© Copyright Hewland Engineering Limited 2001-2009
PAGE 1
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Table of Contents
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Summarization of Contents
TECHNICAL SPECIFICATION
GEAR SELECTION
Explains the process of upshifting and downshifting, including neutral and reverse engagement.
DIFFERENTIAL AND PINION SETTING PROCEDURES
Sideplate Shimstack Calculation
Details the calculation and measurement process for the sideplate shimstack.
Maincase Shimstack Calculation
Explains the calculation for the maincase shimstack and final assembly checks.
Pinion Setting Procedure
Describes the procedure for setting the pinion using special tool SK-1709.
POWERFLOW DIFFERENTIAL
FTR-212-ADJ Backlash Adjustment
Details adjusting backlash via tripod end float on the FTR-212-ADJ differential.
ILLUSTRATED PARTS LIST - 6 SPEED CONFIGURATION (NOT FTRE RATIOS)
CASINGS & ASSOCIATED PARTS - 6 SPEED (NOT FTRE RATIOS)
Illustrates casings and associated components for 6-speed gearboxes.
LAYSHAFT ASSEMBLY - 6 SPEED (NOT FTRE RATIOS)
Diagram of the 6-speed layshaft assembly.
PINION SHAFT ASSEMBLY - 6 SPEED (NOT FTRE RATIOS)
Diagram of the 6-speed pinion shaft assembly.
SELECTOR ASSEMBLY - 6 SPEED (NOT FTRE RATIOS)
Diagram of the 6-speed selector assembly.
6 SPEED PARTS LIST
Detailed list of parts for the 6-speed gearbox assembly.
LIGHTWEIGHT ALTERNATIVE SELECTOR ASSEMBLY
Diagram of the lightweight alternative selector assembly for 6-speed gearboxes.
FTR 6 SPEED SELECTOR ASSEMBLY USING FTREL BARREL
Parts list for the lightweight selector assembly using FTREL barrel.
ILLUSTRATED PARTS LIST - 6 SPEED CONFIGURATION (FTRE RATIOS)
CASINGS & ASSOCIATED PARTS - 6 SPEED (FTRE RATIOS ONLY)
Illustrates casings and components for 6-speed FTRE ratio gearboxes.
LAYSHAFT ASSEMBLY - 6 SPEED (FTRE RATIOS ONLY)
Diagram of the 6-speed FTRE ratio layshaft assembly.
PINION SHAFT ASSEMBLY - 6 SPEED (FTRE RATIOS ONLY)
Diagram of the 6-speed FTRE ratio pinion shaft assembly.
SELECTOR ASSEMBLY - 6 SPEED (FTRE RATIOS ONLY)
Diagram of the 6-speed FTRE ratio selector assembly.
6 SPEED PARTS LIST (FTRE RATIOS ONLY)
Detailed parts list for 6-speed FTRE ratio gearboxes.
ILLUSTRATED PARTS LIST - 5 SPEED CONFIGURATIONS (NOT FTRE RATIOS)
CASINGS & ASSOCIATED PARTS - 5 SPEED (NOT FTRE RATIOS)
Illustrates casings and components for 5-speed gearboxes.
LAYSHAFT ASSEMBLY - 5 SPEED (NOT FTRE RATIOS)
Diagram of the 5-speed layshaft assembly.
PINION SHAFT ASSEMBLY - 5 SPEED (NOT FTRE RATIOS)
Diagram of the 5-speed pinion shaft assembly.
SELECTOR ASSEMBLY - 5 SPEED (NOT FTRE RATIOS)
Diagram of the 5-speed selector assembly.
5 SPEED PARTS LIST (NOT SUITABLE FOR USE WITH FTRE RATIOS)
Detailed parts list for 5-speed gearboxes.
ILLUSTRATED PARTS LIST - DIFFERENTIAL CONFIGURATIONS
TRIPOD DIFFERENTIAL ASSEMBLY
Diagram of the tripod differential assembly.
FTR-212-FD FREE DIFFERENTIAL ASSEMBLY
Diagram of the FTR-212-FD free differential assembly for Mazda.
FTR-212 LIMITED SLIP DIFFERENTIAL
Diagram of the FTR-212 limited slip differential.
FTRL-212 DIFFERENTIAL ASSEMBLY
Diagram of the FTRL-212 differential assembly for Dallara F3.
FTR-212-ADJ PRELOAD ADJUSTABLE DIFFERENTIAL ASSEMBLY
Diagram of the FTR-212-ADJ preload adjustable differential assembly.
FLANGED FREE DIFFERENTIAL ASSEMBLY
Diagram of the flanged free differential assembly.
LJS-212-F FREE DIFFERENTIAL
Diagram of the LJS-212-F free differential.
LD-212 LIMITED SLIP DIFFERENTIAL
Diagram of the LD-212 limited slip differential.
FLANGED FREE DIFFERENTIAL ASSEMBLY SUITABLE FOR INBOARD BRAKE DISCS
Diagram of flanged free differential with inboard brake discs.
LJS-212-F FREE DIFFERENTIAL FOR INBOARD BRAKE DISCS
Diagram of LJS-212-F free differential with inboard brake discs.
FLANGED LIMITED SLIP DIFFERENTIAL ASSEMBLY SUITABLE FOR INBOARD BRAKE DISCS
Diagram of flanged limited slip differential with inboard brake discs.
LD-212 LIMITED SLIP DIFFERENTIAL FOR INBOARD BRAKE DISCS
Diagram of LD-212 limited slip differential with inboard brake discs.
GEARBOX TOOLING
TOOLING PARTS LIST
List of part numbers and descriptions for specialized gearbox tooling.
INSTALLATION DRAWINGS
FTR MAINCASE
Detailed dimensional drawings of the FTR maincase from multiple views.
JFR MAINCASE
Detailed dimensional drawings of the JFR maincase from multiple views.
TECHNICAL BULLETINS
CUSTOMER MEMO – FTRL HUBBED 2ND RATIOS
Information regarding the use of spacers with FTRL hubbed 2nd gear ratios.
TECHNICAL BULLETIN FTC DIFFERENTIAL - LOCKING PERCENTAGE RATING
Provides a formula for rating differential locking percentage based on ramp angles.
FTR TECHNICAL BULLETIN NO. 01A: BEARING CARRIER (FTR-202) AMENDMENT
Details an amendment concerning the FTR-202 bearing carrier.
FTR TECHNICAL BULLETIN NO. 02: BEARING ANTI-ROTATION (FTR-201 & FTR-202)
Addresses the issue of bearing/outer tracks rotating in the maincase/carrier.
FTR TECHNICAL BULLETIN NO. 003: RE-PINNING OF SELECTOR BARREL (FTR-260)
Details the service for re-pinning selector barrels (FTR-260).
FTR TECHNICAL BULLETIN NO. 004: BARREL PIN (DOW-033)
Discusses a new specification for the selector barrel pin (DOW-033).
TECHNICAL BULLETIN FTR 005: REPLACING SELECTOR BARREL PINS
Provides instructions on how to replace selector barrel pins.
FTR TECHNICAL BULLETIN NO. 006: INPUT/CLUTCH SHAFT RETENTION CIRCLIP
Explains a design change for the input/clutch shaft retention circlip.
FTR TECHNICAL BULLETIN NO. 007: PINION THREAD STRIPPING
Recommends actions for pinion thread stripping issues and torque settings.
TECHNICAL BULLETIN NO. 008: FTR (FORMULA BMW SPEC)
Compares two versions of the FTR differential case based on spline face design.
FTR TECHNICAL BULLETIN NO. 09: FTRL GEARS
Introduces a new range of lightweight FTRL gears aimed at weight saving.
FTR TECHNICAL BULLETIN NO. 10: FTR LIGHTENED CLUTCHSHAFTS
Details FTR lightened clutchshafts and their weight savings.
FTR TECHNICAL BULLETIN NO. 011: FTR/FTRL 12:34 PINIONSHAFT – LOCKING NUT & RING
Addresses thread failures on 12:34 ratio pinionshafts and related parts.
FTR TECHNICAL BULLETIN NO. 013: POSITION OF GEAR INDICATOR POTENTIOMETER
Shows the correct position of the gear indicator potentiometer relative to the barrel.
FTR TECHNICAL BULLETIN NO. FTR-014
Details modifications to the reverse idler screw and maincase for lockwire security.
FTR TECHNICAL BULLETIN NO. FTR-015: PINION BEARING NUT REVISION
Describes revisions to the pinion bearing nut design and torque specifications.
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