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Old 15 Jul 2014, 21:35 (Ref:3434249)   #1
Kosmos
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Join Date: Sep 2013
Posts: 13
Kosmos should be qualifying in the top 10 on the grid
Mallory gear ratios?

Hi it's the maiden voyage this weekend in the GR80 Ray - can anyone help with gear ratios for Mallory?

I'm not sure what cwp is currently fitted, are there any crafty techniques to find out? Other than giving the main shaft a spin until you get a complete rotation of the wheels or vise Versa.

Finally, does anyone have a mk9 gearbox idiots manual. I haven't stripped one for a long time I know it's not too difficult, just need remind myself of the "knack"...

Cheers in advance
Dc
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Old 16 Jul 2014, 09:27 (Ref:3434371)   #2
snailpace85
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Midlands
Posts: 64
snailpace85 should be qualifying in the top 10 on the grid
In the old days there were loads of printed tables around giving suggested gear ratios for all the circuits. These days - just type formula ford gear ratios into Google and loads of good stuff comes up!

Scott
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Old 16 Jul 2014, 21:05 (Ref:3434655)   #3
Kosmos
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Join Date: Sep 2013
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Kosmos should be qualifying in the top 10 on the grid
Got it all sorted, thanks for your help. It was all straight forward once I got stuck in.

Just incase anyone in the future needs the info; I found the following which was useful...


HEWLAND Mk 9 GEAR CHANGE CHECKLIST

TOOLS/SUPPLIES SIZES
1. allen head socket 7/32 in.
2. open end wrench 9/16 in.
3. sockets 7/16 in., 13mm, 1-1/14 in.
4. needle nose pliers
5. combination wrench 13 mm
6. flat head screw driver ¼ in.
7. rubber mallet
8. plastic scraper
9. vise grips
10. magnet
11. ratchet 3/8 in., ½ in.
12. extensions 3/8 in., ½ in.
13. breaker bar ½ in.
14. torque wrench
15. drain pans (2)
16. 2 x 4 block or Pegasus Trans. Rack
17. parts tote
18. shop rags
19. paper towels
20. hylomar sealer
21. cotter pins (2) 2 x 5/32

DISASSEMBLY

1. Position first drain pan under transaxle (OK to re-use gear tube)
2. Disconnect vent hose
3. Remove rear cover nuts
4. Tap rear cover gently to remove
5. Remove selector clamp and pin
6. Disconnect selector finger from shift linkage
7. Remove cotter keys
8. Remove drawbolt from bottom shaft (layshaft)
9. Lock transaxle (push 3rd and rev shift buttons in)
10. Loosen (don't remove) bottom castle nut (RH thread)
11. Remove top castle nut (LH thread)
12. Unlock transaxle
13. Remove gear case nuts
14. Tap gear case gently to remove
15. Pull gear case off with right hand, support gears with left
16. Set assembly on wood block in second drain pan or on Pegasus Transmission rack

REASSEMBLY
1. Scrape/clean surfaces of transaxle/case/cover (very clean, no leaks)
2. Apply THIN film of hylomar to gear case
3. Support gears with left hand, gear case with right hand
4. Rotate bottom nut A/R to seat gear case
5. Secure gear case, rain light and tailpipe support
6. Lock transaxle (push 3rd and rev shift buttons in
7. Torque bottom nut (layshaft) to 70 ft-lb. and align cotter key hole (CW)
8. Torque top nut (pinion shaft)to 115ft.-lb. and align cotter key hole (CCW)
9. Install and secure drawbolt and align to cotter key hole
10. Unlock transaxle
11. Spin transaxle with top nut - any strange noises?
12. Engage each gear with shift buttons - rotate bottom nut A/R
13. Position selector finger into shift linkage
14. Secure selector finger pin and clamp
15. Engage each gear with shift lever - rotate bottom nut A/R
16. Install cotter pins into castle nuts (bend long end, clip other)
17. Apply THIN film of hylomar to rear cover
18. Install and secure rear cover
19. Connect vent hose
20. Add 1 qt. gear lube and check with dipstick

OUTPUT GEAR ASSEMBLY (BOTTOM TO TOP)
1. Inner track
2. Needle bearing
3. Fourth gear (dogs up)
4. Rear hub (engaged into dog ring)
5. Dog ring (engaged into shift fork)
6. Third gear (dogs down)
7. Needle bearing
8. Second gear (dogs up)
9. Needle bearing
10. Center hub (engaged into dog ring)
11. Dog ring (engaged into shift fork)
12. First gear (dogs down)
13. Needle bearing (over front hub)
14. Front hub (dogs up)
15. Reverse (gear teeth down, engaged into shift fork)

INPUT GEAR ASSEMBLY (BOTTOM TO TOP)
1. Thrust washer
2. Fourth gear (bevel up)
3. Large spacer
4. Third gear (bevel up)
5. Second gear (bevel down)
6. Large spacer
7. First gear (bevel down)
8. Small spacer
9. Reverse (gears up)
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