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FORD FIESTA R2

TECHNICAL DETAILS SHOP SPECIFICATIONS

For further information, please contact the company:

Plant address: Postal address:

SADEV SADEV
6, rue des GrandMontains BP 1
85110 SAINT PROUANT 85 111 CHANTONNAY
France France

Tel. : (00 33) 2 51 66 42 68 Fax : (00 33) 2 51 66 49 60


E-Mail : sadev@sadev-tm.com

10 July 2009 update


MECANICAL GEARBOX
FORD FIESTA R2
1- Glossary

1- Glossary ......................................................................................... page 1-1


2- Characteristics .............................................................................. page 2-1

1 General details ...................................................................................... page 2-1


2 Pinion technical data ............................................................................. page 2-1
3 Differential technical data ...................................................................... page 2-1
4 Lubrication............................................................................................. page 2-2

3- Tools & assembly components ................................................... page 3-1

1 Glue components ................................................................................. page 3-1


2 Sealing components ............................................................................. page 3-1
3 Tools ..................................................................................................... page 3-3

4- Exploded views ............................................................................. page 4-1

1 Primary geartrain ................................................................................... page 4-1


2 Secondary geartrain .............................................................................. page 4-2
3 Gear selector ......................................................................................... page 4-3
4 Self locking differential .......................................................................... page 4-4
5 Housings ............................................................................................... page 4-5

5- Servicing ........................................................................................ page 5-1

1 Servicing planning ................................................................................. page 5-1


2 Rebuild of the gearbox .......................................................................... page 5-2

10 July 2009 update Page 1-1


MECHANICAL GEARBOX
FORD FIESTA R2
2- Characteristics
1 - GENERAL DETAILS
The M-SPORT/SADEV FORD FIESTA R2 gearbox consists of 5 forward gears and one reverse. The
gearbox is a sequential type.

It is fitted with a SLD with friction discs and ramp pressing plates. The gearbox is delivered ready to
assemble with its clamp and gear sensor.
The reverse gear release cable, the clutch bearing and the power shift are also provided .

Gearbox assembly weight (without reverse gear cable) : about 36 Kg.

2 - PINIONS TECHNICAL DETAILS


The set is homologated by the manufacturer.

Sets :
3 2,125 1,647 1,35 1,142
Reverse Gear

1st 2nd 3rd 4th 5th Primary 12

Primary 12 16 17 20 21 Intermediate 19

Secondary 36 34 28 27 24 Secondary 34

Final drive
Gearbox ref. Optionnal Optionnal First fitting
Final drive ref. CPL13541705011MS CPL12531705011MS CPL12571705011MS
Output Shaft 13 12 12
Crown wheel 54 53 57
4,153 4,416 4,75
3 - SELF LOCKING DIFFERENTIAL TECHNICAL DATA
The triple friction discs differential and pressing plates with ramps run asymmetrically on acceleration
and deceleration (35/90 slopes).

NOTE. It is normal that the SLD preload (60 kilometres) is reduced by around 15%, compared to the
10,5 DaN.m value of a new SLD.
NB. The preload measured under cold conditions (shop work) is about 15% higher than the on
measured under hot conditions.

10 July 2009 update Page 2-1


MECHANICAL GEARBOX
FORD FIESTA R2
2- Characteristics
4 - LUBRICATION
Capacity : 1,2 Litre (lubrication system off)
1 Litre after oil change (lubrication system off)

1st oil change Oil change frequency Viscosity Quality

After first 50 km After every race 75W90

Change gearbox oil:


- Remove both oil drain plugs (A), and clean them.

A A

SPECIAL PRECAUTIONS

No additives should be added to the oil. The resulted consequences are not in any circumstances
covered by the SADEV supplier.
When topping up the gearbox oil, do not mix any other oil with that already into the gearbox.

STORAGE IN USE

Do particularly careful with any bottles which are opened when used :
- Close the bottle again properly after use to prevent the introduction of water or dirt.
- Store the bottles horizontally, protected from severe weather.
- Do not store bottles close to a washing station.
- Do not decant the oil into larger container.

WASHING UNDER PRESSURE

When the gearbox is removed, seal all openings correctly to prevent the introduction of water into the
gearbox.

10 July 2009 update Page 2-2


MECHANICAL GEARBOX
FORD FIESTA R2
3- Tools & assembly components

1 - GLUE COMPONENTS
Glue components and tightening torques are indicated for each part on the exploded views.

WARNING :

Glue components have been chosen during tests sessions. Use only LOCTITE branded products.

Consequence of false glue component choice or a disregard on Loctite indications cant be covered by
SADEV supplier.

2 - SEALING COMPONENTS
Coat the housings contact faces with THREEBOND 1215, insisting on the housing lower part.

10 July 2009 update Page 3-1


MECHANICAL GEARBOX
FORD FIESTA R2
3- Tools & assembly components

3 - TOOLS

FOUT1705000 Preload tool

Primary & secondary nuts


FOUT9003276
tool

10 July 2009 update Page 3-2


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BOITE DE VITESSES MECANIQUE
FORD FIESTA R2
5-Servicing

1 - SERVICING PLANNING
The servicing planning is finalized according to the common validation phases between SADEV and
MSPORT.

This planning value unit accounts for the special stage distance, but considering that the connexion
distance doesnt exceed by twice this value.

Parts Action Frequency


Differential bearings Change 2000 km ES
Primary and secondary shaft bearings Change 2000 km ES
Drain plug seals Change All drain

Drain plug Cleaning and check All drain

Selector spring Change 2000 km ES


Crown wheel screws Change All disassembly
Check and setting in conformity
Differential preload 600 km ES
if necessary
Disassembly / Assembly to Every 5 races and
Check gearbox and revision kit (orings, security screws)
check all parts all disassembly

Note

This planning may change all along the validation plans finalized by MSPORT team.

In case of update release edition, the manufacturer will be informed thanks to a technical note and will
transfer the information to its own customers.

As every mechanical part which is dedicated to racing, no guarantee is


ensured.

10 July 2009 update Page 5-1


BOITE DE VITESSES MECANIQUE
FORD FIESTA R2
5-Servicing
2 - GEARBOX REPAIR
1- Intervention in SADEV workshop

Notes :

x Gearboxes are delivered leaded and numbered.


x The absence of the SADEV lead imposes a really careful attitude in the event of minor or major
problem, and applies to complete reserve of our share if necessary.

Return of gearboxes to revision :

All the time gearboxes return to our buildings, a certain delivery procedure must be respected, so that
our intervention can be total and practical (casing closed for passage to the bench).

We must receive the complete product as described below :

x Release bearing in place


x Clamp tread cap en place
x Engine cut off sensors and reverse gear sensors in place
x Gearbox drained and cleaned
x Oil corks and their seals in place, slightly tightened
x Differential in place
x A card specifying the kilometres of the special stage and connection since the last service is
available near our sales department.

The reverse gear unlocking cable, except in the event of breakdown, has not to be sent to us, and will be
able to stay on the vehicle.

The objective on new gearboxes delivery is to provide a complete kit ready to assemble, which means
that the set we need to make a complete revision corresponds to the complete kit just dismantled.

The absence of elements can be specified on the card, but in the case of doubt, the material will be sent
back re-equipped.

Administrative procedure:

SADEV company only provides elements (and services) of STC FIESTA R2 gearbox through MSPORT
shop.

Any customer who wants a material servicing in our workshop must :

1. send a request for service to MSPORT shop, and a copy to SADEV


2. forward the material and its card in our workshop (description above)
3. Approve the estimate presented by MSPORT shop (after SADEV salesmen sending the work to
perform), in general case.
4. APPROXIMATELY 2 TO 3 WEEKS OF DELIVERY TIM MUST BE CONSIDERED.

10 July 2009 update Page 5-2


BOITE DE VITESSES MECANIQUE
FORD FIESTA R2
5-Servicing
2- Personal revision :

After sale, the parts for customers who want to proceed a revision by themselves, are delivered by
MSPORT shop, which will send us the material request.

SADEV COMPANY IS NOT RESPONSIBLE FOR ANY DAMAGE FOLLOWING A REVISION NOT
EXECUTED IN A SADEV AGREED TECHNICAL SERVICE (LIST ON DEMAND).

Some rules have to be respected :

x Servicing planning so kilometric follow-up


x An estimation of consumption.

10 July 2009 update Page 5-3