DMS 00 0005 Rev 007 Installation Instructions GR6
DMS 00 0005 Rev 007 Installation Instructions GR6
DMS 00 0005 Rev 007 Installation Instructions GR6
INSTRUCTIONS
GR6 FWD REBUILD
DMS-00-0005 REV 007
14 FEBRUARY 2024
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DMS-00-0005 REV 007
10-PLATE (DMS-8088)
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DMS-00-0005 REV 007
9-PLATE (DMS-8505)
OPTIONAL PARTS
● R6 FWD Clutch Fluid - 200ml (DMS-2616)
G
● GR6 FWD Billet Clutch Housing (DMS-8042)
● GR6 FWD Ball Retainer Plate (DMS-8045)
● GR6 FWD Housing Nut (DMS-7144)
● GR6 FWD Housing Lower Seal (DMS-1936)
● GR6 FWD Housing O-Ring (DMS-1937)
● GR6 FWD Output Shaft Seal (DMS-1938)
● GR6 FWD Clutch Housing Electro Magnetic Bearing (DMS-1422)
● GR6 FWD Clutch Housing Bearing (DMS-1433)
● GR6 FWD Output Bearing Upgrade Kit (DMS-7910)
NOTES
T hese instructions are valid for the 9, 10 or 11 plate clutch kit.
●
● TheDodson FWD Clutch Tool Kit (DMS-2329)is recommended.
- Please note that this tool kit is already included in theDodsonGR6 Full Pro Dealer
Tool Kit (DMS-2332).
● The optional parts are available from Dodson.
To order, please contact[email protected].
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DMS-00-0005 REV 007
STEP 2
arefully remove the FWD clutch unit from the main transmission housing and clamp the output
C
spline in a vise usingsoft jaws.
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DMS-00-0005 REV 007
STEP 3
Remove electromagnet retaining circlip using suitable circlip pliers.
Install the Dodson puller and spacer as shown below (all supplied in the DMS-2329 toolkit).
NOTE: tighten the cap screws finger tight only.
Then use the puller to remove the electromagnet from the assembly.
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DMS-00-0005 REV 007
STEP 4
seapunchtocrackthelocknutthenloosenit.UsetheDodsonspecialtool(DMS-2328)toremove
U
theelectromagnet/sealhousing(twopinsonthetoolslotintotheblindholesinthehousinganda
large screwdriver can be slotted through the holes on the top).
STEP 5
Remove the bearing, energiser clutch, ramps, balls, frictions and steels.
Check the conditions of the bearings, ramp plates, energiser plates and the balls.
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DMS-00-0005 REV 007
ASSEMBLY
STEP 1
If reusing the OE housing, skip toStep 2.
Inspect the o-ring on the output shaft and then fit it to the housing using the bolts supplied.
IMPORTANT NOTE
If also using the Dodson FWD Output Bearing Upgrade Kit (DMS-7910), follow the DodsonGR6 FWD
Output Bearing Upgrade Instructions (DMS-00-0042)before refitting the output shaft.
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DMS-00-0005 REV 007
STEP 2
IfonlyrebuildingorcheckingtheconditionoftheFWDclutch,checkthestackheightoftheclutch.
The stack height of a used FWD clutch should not be lower than 35.00mm.
If assembling a new kit, the stack height specification is outlined below for reference.
● 11-Plate kit stack height - 36.30 +/- 0.20mm
● 10-Plate kit stack height - 36.00 +/- 0.20mm
● 9-Plate kit stack height - 36.00 +/- 0.20mm
STEP 3
Installthefrictionandsteels.Starttheinstallationbyplacingasteelinfirst,makesurethattheoil
passagesonthesteelslineupwiththepassagesonthehousingandtrytokeeptheoilholesinthe
friction plate lined up as well.
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DMS-00-0005 REV 007
STEP 4
Install ramp plate, the thick energiser plate & balls - make sure balls are not damaged or discoloured.
T heDodsonFWDBallRetainerPlate(DMS-8045),shownbelow,whichreplacesthethickenergiser
plateandaddstheballretainingfeatureishighlyrecommendedandtheballsareknowntofallout
of their ramps causing a FWD clutch or other failures.
Common damage from balls popping out shown below for reference.
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DO NOT COPY / REPRODUCE IN ANY FORM OR MAKE PUBLIC WITHOUT THE PERMISSION OF DODSON MOTORSPORT.
PAGE10
DMS-00-0005 REV 007
STEP 5
Install energiser frictions as per picture.
See the images below comparing good to use and worn out energisers.
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DMS-00-0005 REV 007
STEP 6
Add the whole bottle (200ml) of Dodson High performance FWD Clutch Fluid (DMS-2616).
STEP 7
Install electromagnet/seal housing. Make sure that the OE seal (replacement: DMS-1936) and OE
O-ring (replacement: DMS-1937) are in good condition and well lubricated.
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DMS-00-0005 REV 007
STEP 8
T ightenelectromagnet/sealhousingclockwisewiththespecialtool.Thisshouldbedonebyhandand
until stop. Check that the clutch pack has 0 clearance-InstallontheFWDoutputshaftandtryto
turn the output shaft inside the FWD clutch unit -it should not turn.
STEP 9
ark the position ofelectromagnet/sealhousinginrelationtotheouterhousingwhentight.Then
M
turn the housinganti-clockwise 90 degrees.
TIP: mark the position using the holes in the special tool as they are 90 degrees apart.
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DMS-00-0005 REV 007
STEP 10
Tighten the OE lock nut (replacement: DMS-7144) with the special tool (DMS-10095).
STEP 11
Warm bearing in the electromagnet and installontohousing-ensurenottomeltthesealsonthe
earing. Ifit’sstilltootight,youcanusetheothersideofthespecialtool(DMS-2328)topressthe
b
bearing/electromagnet fully down.
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DMS-00-0005 REV 007
STEP 12
Install the retaining circlip.
STEP 13
Install the unit back into the transmission housing, ensure that the output shaft seal is in good
condition and lubricated (replacement: DMS-1938), secure the loom and plug.
Fit the drive shaft flange and tighten the nut to140 Nm.
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