Cortina Lotus Mk1/2 (2000E) 5 Speed gearbox
Discussion
Sam
The Lotus Cortina Register forum has just come up with the answer:
In 1966/67, Hewland produced a five speed Cortina gearbox - later to be built and sold by C.T.Wooler ( Engineers ) of Wembley.
The box was developed for race use and resulted from a demand from Cortina, Cortina Lotus and Lotus Elan drivers who used their cars for motorsport. They found that the gap between second and third on the standard box made life a little awkward when coupled to their tuned and often "peaky" engines.
Using the original cast-iron gearbox casing, the Hewland engineers went about the task of fitting five gears whilst retaining the format of a three shaft, constant mesh box. Space within the casing only allowed for a face-dog, non-synchromesh gear engagement system to be used. The lack of synchromesh is compensated by the extremely close ratios of the gears and provided an astoundingly fast gearchange, ideally suited to racing. Hewland used helical gears ( A first for Hewland ) as a compromise between the much needed strength for competition and a reasonably quiet operation for everyday road use.
The Lotus Cortina Register forum has just come up with the answer:
In 1966/67, Hewland produced a five speed Cortina gearbox - later to be built and sold by C.T.Wooler ( Engineers ) of Wembley.
The box was developed for race use and resulted from a demand from Cortina, Cortina Lotus and Lotus Elan drivers who used their cars for motorsport. They found that the gap between second and third on the standard box made life a little awkward when coupled to their tuned and often "peaky" engines.
Using the original cast-iron gearbox casing, the Hewland engineers went about the task of fitting five gears whilst retaining the format of a three shaft, constant mesh box. Space within the casing only allowed for a face-dog, non-synchromesh gear engagement system to be used. The lack of synchromesh is compensated by the extremely close ratios of the gears and provided an astoundingly fast gearchange, ideally suited to racing. Hewland used helical gears ( A first for Hewland ) as a compromise between the much needed strength for competition and a reasonably quiet operation for everyday road use.
But is it still available?? It's not even listed on the history page of Hewland's website, which suggests it was a 'special proiject' with no more than a handful built.
Why do you need a 5 speed box in the first place? If it's to provide relaxed high-speed cruising, then you'll probably find that even if they are available, the Hewland gear clusters will give direct drive in fifth (ie. the same as the standard box), if they were intended for race use, so won't offer any real advantage.
Why do you need a 5 speed box in the first place? If it's to provide relaxed high-speed cruising, then you'll probably find that even if they are available, the Hewland gear clusters will give direct drive in fifth (ie. the same as the standard box), if they were intended for race use, so won't offer any real advantage.
hi new to this site ,
but would like to reply to this item ,
a hewland 5 speed box is in the hands of a chap in scotland , however it has a cracked first gear
the box is at a friend in in the south of england , where it has been stripped and has been laser checked
the problem with those early hewland boxes , was the material used at the time , stuff was case hardened, but was like toffee the further down you go and very limited with the emount of power that can be used i think at the time it would have been 150bhp tops and had modified cast iron casings ,, so was quite heavy for what it was
however what is planned ,
new five speed gear kits built into mag casings , with some very hard steel still to be finalised , envolute dogs
reason for new mag casing, the 3 rail box is now a 4 rail , so a alloy casing from tony tompson or the use of cast iron wont work this has been greatly discussed , hewland had put a lot of effort into it at the time , , but i suppose because of being a very limited market , they probably lost money doing it then it would have been dropped the mag casing and gear sets , will be identical to hewland , abiet, from being made with better material , and some tweeks , power the box will easiy handle will arounf 230bhp ,
it will be tested in my caterham 7 , which has a alloy bdg bottom end 1794cc, with qed lotus twincam big port head , on 48s
and has 230bhp ,
but would like to reply to this item ,
a hewland 5 speed box is in the hands of a chap in scotland , however it has a cracked first gear
the box is at a friend in in the south of england , where it has been stripped and has been laser checked
the problem with those early hewland boxes , was the material used at the time , stuff was case hardened, but was like toffee the further down you go and very limited with the emount of power that can be used i think at the time it would have been 150bhp tops and had modified cast iron casings ,, so was quite heavy for what it was
however what is planned ,
new five speed gear kits built into mag casings , with some very hard steel still to be finalised , envolute dogs
reason for new mag casing, the 3 rail box is now a 4 rail , so a alloy casing from tony tompson or the use of cast iron wont work this has been greatly discussed , hewland had put a lot of effort into it at the time , , but i suppose because of being a very limited market , they probably lost money doing it then it would have been dropped the mag casing and gear sets , will be identical to hewland , abiet, from being made with better material , and some tweeks , power the box will easiy handle will arounf 230bhp ,
it will be tested in my caterham 7 , which has a alloy bdg bottom end 1794cc, with qed lotus twincam big port head , on 48s
and has 230bhp ,
sorry for the very late reply on this topic that i,am very interested in indeed. the new box your planing sounds very exiting and i would like to know a bit more if you let me. engine wise were not a million miles away, i have a couple of options ,one a BRM twin cam and a novamotor 2tr twin cam. drop me a email and i,ll send you some pics. mark.dcs1@btconnect.com
This is a pretty old thread but I have one of these boxes and am considering selling it. I've had it for 35+ years, was told at the time it was a Hewland/derivation, 5th is definitely an o/d, ~ 0.80. Dog engagement, different shifter rail. Dave Bean had one of these and provided additional insight, a very low 1st, gear, just over 3.0.
I have been inspired by another Lotus enthusiast to look more closely at the box I have and realize that 5th is indeed 1:1, not an overdrive as I optimistically stated earlier. In fact, here is the shift pattern and approximate ratios, as eyeballed with vise grips on either end providing those estimates. I don't know if this is the early Hewland or the Wooler version that followed, any thought how to determine that? 
Resurrecting an old thread! I've got two of these Hewland/Wooler dog boxes. From the selector mechanism yours looks like the earlier Hewland type for the Anglia. The Wooler ones seem to have selector rods that look much more like the 2000E selectors except the reverse gear has had the U shape on the end cut down. However, I could well be wrong and the two styles depended on the final application and type of remote, if any. John
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