E Gear LAMBORGHINI GALLARDO 2009 Repair Manual

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The clutch closed position is self tuned when the clutch valve is off, including engine off.
The clutch closed position must be in the range 1050bit and 2000 bit.
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The kiss point is self tuned at each cranking when the gearbox is in neutral. The engine is colder than 70C and the
clutch estimated temperature is colder than 70C.
The average of each calculated kiss point value is used and stored in the TCU memory. 7KH.LVVSRLQWLVSHUIRUPHGGXULQJWKHYHKLFOHOLIHDQGLVKLJKO\¿OWHUHG
For a fast adaptation of kiss point an LaRa-AS (109000)service is implemented.
The range is 300bit < Kisspoint < 800bit (the frequent value is between 350 and 550 bit).
The routine is activated if the following condition are true: • The engine is ON
• No gear is engaged
• The clutch kiss point self tuning has never been performed or a special service is asked by the tested
and it is suspended if one of the following condition is true:
• a new cranking is requested during the self tuning
• the clutch is not able to open
• the clutch closure phase is completed and no clutch rotation is detected
• a gear is requested
• a failure is detected on the clutch position sensor or on the gear valves

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The grid self tuning is composed in four phases:•Stable neutral position research
• Engaging of all gear from Reverse to Sixth
• Stable Neutral engaging
• Plausibility Check
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0 1 2 3 4 5 6 7
Valve ON Position 400 316 705 319 701 319 700 708
Valve OFF Position 409 325 696 328 692 328 691 699
Shift Position 366 475 579 685

When it is necessary to perform the selftuning grid? • Vehicle End of Line
• after every substitution of:
• Gearbox
• Kit
• T.C.U
• Gear and Shift Position Sensors

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When the driver door is opened and the car is sleeping starts theZDNHXSphase. In this phase the TCU is partially
switched on, and if the hydraulic pressure is lower than a limit the pump is activated for maximum 4 seconds.
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In the car there’s a relay that releases the cranking. This relay is controlled by E-Gear TCU.
The cranking is only released if the brake is pushed and not paddles an R switch pushed.
The cranking can be done also with a gear engaged. The system will engage the neutral before release the cranking. 3LFNXS
The pick up is related to the gas pedal position and how it’s pushed.
To perform good pick up is important to keep constant the gas pedal.
During pick up is calculated the clutch wear index, if the engine and clutch temperatures are in a range.
7R$YRLGSLFNXSZLWKEUDNHSXVKHGWKHV\VWHPFRQWUROVWKH&OXWFKWRUTXHWRD¿[HGYDOXH 'ULYDELOLW\0RGHV • Normal Mode , Sport Mode, Corsa Mode: the gearshifts are performed by the driver, with steering paddles,
better keeping constant the gas pedal. The gearshift speed and comfort quality depend on the gas pedal posi-
tion and engine speed.
• Automatic Mode and Automatic Sport Mode: the gearshift are performed directly from the E-Gear TCU, that
decides when to perform them according to the gas pedal position and vehicle speed.
• Underspeed: in order to avoid engine stalling if the driver doesn’t require any DW, E-Gear TCU perform itself
them when the engine speed becomes too low.
• Overspeed: in order to avoid engine limiter intervention the automatic gearshift is done when the maximum
engine speed is reached. This Function is not available in CORSA Mode.

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The drivability modes can be selected by tunnel switches. There are the switches for Automatic, Sport and Cor-
sa Mode
• The paddles can be used for manual gearshift
Comfort 3HUIRUPDQFH
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SPORT • • • • • •
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• The Automatic mode is available only for Normal and Sport mode.
• The ESP program (Normal and Sport) is connected to the E-Gear driving program.
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When the driver requests a gear shift via shift paddles on steering wheel while driving in Automatic mode, the systemswitched to manual mode and the gearshift is executed. After 8 seconds the system goes back to Automatic modeif there is no addition manual gear request.
The E-Gear SW siplays on dashboard always the mode it is currently using. Tip-In mode is displayed like Manual
mode.
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In Automatic mode (normal and sport) a curve detection function is active. This function prevent an automatic upshift when the steering wheel is turned over a threshold (at low speed) or the lateral acceleration is higher than a thre-
shold (at medium – high speed).
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7ZRWHPSHUDWXUHOLPLWDUHGH¿QHG • A warning limit which means, when the clutch temperature is higher, the clutch is loosing its capacity of torque
transmission and it is near to the damage limit
• A damage limit, which means, when the clutch temperature is higher, the clutch is no more able to transmit the
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When the clutch temperature is higher than the warning limit:• Anticipation of the automatic underspeed 2nd --> 1st (the clutch speed threshold for starting the underspeed
gear shift is higher than the normal case), in order to avoid pickup in 2nd gear.
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When the clutch temperature is higher than the damage limit: • Switch on the warning lamp and the message “Clutch overheated” to the driver.
• Store a DTC error code in the TCU memory if the clutch temperature remains over this limit.

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Launch Control
The mode “Launch Control” realises the max. possible acceleration during pick up.
The activation is done if the following condition are true: •Brake pressed
• CORSA mode activated
• ESP deactivated
When the “launch control” is activated the engine speed is reasing according to the gas pedal position.
The Pick-UP starts immediately when the Brake pedal is Released.
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A Special buzzer is used by the dashboard, that indicate that the clutch is too hot (c,a 200°), is switched on by Gear- box ECU.
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A Driver Warning Message in the dashboard display, that indicate that the car need workshop attention, is switched
on by Gearbox ECU.
The Symbol ( $)LJ) is displayed permanently.

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The “Thrust Mode” function is an extreme procedure whose purpose is to fully exploit all of the vehicle’s potentialswhen starting the car in a standstill position with the maximum acceleration possible. In this way we will get themaximum performance in terms of acceleration.
The conditions necessary for enabling the function are: 1. twater temperature > 60°C(otherwise the engine is limited by default and it is impossible to get the required
high performance start)
2. &256$ EXWWRQHQDEOHG YHUL¿HGZKHQWKH&256$OLJKWLVRQ
3. disable the (63 E\ SUHVVLQJ WKH EXWWRQ RQ WKH LQVWUXPHQW FOXVWHU %-$  YHUL¿HG ZKHQ WKH (63 2)) OLJKW LV
on)
4. press the brake pedal
5.  HQJDJH¿UVWJHDU
6. press the accelerator all the way down (the engine will automatically run at around 5500-6000 rpm)
7. release the brake pedal
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choking of the accelerator pedal makes the system leave the launch control strategy  VR \RX PLJKW ¿QG
yourself no longer with the automatic gearshift, but with the manual gearshift.
Important!
The Thrust Mode procedure entails enormous stress on all mechanical parts regarding the engine-gearbox- transmission.

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*HDUER[WHFKQLFDOGDWD • Fast engagement 6 gear ratios + reverse gear
•  6\QFKURQLVHUVZLWKÀRDWLQJULQJV
• Meshing clearance (all gears) 0.11 ÷ 0.03 mm
• Lubrication with gear pump
• Net Weight: 80 Kg
• Oil quantity: 4 Lt
• Number teeth: 25
• Gearbox ratios:
67' &20)257
(Comfort Package)
1st gear 1 : 3,313 1 : 2,563
2nd gear 1 : 2,053 1 : 1,850
3rd gear 1 : 1,458 1 : 1,423
4th gear 1 : 1,138 1 : 1,138
5th gear 1 : 0,939 1 : 0,939
6th gear 1 : 0,784 1 : 0,806
Reverse 1 : 2,813 1 : 2,813
countershaft/front differential input shaft 1 : 1,409
countershaft/rear differential input shaft 1 : 1,240
• 0DQXDOW\SH with cable control
• (*HDU W\SH robotised with electronically managed electro-hydraulic control and 4 function modes: normal,
automatic, sport and low adherence.
Hydraulic circuit pressure: approx. 40 – 50 bar
Valve trigger pressure approx. 90 bar
System capacity (000300)

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1 Clutch Housing
2 Ball Bearing
3 Clutch Shaft
4 Drive Shaft
5 Main Shaft Front Ring Nut
6 Ball Bearing
7 Thrust Washer
8 Roller Cage
9 Complete 4th Speed Gear
10 Retaining Ring
11
3rd-4th Speed Double/Triple Cone Synchroniser
12 Complete 3rd Speed Gear
13 Roller Cage
14 Complete 6th Speed Gear
15 6th Speed Gear Spacer
16 Retaining Ring
17 5th-6th Speed Double Cone Synchroniser
18 Complete 5 Th Speed Gear
19 Roller Cage
20 Complete 3rd-4th Speed Shaft
21 Complete 3rd-4th Speed Selector Fork
22 Complete 1st-2nd Speed Selector Fork
23 Complete Reverse Gear Shift Shaft
24 O-ring
25 Ball Bushing
26 Roller Bearing
27 Complete 5th-6th Speed Selector Fork
28 Reverse Drive Gear
29 Ring Nut
30 Complete Reverse Fork
31 Rear Cover
32 Complete Reverse Synchroniser
33 Roller Cage
34 Complete Reverse Idle Gear
35 Reverse Gear Bushing
36 Thrust Washer
37 Complete 1st Speed Gear 38
Roller Cage
39 Retaining Ring
40 1st-2nd Speed Triple Cone Synchroniser
41 Complete 2nd Speed Gear
42 Roller Cage
43 Spacer Ring
44 Ring
45 Lay Shaft
46 Bearings Retaining Plate
47 Intermediate Plate
48 Pinion Driving Gear
49 Drive Driving Gear
50 Drive Driven Gear
51 Roller Bearing
52 Radial Shaft Seal
53 Roller Bearing
54 Ring Nut
55 Drive Shaft
56 Ball Bearing
57 Drive Shaft Cover
58 Pinion Adjusting Washer
59 Tapered Roller Bearing
60 Preload Adjusting Washer
61 Pinion Driven Gear
62 Tapered Roller Bearing
63 Ring Nut
64 Manual Gearbox Gear Shift Mechanism
65 Complete Oil Pump
66 Roller Casing
67 Idle Gear Shoulder Ring
68 Idle Gear - Reverse
69 Driving Dowels
70 Driving Pin
71 Pinion
72 Gearbox Housing
73 Washer
74 Retaining Ring
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