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Xtracer 1152, Manual

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Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual 

© 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA. 

Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States 

26 

8.  Appendix B – Dog Damage Sheet 

Summary of Contents for 1152

Page 1: ...udinal Transaxle Sportscar Gearbox Manual 2015 Xtrac Limited Gables Way Kennet Park Thatcham Berkshire RG19 4ZA Xtrac Inc 6183 W 80th Street Indianapolis IN 46278 United States 1 1152 Longitudinal Sportscar Transaxle Gearbox Manual ...

Page 2: ...ential 14 4 4 1 Description 14 4 4 2 Ramp Angles 15 4 4 3 Number of Friction Faces 15 4 4 4 Positive Preload 15 4 4 5 Differential Test Rig 15 5 Gearbox Assembly and Maintenance 16 5 1 General Assembly Notes 16 5 1 1 Torque Settings 17 5 2 Cluster Setup 18 5 2 1 Ratio Change Procedure 18 5 2 2 Selector Barrel Setup 19 5 3 Differential Setup 21 5 4 Spiral Bevel Gear Assembly 21 5 5 Lifing Chart 21 ...

Page 3: ...ted States 3 13 Appendix G Example Lifing Sheet 32 14 Appendix H Ratio List 1152B LMP3 34 15 Appendix J Ratio List 1152 Generic 39 16 Appendix K Manual Revision Sheet 42 17 Appendix L Exchange Server Log In Procedure 42 18 Appendix M Xtrac Standards 45 19 Appendix N Technical Bulletins 50 Issue 1 0 21 04 15 Issue 2 0 10 12 15 2015 Xtrac Limited Gables Way Kennet Park Thatcham Berkshire RG19 4ZA ...

Page 4: ...e various Loctite adhesives for thread locking bonding and sealing a list of which is detailed below Loctite 270 All studs fitted into casings Loctite 648 For high temperature retention of parts with a clearance or interference fit i e retaining bushes bearings seals Loctite 406 Rapid bonding of rubbers when used with Loctite 7239 Polyolefin Primer bonds Used for O ring sealing and bonding Loctite...

Page 5: ...nts used must be as listed in the Xtrac service documentation The life and durability of the gearbox internal parts is considerably influenced by factors other than engine and chassis characteristics These can be classified as gearbox misuse If the gearbox is damaged in transit during incorrect installation or as a result of accident puncture damage or abnormal weather conditions Inadequate coolin...

Page 6: ... the Terms and Conditions of Sales which include the following Goods intended for motorsport or for product development evaluation or experimentation may operate under extreme loads and conditions and you agree that it is your responsibility to ensure that the Goods are correctly inspected adjusted and maintained at all times to suit the specific conditions in which they may be used Lightweight an...

Page 7: ...lutch shaft directly to the longitudinally mounted layshaft The layshaft drives the mainshaft through the change gear ratios The mainshaft gears are mounted on hubs on the mainshaft and transmit drive to the shaft itself through sliding dog rings The mainshaft transmits drive into the bevel pinion which drives the transversely mounted bevel wheel The bevel wheel in turn drives a Salisbury type pla...

Page 8: ...oad fitted as standard A choice of fixed ramp angles is available Output flanges To suit 108mm 6 ball type CV joints Oil Pump A 9mm wide single stage eccentric lobe oil pump is included to pressure feed the recirculating gearbox lubrication circuit For more details see section 4 2 Oil System Weight 64 kg 141 lb dry weight Gearchange Actuation Xtrac Megaline P1254 IVA pneumatic actuator Dowels and ...

Page 9: ... also be adjusted For details see section 4 4 Differential 3 3 Optional Extras cost options Gear Ratios Gear ground and Xtrem polished Final Drive Bevel Set Full form ground and Xtrem polished Clutch Actuation An AP Racing clutch slave cylinder from the CP6859 family can be supplied fitted to the gearbox 3 4 Excluded Items Gearchange Actuator 1254 932 000A Xtrac Megaline IVA pneumatic actuator Bel...

Page 10: ... at the rear of the gearbox and driven by the layshaft operates as part of a simple re circulating system The oil is picked up through the oil filter within the baffled scavenge area in the rear portion of the cluster housing The scavenge area is positioned to provide pickup independent of car accelerations and reduce the effects of windage The oil should be fed to a remote cooler from the oil out...

Page 11: ...ure sensor A temperature sensor customer supply can be positioned on the rear of the gearbox where a M12 x 1 5 thread is provided Xtrac recommend using the Bosch NTCM12 temperature sensors see section 10 Appendix D Electrical Component Data Sheets 4 2 4 Filtration and Magnets A steel mesh filter 125 micron 0 005 gauze size which is easily accessible from the rear of the gearbox can be readily chec...

Page 12: ...aused by the additional preload applied from cold casings The gearbox oil can be preheated by running of the powertrain with the vehicle on stands the use of an external oil heater or an oil to water cooler connected to the engine cooling system Where these systems are unavailable it is imperative that the vehicle is driven in a sympathetic manner until the minimum gearbox oil temperature is reach...

Page 13: ...gear by a selector fork transmitting drive from the gear to the dog ring through the hub and into the mainshaft itself The entire cluster can be removed as one assembly from the rear of the gearbox as installed for ease of inspection and maintenance The barrel should be shimmed to ensure it holds the selector forks and dog rings central to the gear cluster A cluster setting jig 1152 999 006A is av...

Page 14: ...al ramp forces through two symmetrical friction plate packs giving the differential very linear and predictable locking characteristics The side gear rings ramps act against a matching cross pin when drive coast torque is applied to the differential The side gear pinion mates are free to rotate about the cross pin legs independently of the ramp forces The standard factory setting for the different...

Page 15: ...aces The number of friction faces in the differential can be adjusted from 2 to 4 faces per side in order to produce different locking gradients The number of friction faces must be kept equal on each side of the differential cassette to ensure the differential has symmetrical characteristics for right and left hand corners 4 4 4 Positive Preload Two belleville disc springs are used in the differe...

Page 16: ... or to arrange testing please contact your business manager 5 Gearbox Assembly and Maintenance 5 1 General Assembly Notes Only genuine Xtrac parts should be used when overhauling the 1152 gearbox Key steel components manufactured by Xtrac are made with our own specification of steel either X36C or XVAR1 All Xtrac components are manufactured to our own in house quality standards and are inspected a...

Page 17: ...g bearings as this will weaken the casting material Xtrac recommend the use of an oven to control the temperature and to ensure the heat is distributed evenly Fit bearings promptly after removing the casing from the oven to avoid extra heating cycles being required 5 1 1 Torque Settings If not stated on specific build sheets or assembly drawings all fasteners in the transmission should be tightene...

Page 18: ... M6 k nuts and stow the unit safely 2 Remove the cluster cover assembly from the gearbox by loosening the 11off M8 k nuts and using the two M6 X 1 0 jacking threads if required Secure the 1152 499 008A Shaft Holding Tool as part of the tooling assembly 1152 999 005A in a vice and place the cluster cover assembly on the holding tool rotating the layshaft and mainshaft as required so their respectiv...

Page 19: ...wapped reassembly is in the reverse order as points 1 7 Note the overlapping gear order 1st 2nd 3rd 5th 4th 6th and ensure that all selector forks locate inside the respective tracks on the gearchange barrel before the selector rail is refitted 5 2 2 Selector Barrel Setup The tolerance stack up on individual parts across the cluster assembly can affect the position of the dog rings relative to the...

Page 20: ...and off values are consistently biased in a single direction then the 195 401 014 gearchange barrel spacer should be adjusted to balance these values See 1152 902 000A Cluster Cover Assembly drawing 4 After adjusting the gearchange barrel spacer by surface grinding or selecting a larger size and re assembling check all of the values again to ensure the change was satisfactory Please note that upon...

Page 21: ... which is included in Appendix C Example Bevel Setting Sheet and spacer sizes are included in the Build Verification Sheet Please refer to these and assembly drawing 1152 999 007A for further information 5 5 Lifing Chart The following chart should be used to ensure that component life is not exceeded and premature failures are prevented by regular inspection Check and replace in accordance with th...

Page 22: ...Shaft 1500 3000 6000 Layshaft Integral 1 st 2 nd gear ratio set 1500 3000 6000 3 rd Gear Ratio hobbed 500 1000 2000 3 rd Gear Ratio ground 1500 3000 6000 4 th 6 th Gear Ratios 1500 3000 6000 Dog Rings 1500 3000 6000 Layshaft Mainshaft Nuts 1500 3000 6000 Gearchange Barrel 1500 3000 9000 Selector Forks 1500 3000 9000 Mainshaft 1500 3000 9000 Mainshaft Hubs 1500 3000 6000 Reverse Idler Mainshaft Gea...

Page 23: ...ted prior to despatch to check the gearchange operation lubrication system and build integrity 6 1 2 Training Servicing The 1152 gearbox is designed and manufactured for use in cost control categories and thus great emphasis is placed not only on its reliability but also on ease of servicing and assembly Product training sessions at our UK facility are available to provide technicians with the bas...

Page 24: ...Street Indianapolis IN 46278 United States 24 6 1 3 Contacts Xtrac Limited Gables Way Kennet Park Thatcham Berkshire RG19 4ZA England www xtrac com Email sales xtrac com Tel 44 1635 293 800 Xtrac Inc 6183 W 80th Street Indianapolis IN 46278 United States www xtrac com Email sales xtrac com Tel 1 317 472 2454 For individual contact details please see www xtrac com ...

Page 25: ...tandard Tightening Torques Description Location Sub assembly Torque Comments Pinion Nut 1152 475 001A 1152 901 000A 400Nm 295 lbf ft Oil Threads Gearchange Barrel Nut 105 432 002A 1152 902 000A 68Nm 50 lbf ft Loctite 648 Differential Lid 600 449 001A 1152 949 000A 230Nm 170 lbf ft Oil Threads Layshaft Nut 199 421 006A 1152 996 000 136Nm 100 lbf ft Oil Threads Mainshaft Nut 099 422 006B 1152 996 00...

Page 26: ...1152 Longitudinal Transaxle Sportscar Gearbox Manual 2015 Xtrac Limited Gables Way Kennet Park Thatcham Berkshire RG19 4ZA Xtrac Inc 6183 W 80th Street Indianapolis IN 46278 United States 26 8 Appendix B Dog Damage Sheet ...

Page 27: ...Longitudinal Transaxle Sportscar Gearbox Manual 2015 Xtrac Limited Gables Way Kennet Park Thatcham Berkshire RG19 4ZA Xtrac Inc 6183 W 80th Street Indianapolis IN 46278 United States 27 9 Appendix C Example Bevel Setting Sheet ...

Page 28: ...Sportscar Gearbox Manual 2015 Xtrac Limited Gables Way Kennet Park Thatcham Berkshire RG19 4ZA Xtrac Inc 6183 W 80th Street Indianapolis IN 46278 United States 28 10 Appendix D Electrical Component Data Sheets 10 1 Bosch Temperature Sensor NTC M12 L ...

Page 29: ...et Park Thatcham Berkshire RG19 4ZA Xtrac Inc 6183 W 80th Street Indianapolis IN 46278 United States 29 11 Appendix E Oil Pumps and Flow 11 1 Oil Pump Pressure and Flow Rates The graphs below show typical values of flow rate pressure for the gearbox fitted with the standard 9mm eccentric rotor pump assembly ...

Page 30: ...differential compared to a baseline where a 30 degree ramp with a total of 16 friction faces is the maximum achievable locking note the maximum number of friction faces in the 1152 differential is 8 in total Table 3 Differential Locking Variables This data has been calculated based on a mixture of theoretical and experimental data and is a guide only values are not exact RAMP ANGLE DEG FRICTION FA...

Page 31: ...ongitudinal Transaxle Sportscar Gearbox Manual 2015 Xtrac Limited Gables Way Kennet Park Thatcham Berkshire RG19 4ZA Xtrac Inc 6183 W 80th Street Indianapolis IN 46278 United States 31 Figure 5 Differential Locking Performance ...

Page 32: ... Xtrac Limited Gables Way Kennet Park Thatcham Berkshire RG19 4ZA Xtrac Inc 6183 W 80th Street Indianapolis IN 46278 United States 32 13 Appendix G Example Lifing Sheet Included below is a copy of a session mileage sheet to be completed after periods of running the 1152 gearbox ...

Page 33: ...ssion Mileage Summary P1000 Oliver Grant Session Summary Date Circuit Car No Driver Session Gearbox Summary Distance Units Track Temp Air Temp Gearbox No Max Oil Temp Oil Fill Volume Session Mileage Record Serial No Previous Total Mileage Milleage in Current Session New Total Mileage Part Description Notes Notes ...

Page 34: ...r Gearbox Manual 2015 Xtrac Limited Gables Way Kennet Park Thatcham Berkshire RG19 4ZA Xtrac Inc 6183 W 80th Street Indianapolis IN 46278 United States 34 14 Appendix H Ratio List 1152B LMP3 Included below is a copy of 1152B LMP3 ratio list and speed chart ...

Page 35: ... Output Sum Ratio 19 28 47 1 474 19 24 43 1 263 23 25 48 1 087 Input Output Sum Ratio 11 31 42 2 818 49 Sum Collared 3rd 4th 6th 27 10 2015 Date Final Drive Issue 6 Approved MBB Note Ratings charts pages 3 4 supplied in accordance with ISO6336 2006 are based on an engine speed of 7000RPM and torque of 540Nm Rating values are comparative a higher value means that a gear is comparatively stronger or...

Page 36: ...linson 120 1152 001 Drg 27 10 2015 Date MBB Approved 6 13 37 15 34 13 23 17 30 19 28 19 24 23 25 3000 3500 4000 4500 5000 5500 6000 6500 7000 30 50 70 90 110 130 150 170 190 210 230 250 270 290 310 330 Engine RPM kph Speed Chart Tyre Diameter 11 31 mm 698 Final Drive Xtrac reserve the right to change ratios without notice Page 2 of 4 ...

Page 37: ...pproved 13 37 15 34 13 23 17 30 19 28 19 24 23 25 0 55 0 60 0 65 0 70 0 75 0 80 0 85 0 90 0 95 1 00 1 05 1 10 1 15 Safety Factor SF Ratio Pitting Safety Factors for comparison purposes Input Gear Output Gear Key 1 st 2 nd Gear Torque Nm 540 3 rd Gear 4 th 6 th Gear Minimum Safety Factors Shown For Selected Ratios Xtrac reserve the right to change ratios without notice Page 3 of 4 ...

Page 38: ...15 MBB 6 13 37 15 34 13 23 17 30 19 28 19 24 23 25 0 50 0 60 0 70 0 80 0 90 1 00 1 10 1 20 1 30 1 40 1 50 1 60 1 70 1 80 Safety Factor SF Bending Safety Factors for comparison purposes Input Gear Output Gear Key 1 st 2 nd Gear Torque Nm 540 3 rd Gear 4 th 6 h Gear Minimum Safety Factors Shown For Selected Ratios Xtrac reserve the right to change ratios without notice Page 4 of 4 ...

Page 39: ...Gearbox Manual 2015 Xtrac Limited Gables Way Kennet Park Thatcham Berkshire RG19 4ZA Xtrac Inc 6183 W 80th Street Indianapolis IN 46278 United States 39 15 Appendix J Ratio List 1152 Generic Included below is a copy of 1152 Generic ratio list and speed chart ...

Page 40: ... 200 18 31 49 1 722 21 25 46 1 190 14 24 38 1 714 16 19 35 1 188 13 22 35 1 692 22 26 48 1 182 16 27 43 1 688 23 27 50 1 174 14 23 37 1 643 18 21 39 1 167 16 26 42 1 625 19 22 41 1 158 15 24 39 1 600 20 23 43 1 150 17 27 44 1 588 21 24 45 1 143 14 22 36 1 571 22 25 47 1 136 15 23 38 1 533 23 26 49 1 130 24 27 51 1 125 25 28 53 1 120 195 42M 4A Hobbed 17 19 36 1 118 195 421 004A 033 422 008A 26 29 ...

Page 41: ...rg 07 12 2015 Date MBB Approved 6 1st 13 37 2nd 15 34 2nd 13 29 3rd Min 15 29 4th Min 17 30 3rd Max 15 23 6th Max 25 24 3000 3500 4000 4500 5000 5500 6000 6500 7000 50 70 90 110 130 150 170 190 210 230 250 270 290 310 330 350 Engine RPM kph Speed Chart Tyre Diameter 11 31 mm 698 Final Drive Xtrac reserve the right to change ratios without notice Page 2 of 2 ...

Page 42: ...sion Sheet Issue Description of Change Date Initials 1 0 New manual 02 06 15 MBB 2 0 Manual extended with additional information 10 12 15 MBB 17 Appendix L Exchange Server Log In Procedure Go to Xtrac s website at www xtrac com and select Xchange Login from the menu at the top Enter your company login details at the Xchange login screen and click on the login button For your username and password ...

Page 43: ...ortscar Gearbox Manual 2015 Xtrac Limited Gables Way Kennet Park Thatcham Berkshire RG19 4ZA Xtrac Inc 6183 W 80th Street Indianapolis IN 46278 United States 43 This will take you to the download area where a list of files will be visible for download ...

Page 44: ...tates 44 To download each file click on the Download button next to each file in the list IMPORTANT NOTES The 1152 Xchange account is a generic product account and cannot be used to send any data to Xtrac Please use your own customer Xchange account to send large data files to Xtrac if you do not have an account and wish to set one up please contact your Xtrac business manager or engineering conta...

Page 45: ...rtscar Gearbox Manual 2015 Xtrac Limited Gables Way Kennet Park Thatcham Berkshire RG19 4ZA Xtrac Inc 6183 W 80th Street Indianapolis IN 46278 United States 45 18 Appendix M Xtrac Standards Xtrac standards have been included for reference purposes only ...

Page 46: ...UMENT REFERENCE XS036_EN_THREADED_JOINT_05 doc AUTHOR Mickael Tessier APPROVED BY Jon Marsh Chief designer AGREED BY Martyn Silby Quality Assurance Manager Version No Date Produced 5 1 09 02 2015 Paper based copies of this document are for reference only Paper copies of this document are valid for 30 days from the date Last printed below and should be checked before expiry ...

Page 47: ...shop best practice Torques for Nut onto 3S145D stud in steel or SHC bolt into steel marked as TBC pending further evaluation by AEG M8 x 1 25 was 30Nm and 22ft lbf M10 x 1 25 was 48Nm and 35ft lbf M10 x 1 5 was 47Nm and 35ft lbf All M12 tightening torques marked as TBC pending further evaluation by AEG 5 16 UNF UNC was 28Nm and 21ft lbf 3 8 UNF UNC was 54Nm and 40ft lbf 18 10 11 M Tessier 5 0 Revi...

Page 48: ... Verification Tools and recorded as design verification against the assembly concerned 3S 145D Or Higher Grade Material Studs Screws Ti64 Studs Screws Nm ft lbf Nm ft lbf METRIC M4 x 0 7 3 2 3 2 M5 x 0 8 7 5 6 4 M6 x 1 0 11 8 10 7 M7 x 1 0 18 13 15 11 M8 x 1 25 26 19 22 16 M10 x 1 25 52 38 45 33 M10 x 1 5 50 37 44 32 M12 x 1 5 87 64 76 56 M12 x 1 75 85 63 74 55 IMPERIAL 1 4 UNF 13 10 11 8 1 4 UNF ...

Page 49: ...0 6 0 Ti64 20 5 15 0 14 0 9 0 7 5 6 0 6 0 M10x1 5 3S 145D 25 5 18 5 17 5 11 5 9 5 6 0 6 0 Ti64 19 5 14 0 13 0 8 5 7 5 6 0 6 0 M12x1 5 3S 145D 32 5 23 5 22 0 14 0 12 0 7 5 7 5 Ti64 24 5 18 0 16 5 10 5 9 0 7 5 7 5 M12x1 75 3S 145D 31 0 22 5 21 0 13 5 11 5 7 5 7 5 Ti64 23 5 17 0 16 0 10 5 9 0 7 5 7 5 M14x2 0 3S 145D 36 5 26 5 24 5 16 0 13 5 8 5 8 5 Ti64 27 5 20 0 18 5 12 0 10 0 8 5 8 5 IMPERIAL 1 4 U...

Page 50: ...ianapolis IN 46278 United States 50 19 Appendix N Technical Bulletins Periodically technical bulletins will be issued covering any issues or changes made to the gearbox At the earliest opportunity please forward e mail contact details to any of the Xtrac contacts listed in this manual so that bulletins and other information can be passed on efficiently throughout the season ...

Page 51: ... 900 000A gearbox in the LMP3 application it has been determined that the diameter of the ground nose journal on the 1152 420 000A Clutch Shaft requires amendment to optimise the fit inside the engine crank bush Clutch shafts with issue number 3 or lower were manufactured with the ground nose journal diameter measuring Ø15 938 15 927mm These parts require modification to reduce the diameter to Ø15...

Page 52: ...ise notified All 1152 900 000A gearboxes fitted with the 1152 420 000A clutch shaft and supplied by Xtrac from 05 05 2015 will also have the issue number 4 or higher and will be manufactured with the reduced nose journal diameter unless otherwise notified For further information please contact Business Manager Ben Green T 44 1635 293 421 M 44 7780 333 433 ben_green xtrac com Senior Design Engineer...

Page 53: ...Information Only Ref Description 1 1152 407 000A BELLHOUSING The 1152 407 000A Bellhousing has been up issued to revision 5 to incorporate the following design changes 1 Material has been added around the floor fixings to increase casing strength ref Figure 1 1 Figure 1 2 2 The cast logos that previously featured on top of the casing have been removed ref Figure 1 1 Figure 1 1 Bellhousing Updates ...

Page 54: ...anges will be phased in imminently on LMP3 transmission builds 2 1152 401 000A MAINCASE The 1152 401 000A Maincase has been up issued to revision 5 to add material around the rear wing fixings to increase casing strength ref Figure 2 1 Figure 2 1 Maincase Update 2 ...

Page 55: ...2 Oil Filter and 102 0271 O Ring Viton 16 x 2 ref Figure 3 1 for an alternative specification 161 0032 Oil Filter and 102 0825 O Ring Viton 30 x 1 ref Figure 3 2 Figure 3 1 Revision 1 Pump Housing Assembly Figure 3 2 Revision 2 Pump Housing Assembly This change will be phased in imminently on new builds All gearbox rebuilds from 07 07 15 onwards will feature the new Oil Filter and O Ring as standa...

Page 56: ... This is due to the creation of a new specification 1152 475WB 1131 Crownwheel to reflect changes in the manufacturing process Figure 4 1 1152 475WPA 1131 Crownwheel Pinion Set Figure 4 2 1152 475WPB 1131 Crownwheel Pinion Set This change will be phased in imminently on new builds All gearbox rebuilds from 07 07 15 onwards will be fitted with the new Crownwheel Pinion Set assembly as standard unle...

Page 57: ...anufacturing process This change will be phased in imminently on new builds and rebuilds For further information please contact Business Manager Ben Green T 44 1635 293 421 M 44 7780 333 433 ben_green xtrac com Senior Design Engineer Mark Brogden T 44 1635 293 428 M 44 7788 237 475 mark_brogden xtrac com Prepared By Angelo Wilson Signed ANW Approved By Mark Brogden Signed MBB 2 ...

Page 58: ...ember 2015 From that time onwards all new gearbox builds and rebuilds warranting a replacement 3rd gear will be supplied with the uprated gear set Until that time it is advised that customers limit the life of their current 233 42M 3A 1730 gear sets to 2000km In addition customers are encouraged to crack check their current 3rd gear sets before each prolonged period of running in line with Xtrac s...

Page 59: ... Description 1 1152 407 000A BELLHOUSING The 1152 407 000A Bellhousing has been up issued to revision 6 to add material around the floor fixings to increase casing strength Please see Figure 1 1 Figure 1 2 for reference where surfaces coloured yellow have been modified Please note that there have been no changes to any of the floor mount fixing positions as a result of this modification Figure 1 1...

Page 60: ...build 41 onwards For further information please contact Business Manager Ben Green T 44 1635 293 421 M 44 7780 333 433 ben_green xtrac com Senior Design Engineer Mark Brogden T 44 1635 293 428 M 44 7788 237 475 mark_brogden xtrac com Prepared By Tony Carrozza Signed TZZ Approved By Mark Brogden Signed MBB ...

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