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Xtracer 1152 Manual

Longitudinal sportscar transaxle gearbox
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1152
Longitudinal Sportscar Transaxle
Gearbox Manual
Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual
1
© 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA.
Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States

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Summary of Contents for Xtracer 1152

  • Page 1 Longitudinal Sportscar Transaxle Gearbox Manual 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...

  • Page 2: Table Of Contents

    11.1. Oil Pump Pressure and Flow Rates ............29 Appendix F – Differential Characteristics ............30 Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA.
  • Page 3 Issue 2.0 – 10/12/15 © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA.

  • Page 4: Summary Of Lubricants And Greases

    302 grade Goodridge, 0.81mm gauge 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...

  • Page 5: Operating Requirements

    Xtrac is extremely proud of the quality, success and reputation of their products and we are delighted that you have chosen to use the 1152 gearbox. The design of each gearbox is the subject of much research and development, technical analysis and detailed testing.
  • Page 6 10.5, any such components or gearboxes, by their very nature, are not warranted as to their suitability for use or performance.’ Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA.

  • Page 7: Specification

    Specification The 1152 gearbox has been designed for use in Sportscar endurance and sprint races, using many existing tried and tested parts packaged to suit the specific needs of high duty Sportscar formulae. The unit is a longitudinal transaxle design for use in rear wheel drive vehicles and comprises six forward gears plus reverse.
  • Page 8 Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA.

  • Page 9: Standard Options (No Cost)

    Oil Cooler & Lines Customer supplied. Clutch 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...

  • Page 10: Gearbox Operation

    The cooled oil is distributed internally through the dedicated oil feeds within the gearbox. Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA.

  • Page 11: Dedicated Oil Feeds

    90 - 110°C (194 - 230°F)* Minimum/Maximum System Pressure Minimum 0.5 Bar/Maximum 1.9 Bar 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...

  • Page 12: Gear Cluster

    4.3. Gear Cluster The 1152 gear cluster comprises straight cut, hobbed and/or ground gears mounted on the easily removable rear cover subassembly, shown in Figure 1 - Section View of Gear Cluster Assembly. The gearchange operation is a ‘dog’ type.

  • Page 13: Reverse Gear

    (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 available for this operation after gearchange barrel and/or barrel bearing replacement.

  • Page 14: Differential

    Appendix F – Differential Characteristics. Figure 2 – Section View of Pate Differential Assembly Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA.

  • Page 15: Ramp Angles

    The following rig operational modes are available: 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...

  • Page 16: Gearbox Assembly And Maintenance

    Lightly oil the parts before assembly and do not use any lubricants other than those stated in this manual. The oil filter fitted to the 1152 gearbox must be replaced at least every 6000km (3728 miles) or sooner if debris has started to collect. The filter is situated on the suction side of the pump, so any blockage will manifest as a reduced pressure in the feed lines to the gearbox oil feeds/sprays.

  • Page 17: Torque Settings

    An example of the use of Torque Seal is shown in Figure 3 - Correct Application of Torque Seal. Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA.

  • Page 18: Cluster Setup

    Figure 3 - Correct Application of Torque Seal 5.2. Cluster Setup The cluster should be assembled referring to the Xtrac assembly drawings 1152- 902-000A and 1152-996-000*, in conjunction with the instructions presented here. 5.2.1. Ratio Change Procedure The instructions presented below describe the simplest method of changing a gear ratio set.

  • Page 19: Selector Barrel Setup

    999-005A) and a 5/8” Hex Drive (1/2” Square). Do not fully remove the locking nuts at this stage. Lift the cluster cover assembly from the 1152-499-008A holding tool and place it cluster plate down on the 1152-999-004A Cluster Stand Assembly. The layshaft and mainshaft locking nuts can now be removed by hand from their respective shafts.
  • Page 20 Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA.

  • Page 21: Differential Setup

    5.3. Differential Setup The differential should be disassembled, assembled and setup in accordance with drawing 1152-949-000A Plate Differential Assembly and using the tooling as follows: - 626-499-004A Splined Socket 41T (for measuring turnover torque) - 626-499-005A Splined Socket 41T (for measuring turnover torque)
  • Page 22 See separate 1254 manual *See technical bulletin 1152-0003. 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...

  • Page 23: General Information

    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 basic knowledge to carry out their own routine maintenance work.

  • Page 24: Contacts

    Tel: +1 317 472 2454 For individual contact details please see www.xtrac.com 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...

  • Page 25: Appendix A - Non Standard Tightening Torques

    Oil Threads (099-422-006B) (100 lbf ft) 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...

  • Page 26: Appendix B - Dog Damage Sheet

    8. Appendix B – Dog Damage Sheet 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...

  • Page 27: Appendix C - Example Bevel Setting Sheet

    9. Appendix C – Example Bevel Setting Sheet 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...

  • Page 28: Appendix D - Electrical Component Data Sheets

    10. Appendix D – Electrical Component Data Sheets 10.1. Bosch Temperature Sensor NTC M12-L 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...

  • Page 29: Appendix E - Oil Pumps And Flow

    The graphs below show typical values of flow rate & pressure for the gearbox fitted with the standard 9mm eccentric rotor pump assembly. Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA.

  • Page 30: Appendix F - Differential Characteristics

    This data has been calculated based on a mixture of theoretical and experimental data and is a guide only, values are not exact. Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA.
  • Page 31 Figure 5 - Differential Locking Performance 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...

  • Page 32: 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. Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA.
  • Page 33 Application Gearbox Report - Session Mileage Summary AE-7799-01A 04/04/2012 Project Code P1000 Report Author Oliver Grant Session Summary Date Circuit Car No. Driver Session Track Condition Gearbox Summary Gearbox No. Max Oil Temp Oil Fill Volume Air Temp Track Temp Distance Units Miles Kilometres...

  • Page 34: Appendix H - Ratio List-1152B-Lmp3

    14. Appendix H – Ratio List-1152B–LMP3 Included below is a copy of 1152B-LMP3 ratio list and speed chart. Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA.
  • Page 35 Tel: +44(0) 1635 293 800 Gearbox Type: 1152B Fax: +44(0) 1635 293 700 e-mail: sales@xtrac.com - LMP3 Web Site: www.xtrac.com (Integral Layshaft) 1152-42M-000A* *= Layshaft Set Code e.g. 1152-42M-000AA (1152-421-000A* / 033-422-008A) / 033-422-008A) Code(*) Input Output Ratio Input Output Ratio 2.846 2.267...

  • Page 39: Appendix J - Ratio List-1152-Generic

    15. Appendix J – Ratio List-1152–Generic Included below is a copy of 1152-Generic ratio list and speed chart. Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA.
  • Page 40 Gearbox Type: 1152 Fax: +44(0) 1635 293 700 e-mail: sales@xtrac.com - GENERIC Web Site: www.xtrac.com (Integral Layshaft) 1152-42M-000A* (Hobbed) *= Layshaft Set Code e.g. 1152-42M-000AA (1152-421-000A* / 033-422-008A) / 033-422-008A) – 6 Cont. Code(*) Input Output Ratio Input Output Sum Ratio...

  • Page 42: Appendix K - Manual Revision Sheet

    For your username and password please contact your business manager. 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...
  • Page 43 This will take you to the download area where a list of files will be visible for download Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA.
  • Page 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 contact.

  • Page 45: Appendix M - Xtrac Standards

    18. Appendix M – Xtrac Standards Xtrac standards have been included for reference purposes only. 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...
  • Page 46 XTRAC STANDARD DOCUMENT TITLE XS036 - Xtrac Standard for Threaded Joint DOCUMENT 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 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’...
  • Page 47 Document Amendment History Date Author Version Description of Change 11-01-10 Xtrac M3 x 0.5 added and M4 x 0.7 Modified 25-01-10 M.KERR Additional notes to define limits of tightening torque for studs into casings and addition of loctite specification as standard. Verification note also added.
  • Page 48 1. Introduction / Scope This standard exists to provide recommendations on tightening torques and minimum lengths of thread engagement. 2. Tightening Torques Please note: In all applications, Loctite 270 thread lock shall be used when assembling studs into casings. When defining tightening torques for studs into casings the torque used shall never exceed the nut tightening torque specified in the table below.
  • Page 49 3. Length of engagement for mating threads If failure of a threaded assembly should occur, it is preferable for the screw to break rather than have either the external or internal thread strip. In other words, the length of engagement of mating threads should be sufficient to carry the full load necessary to break the screw without the threads stripping.

  • Page 50: Appendix N - Technical Bulletins

    Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA.
  • Page 51 Ref Description 1152-420-000A CLUTCH SHAFT Following initial testing and racing of the 1152-900-000A 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.
  • Page 52 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.
  • Page 53 For Information Only Ref Description 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).
  • Page 54 These changes will be phased in imminently on LMP3 transmission builds. 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 ©...
  • Page 55 This change will be phased in imminently on new builds and rebuilds. 1152-903-000A PUMP HOUSING ASSEMBLY The 1152-903-000A Pump Housing Assembly has been up-issued to revision 2 to replace the 00P-161-0042 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...
  • Page 56 The 1152-475WPA-1131 Crownwheel & Pinion Set assembly (ref. Figure 4.1) has been replaced by 1152-475WPB-1131 Crownwheel & Pinion Set assembly (ref. Figure 4.2). This is due to the creation of a new specification 1152-475WB-1131 Crownwheel to reflect changes in the manufacturing process.
  • Page 57 600-449-000B DIFFERENTIAL BODY The 600-449-000A Differential Body has been replaced by 600-449-000B Differential Body. This is to reflect changes in the manufacturing process. This change will be phased in imminently on new builds and rebuilds. For further information please contact: Business Manager: Senior Design Engineer: Ben Green...
  • Page 58 For Information Only Ref Description 233-42M-3A-1730 – 233A GEAR SET COLLARED 17:30 The 233-42M-3A-1730 collared 3 gear set used in the 1152-996-000B cluster assembly is to be replaced by an uprated 233-42M-3B-1323 collared 3 gear set for improved durability. The uprated gear sets are scheduled to be available in calendar week 38 (week commencing 21 September 2015).
  • Page 59 Ref Description 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.
  • Page 60 Figure 1.2: Bellhousing Updates These changes will be phased in from transmission build #41 onwards. For further information please contact: Business Manager: Senior Design Engineer: Ben Green Mark Brogden T: +44 1635 293 421 T: +44 1635 293 428 M: +44 7780 333 433 M: +44 7788 237 475 ben_green@xtrac.com mark_brogden@xtrac.com...

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