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1152 Longitudinal Sportscar Transaxle Gearbox Manual

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1152 Longitudinal Sportscar Transaxle Gearbox Manual 1152 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. 1 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States Contents 1. Summary of Lubricants and Greases .................................................................. 4 2. Operating requirements ...................................................................................... 5 3. Specification ........................................................................................................ 7 3.1. General Items .............................................................................................. 7 3.2. Standard Options (no cost) .......................................................................... 9 3.3. Optional Extras (cost options) ...................................................................... 9 3.4. Excluded Items ............................................................................................ 9 4. Gearbox Operation ............................................................................................ 10 4.1. Gearchange Description ............................................................................ 10 4.2. Oil System .................................................................................................. 10 4.2.1. Description ............................................................................................ 10 4.2.2. Dedicated Oil Feeds ............................................................................. 11 4.2.3. Sensors ................................................................................................ 11 4.2.4. Filtration and Magnets .......................................................................... 11 4.2.5. Setup/Running Conditions .................................................................... 11 4.3. Gear Cluster ............................................................................................... 12 4.3.1. Reverse Gear ....................................................................................... 13 4.4. Differential .................................................................................................. 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 6. General Information .......................................................................................... 23 6.1. Customer Support ...................................................................................... 23 6.1.1. Gearbox & Parts Supply ....................................................................... 23 6.1.2. Training/Servicing ................................................................................. 23 6.1.3. Contacts ............................................................................................... 24 7. Appendix A – Non Standard Tightening Torques .............................................. 25 8. Appendix B – Dog Damage Sheet .................................................................... 26 9. Appendix C – Example Bevel Setting Sheet ..................................................... 27 10. Appendix D – Electrical Component Data Sheets .......................................... 28 10.1. Bosch Temperature Sensor NTC M12-L .................................................... 28 11. Appendix E – Oil Pumps and Flow ................................................................. 29 11.1. Oil Pump Pressure and Flow Rates ........................................................... 29 12. 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. 2 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States 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 Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA. 3 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States 1. Summary of Lubricants and Greases The following lubricants and greases have been used by Xtrac during the assembly and testing of the 1152 gearbox: Gearbox Oil Type Xtrac XL1 or any other fully synthetic SAE 75W90 gear oil. Assembly Grease Neo Z12 Lithium Grease O-ring Assembly Grease Polylub Gly 151 Xtrac use 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 572 For the locking and sealing of metal tapered threads and fittings. Araldite 2014 For permanent fitment of parts not to be disassembled i.e. blanking plugs. Note: all black casting core plugs are permanently fitted with Araldite 2014 and no attempt should be made to remove them. Lockwire 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. 4 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States 2. Operating requirements For optimum Performance and Safety – Warranty issues 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. However, as with all motorsport products, it is vital that they are correctly maintained and adjusted for each individual circumstance. This manual is intended to ensure that you obtain the maximum performance and reliability from this gearbox. The gearbox should be operated within the temperature and pressure limits given. Gearbox oil level must be maintained at all times and the oil needs to be replaced regularly. Gearbox oil and other lubricants 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 cooling and exceeding operating temperature. Un-approved or insufficient oil or grease. • Incorrect maintenance or adjustment or work by unauthorised and/or untrained personnel. • Modification or work to any component or use of non Xtrac parts. • System related sensor, valve and pump failures. • Engine, gear change or clutch and driveline loads beyond the design limits. • Exceeding designated life or failure to keep adequate lifing records. • Engine and/or vehicle dynamometer and rolling road use. Full and comprehensive lifing records must be maintained by the Customer during use.
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