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

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. We would stress that after each event or prolonged period of running, the gearbox should be carefully inspected and stripped as appropriate. In the manual there are lifing recommendations for critical components detailed in section 5.5 -

Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA. 5 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States

Lifing Chart. If in doubt please contact our Commercial Department who will advise you or if necessary put you in contact with one of our engineers.

It is important to ensure the correct lubricants are used, such as Xtrac developed XL1 and XG1, and that all adjustments and tolerances are as specified. The use of parts not supplied by Xtrac will automatically invalidate any warranty or other liability which would normally be assumed by Xtrac.

Your attention is drawn in particular to sections 10 and 15 of 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 and weight optimised components are supplied subject to warranty only against manufacturing defects. It is possible that in certain conditions operating life may be reduced. Prototype and experimental gearboxes or components manufactured by us to our design or manufactured by us to your design are supplied subject to warranty only against manufacturing defects. Subject to Conditions 10.4 and 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. 6 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States

3. 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 .

Xtrac Part Description: Longitudinal Transaxle Gearbox Assembly

Xtrac Part Number: 1152 -900 -000 B (LMP3)

1152-900-000* (Generic)

3.1. General Items

Drive is transmitted from the engine, through the clutch 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 plate differential. CV-type output flanges drive customer-specified CV joints and driveshafts.

The change gears are non-synchromesh using 6 flat top dogs, engaged using a full length barrel. The cluster can be removed as a single unit.

The sequential gearchange operates in the following sequence R, N, 1, 2, 3, 4, 5, 6.

For use in LMP3, the gearbox is rated at ~ 540Nm (400 lbf.ft) input torque *(see note below).

For use outside LMP3 and fitted with the option uprated cluster and bevel set, the gearbox is rated at ~620Nm (457 lbf.ft) input torque *(see note below).

Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA. 7 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States

Casings The casing material is Aluminium L169 and all casings have o-ring face sealing.

Change Gears Six gears with optimised tooth width (gears 1 st - 6th have a gear width of 17.55mm). The gears are mounted on 3.523” (89.484mm) centres, with 1 st & 2 nd input gears integral with the layshaft. For more details see Appendix H – Ratio List-1152B–LMP3 and Appendix J – Ratio List- 1152–Generic.

Final Drive Bevel Set High efficiency hard cut cyclo palloid spiral bevel set (LMP3 standard) or option full form ground spiral bevel set. 11:31 ratio is standard fitment for the 1152 gearbox.

Differential Salisbury plate type with fixed preload 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 Studs Included for gearbox to bellhousing face.

*The rating figure given is considered an approximation and is dependent on engine characteristic as well as absolute value. The method upon which engine torque is delivered through the transmission can vary considerably depending on the physical engine characteristic, firing order, fuel and spark strategy, turbo delivery and any traction limiting system that is utilised. The life and durability of the gearbox internal parts is also considerably influenced by factors other than engine output characteristics, for example oil type, operating temperature and operating environment.

Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA. 8 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States

3.2. Standard Options (no cost)

Clutch Shaft Designed to suit customer installation.

Gearing Gear ratios can be selected from the ratio list. See Appendix H – Ratio List-1152B–LMP3 and Appendix J – Ratio List-1152–Generic. Differential Settings Various fixed ramp angles are available and the number of friction faces in the plate differential can 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.

Bellhousing Assembly 1152-807-000A Dressed Bellhousing Assembly (LMP3 specification) or other.

Assembly Tooling See 1152-999-000A drawing for a list of assembly tooling.

Gearbox Mounting Dowels, studs, bolts etc.

Oil Temperature Sensor See section 4.2.3 - Sensors for details.

Oil Cooler & Lines See section 4.2.1 - Description for details.

Clutch Customer supplied.

Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA. 9 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States

4. Gearbox Operation

4.1. Gearchange Description

Sequential gearchange operated by Xtrac’s well proven and latest technology ‘overlapping’ polynomial barrel. The gears are engaged sequentially R, N, 1, 2, 3, 4, 5, 6. No mechanical neutral/reverse lock out is available, as the lock out will be enabled by the AGS gear change strategy. The gearbox is also specifically designed to use Xtrac/Megaline’s P1254 Integrated Valve Actuator (IVA), see below.

4.2. Oil System

4.2.1. Description

An internal single stage eccentric lobe style pump, fitted 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 port (-8) and returned using external hose (not Xtrac supplied) to the gearbox oil-in port (-8). The use of an oil cooler is recommended when the gearbox is expected to run for extended periods of time or in ambient temperatures generally greater than 25.0ºC (77ºF). However, the use of a cooler is also largely dependent on the in-car installation and the extent to which cool air is allowed to circulate around the outer surfaces of the gearbox casing. 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. 10 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States

NOTE: If an oil cooler is not fitted, a link pipe should be fitted between the oil out and oil in fittings to allow the oil to re-circulate and pass through the dedicated feeds.

4.2.2. Dedicated Oil Feeds

There are dedicated oil feeds/sprays to the dog rings, mainshaft gear hub bearings, pinion & pinion bearings, differential cassette, crownwheel & crownwheel bearings, reverse idler bearing and the forward-most layshaft bearing. Please refer to drawing 1152-950-100A for a graphical layout of the oil system. All other components are adequately lubricated from the ‘splash’ lubrication of the oil inside the gearbox.

4.2.3. Sensors

Provision has been made for an oil temperature 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 checked to reveal any evidence of tooth/dog damage and replaced accordingly. If there is a build up of debris, the filter MUST be replaced for a new one. Note that the flow of oil through the filter is inside to outside, so any debris will be found inside the filter and not on the outer surface. The oil drain plug has an integral magnet which will attract and retain debris. This can also be used as an indication of tooth/dog wear.

4.2.5. Setup/Running Conditions

Oil Type Xtrac XL1 or any other fully synthetic SAE 75W90 gear oil

Oil Quantity 1.6 litre + line/cooler volume

Optimum Sump Temperature 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. 11 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States

*The gearbox oil must be allowed to reach a minimum sump temperature of 60 Degrees C (140 Degrees F) before full torque is applied, to ensure maximum durability of the gearbox. Highly loaded running of a cold gearbox is not recommended due to the risk of premature bearing failure caused 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 reached.

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.

Figure 1 - Section View of Gear Cluster Assembly

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

The gear cluster comprises:

• A layshaft with integral 1 st & 2 nd gears. All other drive gears are slide on. Note the ‘overlapping’ gear order ‘1 st , 2 nd , 3 rd , 5th , 4 th , 6 th ’.

• Mainshaft with 6 mainshaft gears on 3 hub assemblies plus a reverse gear on the reverse hub assembly.

• A single, full length barrel with 3 change gear selector forks and a reverse gear selector fork, mounted on a selector rail.

Drive is transmitted from the clutch shaft directly to the layshaft, driving all layshaft gears at layshaft speed. All mainshaft gears are in permanent mesh with these gears but are not coupled to the mainshaft. The reverse mainshaft gear is in constant mesh with the reverse idler gear (mounted in the maincase), which itself is in constant mesh with the integral input reverse gear on the layshaft. A dog ring is engaged with the selected mainshaft 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 available for this operation after gearchange barrel and/or barrel bearing replacement. It is essential that this is checked periodically. Please refer to the assembly procedure given in section 5.2.2 - Selector Barrel Setup. In addition, the dog ring and mainshaft gear dogs should be checked and replaced if the dogs show signs of damage, in order to avoid inconsistent gear changes and further damage to other systems. Refer to Appendix B – Dog Damage Sheet for guidance.

4.3.1. Reverse Gear

Care should be taken when engaging and driving in reverse gear. Whilst the reverse gear engagement mechanism is via a dog ring (constant mesh gear train), the gearbox layshaft speed should be allowed to reduce to 500rpm maximum before reverse gear is selected and engaged. An engine output torque limit of 150Nm should be applied whilst driving in reverse gear.

Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA. 13 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States

4.4. Differential

4.4.1. Description

The gearbox is fitted with a Salisbury-type plate differential as standard, shown in Figure 2 – Section View of Pate Differential Assembly. The side gears are axially supported by thrust washers and do not react against any locking part of the differential. The differential is locked by axial 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 differential is:-

• 60 degree drive ramp angle / 30 degree coast ramp angle

• 4 friction faces per side (8 in total)

• 48-90Nm static positive preload (new)

An example locking torque vs. input torque plot and table of differential locking variables can be found in 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. 14 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States

4.4.2. Ramp Angles

A number of ramp angle combinations are available for the differential. Note that a corresponding cross pin is also required. The following combinations are given in Table 1 - Available Ramp Angles.

Table 1 - Available Ramp Angles Available Angles Side Gear Ring s (Ramps) Cross Pin 45/30 00P-183-0004 & 00P-183-0005 183-0006 55/45 00P-183-0019 & 00P-183-0020 183-0021 60/30 00P-183-0013 & 00P-183-0014 183-0021 75/45 00P-183-0016 & 00P-183-0017 183-0018

Note: Lower ramp angles give higher locking values. The first value specifies drive and second value specifies coast. (i.e. 60/30 = 60˚ drive and 30˚ coast). However, the ramps can be fitted in reverse if preferred, e.g. ramp angle of 55/45 fitted in reverse would give 45˚ drive and 55˚ coast.

4.4.3. Number of Friction Faces

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 differential cassette to provide a static axial ‘preload’ through the plate pack, across the differential. The preload value is not adjustable and will vary between 48-90Nm on build (new) within the manufacturing tolerances of the differential components. For guidance on differential build, please refer to assembly drawing 1152-949-000A.

4.4.5. Differential Test Rig

As part of Xtrac’s research and development department, we have developed the Quasi-Transient Differential Test Rig (QT-DTR) which enables testing of mechanical plate and Viscous Combined Plate (VCP) type differentials. The differential can be subjected to varying levels of input torque and differential speed to study the locking characteristics of available configurations. 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. 15 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States

• Manual operation.

• Sequence testing which will result in a differential characteristic map.

• Quasi-transient testing, a combination of closed/open-loop testing within a time domain to analyse differential response.

Output data is available in various recognised formats. The data recorded in the test can then be used to accurately set up the differential to best suit the customer needs, significantly reducing track testing time.

The QT-DTR is available for rental use on a daily basis including Xtrac technician support. Xtrac will design and manufacture the appropriate tooling to mount the customer’s differential onto the rig and, in conjunction with the customer, determine the most appropriate test strategy and procedure. Testing is then undertaken and a fully documented results package is available as required. For more information 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 at multiple stages of manufacture.

It is good practice to replace all lip seals and k-nuts after removal. O-rings, the oil filter, circlips and bearings can be reused, but they must be inspected regularly and replaced as soon as any sign of wear or degradation is evident. A consumables kit 1152-981-005A is available, containing all o-rings, seals, nuts and washers which should be replaced on a regular basis when carrying out a scheduled inspection. 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.

Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA. 16 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States

Lint free cloths are recommended for wiping down internals. If paper tissue is used, care must be taken to ensure fibres are not left behind which will result in a blocked oil filter.

All joint faces are sealed with o-rings, Silicon sealant MUST NOT be used anywhere on the gearbox, as excess sealant can enter the oil system and clog the filter or oil sprays around the gearbox. This will lead to premature failure of the transmission.

All components are supplied from Xtrac as "ready to fit". Extra polishing and fettling of components is not required and may, in the case of gearchange components, cause failure to other parts, especially gear dogs and dog rings.

Since bearings have press fit tolerances, always heat the casings for the fitment or removal of bearings to avoid damage to the bearings or casings. Do not heat the gearbox casings above 135 °C (275 °F.) when fitting 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 tightened as per the Xtrac Standard XS036 given in Appendix M – Xtrac Standards. Any non-standard tightening torques are listed in Appendix A – Non Standard Tightening Torques.

Studs should be inserted tight into the casting using Loctite 270 thread locker. They must then be allowed to cure for 1 hour at room temperature before further assembly.

Bolts must either be inserted with Loctite 270/272 (when internal) or be inserted with Loctite 241 (when external) and wire-locked, unless otherwise stated.

At each build, mark the torque tightened position of all nuts, bolts and screws, by applying Torque Seal across the fixing and stationary part, to indicate any loss of tightness or movement, thus avoiding unnecessary spanner checks, which can lead to over tightened fasteners and stripped casing threads. 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. 17 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States

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.

1. Remove the 1254-932-000A Xtrac/Megaline ‘IVA’ pneumatic gearchange actuator from the rear of the gearbox, by loosening the 2off 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 respective splines engage with the holding tool.

3. Remove the 1152-903-000A Pump Housing Assembly from the cluster cover assembly, by loosening the 9off M6 k-nuts and using the two M6 X 1.0 jacking threads if required. Store the pump housing assembly safely aside.

4. Remove the two circlips inside the layshaft and mainshaft locking nuts and remove the splined lock rings. Loosen both locking nuts in turn, using the 199- 499-004A Gearbox Assembly Socket (as part of the tooling assembly 1152-

Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA. 18 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States

999-005A) and a 5/8” Hex Drive (1/2” Square). Do not fully remove the locking nuts at this stage.

5. 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.

6. The mainshaft should be withdrawn from the top of the assembly, leaving the mainshaft assembly components stacked on the cluster plate. Loosen the selector rail by holding on the two flats at the top end and turning anti- clockwise. Pull the selector rail out and place aside.

7. The hub assemblies can now be lifted off the stack as necessary in order to access the gear ratio set to be changed. The layshaft can also be withdrawn in a similar way to the mainshaft, in order to aid disassembly.

8. Once the gear ratio set has been swapped, reassembly is in the reverse order as points 1-7. Note the ‘overlapping’ gear order ‘1 st , 2 nd , 3 rd , 5th , 4 th , 6 th ’ 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 mainshaft gears. The gearchange barrel should therefore be shimmed to ensure it holds the selector forks and dog rings central to the dogs of the mainshaft gears. The alignment needs to be checked and altered when a new barrel, barrel bearings or mainshaft assembly is fitted to the gearbox. Xtrac can offer more advanced training on the following procedure. If help is required during setup please contact your business manager.

1. With the cluster assembly complete and fully assembled onto the cluster plate, mount it onto the 1152-999-006A Cluster Setting Assembly and clamp in a vice.

2. Rotate the barrel to each ‘in gear’ position using the 1152-499-010A Barrel Socket and measure the dog stand off using feeler gauges, as shown in Figure 4 - Measuring Dog Stand Off. The dog stand off is the distance between each mainshaft gear dog root and the tip of the dog ring dog. A small

Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA. 19 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States

amount of force should be exerted on the fork (at the selector rail journal) to remove backlash. Dog stand off values are typically 0.05mm to 0.2mm (0.002” to 0.008”).

Figure 4 - Measuring Dog Stand Off

3. The dog rings reside between pairs of gears (i.e. 1 st and 2nd , 3rd and 5th , 4th and 6th ). If the dog stand 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 initial assembly, the 105-432-153* gearchange barrel bearing spacer between the inner races of the two barrel bearings is ground to the same size as the cluster plate abutment shoulder between the outer races of the two bearings, and hence requires no further adjustment unless the cluster plate is changed.

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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) - 336-499-004A Diff Cap Holding Tool - 600-499-006A Diff Body Holding Tool

5.4. Spiral Bevel Gear Assembly

The crownwheel and pinion should only be replaced by technicians experienced in crownwheel and pinion setups. Xtrac recommends that teams have Xtrac training prior to attempting such changes. Xtrac also offer an overhaul service. Each gearbox is supplied with a Bevel Setting sheet, a sample of 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 the recommended distances in Table 2 - Typical Component Life Ratings.

Mark all parts for lifing purposes and note in build records. Typical lives of the most critical parts are tabulated below. All parts not included in the list require inspection after 6000km (3728 miles).

Visual inspection should identify any parts with dents, scratches, significant wear or corrosion. For an indication of acceptable dog wearing levels for both mainshaft gears and dog rings, please see Appendix B – Dog Damage Sheet.

NOTES: The table below is provided for guidance on the expected life of key components based on Xtrac's experience of this product in sports car applications, however no warranty is implied by figures stated below and lifing

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targets are no substitute for testing and regular inspection of the gearbox internals.

Component life is affected by the precise application and can be influenced by circuit layout and conditions as well as driver style. Many of the components stated above with a maximum 'typical' life of 6000km may be found to perform successfully for extended mileage however extended running above 6000km is done at a customer's risk.

Table 2 - Typical Component Life Ratings Visual Inspection Crack Check Every Typical Life Component Every (km) (km) (km) Clutch Shaft 1500 3000 6000 Layshaft (Integral 1 st / 2 nd gear ratio set) 1500 3000 6000 3rd Gear Ratio (hobbed) 500 1000 2000* 3rd Gear Ratio (ground) 1500 3000 6000 4th – 6th 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 Gears 1500 3000 9000 Detent Plunger 1500 - 9000 Detent Spring - - 6000 Oil Pump Rotors 1500 3000 6000 Oil Filter 1500 - 6000 Spiral Bevel Set 1500 3000 6000 Differential End Cap & Body 3000 3000 9000 Friction Plates 3000 - 6000 Side Gears 3000 3000 6000 Pinion Mates 3000 3000 6000 Side Gear Rings 3000 3000 9000 Cross Pin 3000 3000 9000 Output Flanges 1500 3000 6000 All Bearings 3000 - 6000 All K-nuts, O-rings & Seals Fit new when removed Gearbox Oil Drain and replace oil every 1500km 1254-932-000A Actuator See separate 1254 manual *See technical bulletin 1152-0003.

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6. General Information

Please note that all Xtrac products and services are supplied subject to our Terms & Conditions of Sale, a copy of which is available on request.

6.1. Customer Support

6.1.1. Gearbox & Parts Supply

Standard gearbox assemblies and spare parts are generally held in stock at our UK and USA facilities. All gearbox assemblies are thoroughly rig tested and inspected 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 basic knowledge to carry out their own routine maintenance work. However, if required, Xtrac will be able to carry out maintenance/rebuild at facilities in the UK and at our service centre in the USA.

Customers will receive parts lists, manuals, assembly drawings and appropriate technical bulletins containing updates on maintenance procedures, parts information, performance and safety issues.

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6.1.3. Contacts

Xtrac Limited Xtrac Inc Gables Way 6183 W. 80th Street Kennet Park Indianapolis Thatcham IN Berkshire 46278 RG19 4ZA United States England www.xtrac.com www.xtrac.com Email: [email protected] Email: [email protected] Tel: +44 1635 293 800 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. 24 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States

7. Appendix A – Non Standard Tightening Torques

Location Description Torque Comments (Sub-assembly)

Pinion Nut 400Nm 1152-901-000A Oil Threads (1152-475-001A) (295 lbf ft) Gearchange Barrel Nut 68Nm 1152-902-000A Loctite 648 (105-432-002A) (50 lbf ft) Differential Lid 230Nm 1152-949-000A Oil Threads (600-449-001A) (170 lbf ft) Layshaft Nut 136Nm 1152-996-000* Oil Threads (199-421-006A) (100 lbf ft) Mainshaft Nut 136Nm 1152-996-000* Oil Threads (099-422-006B) (100 lbf ft)

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8. Appendix B – Dog Damage Sheet

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

10. Appendix D – Electrical Component Data Sheets

10.1. Bosch Temperature Sensor NTC M12-L

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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.

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12. Appendix F – Differential Characteristics

The table below and accompanying chart are provided as a reference guide to aid differential setups and maps the expected locking performance of the 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 RAMP ANGLE BASELINE FRICTION FACES (DEG) (%)

30 16 100

35 16 83 30 12 75 40 16 70 45 16 59 35 12 63 40 12 53 30 8 50

45 12 44

35 8 42 40 8 35 60 16 33 45 8 29 60 12 25 60 8 16 75 16 13 75 12 10

80 16 7

75 8 6 80 12 5 80 8 3 85 8,12,16 0

This data has been calculated based on a mixture of theoretical and experimental data and is a guide only, values are not exact.

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Figure 5 - Differential Locking Performance

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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.

Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA. 32 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States Application Gearbox Report - Session Mileage Summary Project Code P1000 AE-7799-01A 04/04/2012 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

Session Mileage Record

Milleage in Previous New Total Part Description Serial No +Current = Notes Total Mileage Session Mileage

Notes

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. 34 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States Tel: +44(0) 1635 293 800 Fax: +44(0) 1635 293 700 Gearbox Type: 1152B e-mail: [email protected] Web Site: www.xtrac.com - LMP3

1st / 2 nd (Integral Layshaft) 1152-42M-000A* *= Layshaft Set Code e.g. 1152-42M-000AA (1152-421-000A* / 033-422-008A) ( / 033-422-008A) 1st 2 nd Code(*) Input Output Sum Ratio Input Output Sum Ratio A 13 37 50 2.846 15 34 49 2.267

Collared 3 rd 233-42M-3A (Hobbed) j (233-421-003A / 033-422-008A) 233-42M-3B (Ground) k (233-421-003B / 033-422-008E)

Input Output Sum Ratio 13 23 36 1.769 k 17 30 47 1.765 j

4th – 6 th 195-42M-4A (195-421-004A / 033-422-008A)

Input Output Sum Ratio 19 28 47 1.474 19 24 43 1.263 23 25 48 1.087

Final Drive Input Output Sum Ratio 11 31 42 2.818

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 has more resistance to pitting than a lower value. Where possible, always select a gear with the highest values. The gear width is taken into account when the rating is calculated.)

Drawn Drg Date Approved Issue Tony Collinson 120-1152-001 27/10/2015 MBB 6 Page 1 of 4 Xtrac reserve the right to change ratios without notice. Tel: +44(0) 1635 293 800 Fax: +44(0) 1635 293 700 Gearbox Type: 1152B e-mail: [email protected] Web Site: www.xtrac.com - LMP3

Speed Chart 17:30 13:37 13:23 19:28 23:25 19:24 15:34 7000

6500

6000

5500

5000 Engine RPM Engine

4500

4000

3500 Final Drive 11:31 Tyre Diameter 698 mm 3000 30 50 70 90 110 130 150 170 190 210 230 250 270 290 310 330 kph

Drawn Drg Date Approved Issue Tony Collinson 120-1152-001 27/10/2015 MBB 6 Xtrac reserve the right to change ratios without notice. Page 2 of 4 Tel: +44(0) 1635 293 800 Fax: +44(0) 1635 293 700 Gearbox Type: 1152B e-mail: [email protected] Web Site: www.xtrac.com - LMP3

Pitting Safety Factors (for comparison purposes) 1.15

1st / 2nd Gear 3rd Gear 4th - 6 th Gear 1.10

1.05 23:25 1.00 19:24

0.95 19:28 0.90

0.85 17:30 13:23

Safety Factor Safety (SF) 0.80

0.75 15:34

0.70

Key 0.65 Torque 540 13:37 Nm 0.60 Input Gear

Minimum Safety Factors Shown For Selected Ratios Output Gear 0.55 Ratio

Drawn Drg Date Approved Issue Tony Collinson 120-1152-001 27/10/2015 MBB 6 Xtrac reserve the right to change ratios without notice. Page 3 of 4 Tel: +44(0) 1635 293 800 Fax: +44(0) 1635 293 700 Gearbox Type: 1152B e-mail: [email protected] Web Site: www.xtrac.com - LMP3

Bending Safety Factors (for comparison purposes) 1.80

1st / 2nd Gear 3rd Gear 4th - 6 h Gear 1.70

1.60

1.50

1.40 13:23

1.30 19:24

1.20 23:25

1.10 Safety Safety Factor (SF) 19:28

1.00 17:30

0.90

0.80 15:34 Key 0.70 Torque 540 Nm 13:37 Input Gear 0.60 Minimum Safety Factors Shown For Selected Ratios Output Gear 0.50

Drawn Drg Date Approved Issue Tony Collinson 120-1152-001 27/10/2015 MBB 6 Page 4 of 4 Xtrac reserve the right to change ratios without notice.

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. 39 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States Tel: +44(0) 1635 293 800 Fax: +44(0) 1635 293 700 Gearbox Type: 1152 e-mail: [email protected] Web Site: www.xtrac.com - GENERIC

1st / 2 nd (Integral Layshaft) 1152-42M-000A* (Hobbed) *= Layshaft Set Code e.g. 1152-42M-000AA (1152-421-000A* / 033-422-008A) ( / 033-422-008A) 1st 2 nd 4th – 6 th Cont. Code(*) Input Output Sum Ratio Input Output Sum Ratio Input Output Sum Ratio A 13 37 50 2.846 15 34 49 2.267 17 24 41 1.412 m 20 28 48 1.400 l 1152-42M-000B* (Ground) 18 25 43 1.389 l (1152-421-000B* / 033-422-008H) 16 22 38 1.375 l m ( / 033-422-008H) 19 26 45 1.368 l st nd 1 2 20 27 47 1.350 l m Code(*) Input Output Sum Ratio Input Output Sum Ratio 18 24 42 1.333 l A 13 37 50 2.846 13 29 42 2.231 19 25 44 1.316 l 16 21 37 1.313 m 20 26 46 1.300 l rd Collared 3 17 22 39 1.294 l m 233-42M-3A (Hobbed) j 21 27 48 1.286 l (233-421-003A / 033-422-008A) 18 23 41 1.278 l 233-42M-3B (Ground) k 19 24 43 1.263 l (233-421-003B / 033-422-008E) 16 20 36 1.250 m Input Output Sum Ratio 20 25 45 1.250 l 15 29 44 1.933 k 21 26 47 1.238 l 15 28 43 1.867 k 22 27 49 1.227 l 16 29 45 1.813 k 18 22 40 1.222 l m 14 25 39 1.786 k 23 28 51 1.217 l 13 23 36 1.769 k 19 23 42 1.211 l 17 30 47 1.765 j k 20 24 44 1.200 l 18 31 49 1.722 j k 21 25 46 1.190 l 14 24 38 1.714 k 16 19 35 1.188 l m 13 22 35 1.692 k 22 26 48 1.182 l 16 27 43 1.688 j k 23 27 50 1.174 l 14 23 37 1.643 j k 18 21 39 1.167 l 16 26 42 1.625 j k 19 22 41 1.158 l 15 24 39 1.600 j k 20 23 43 1.150 l m 17 27 44 1.588 j k 21 24 45 1.143 l 14 22 36 1.571 k 22 25 47 1.136 l 15 23 38 1.533 j 23 26 49 1.130 l 24 27 51 1.125 l th th 4 – 6 25 28 53 1.120 l 195-42M-4A (Hobbed) l 17 19 36 1.118 m (195-421-004A / 033-422-008A) 26 29 55 1.115 l 195-42M-4E (Ground) m 18 20 38 1.111 l (195-421-004E / 033-422-008H) 19 21 40 1.105 l Input Output Sum Ratio 20 22 42 1.100 l 17 30 47 1.765 l 21 23 44 1.095 l 18 31 49 1.722 l 22 24 46 1.091 l 17 29 46 1.706 l 23 25 48 1.087 l m 16 27 43 1.688 l 24 26 50 1.083 l 17 28 45 1.647 l 26 28 54 1.077 l 16 26 42 1.625 l 29 31 60 1.069 l 15 24 39 1.600 l 17 18 35 1.059 l m 17 27 44 1.588 l 19 20 39 1.053 l 14 22 36 1.571 l 22 23 45 1.045 l m 18 28 46 1.556 l 26 27 53 1.038 l 15 23 38 1.533 l 24 24 48 1.000 l 14 21 35 1.500 m 25 24 49 0.960 l m 18 27 45 1.500 l 19 28 47 1.474 l 17 25 42 1.471 l m 18 26 44 1.444 l Final Drive 21 30 51 1.429 l Input Output Sum Ratio 19 27 46 1.421 l 11 31 42 2.818

Drawn Drg Date Approved Issue Tony Collinson 120-1152-001 07/12/2015 MBB 6 Page 1 of 2 Xtrac reserve the right to change ratios without notice. Tel: +44(0) 1635 293 800 Fax: +44(0) 1635 293 700 Gearbox Type: 1152 e-mail: [email protected] Web Site: www.xtrac.com - GENERIC

Speed Chart 1st 2nd 2nd 17:30 15:29 25:24 15:23 13:37 13:29 15:34 4th Min 4th 3rd Min 3rd 6th Max 6th Max 3rd 7000

6500

6000

5500

5000 Engine RPM Engine

4500

4000

3500 Final Drive 11:31 Tyre Diameter 698 mm 3000 50 70 90 110 130 150 170 190 210 230 250 270 290 310 330 350 kph

Drawn Drg Date Approved Issue Tony Collinson 120-1152-001 07/12/2015 MBB 6 Xtrac reserve the right to change ratios without notice. Page 2 of 2

16. Appendix K – Manual Revision Sheet

Issue Description of C hange 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 please contact your business manager.

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This will take you to the download area where a list of files will be visible for download

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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.

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18. Appendix M – Xtrac Standards

Xtrac standards have been included for reference purposes only.

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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

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.

Date Au thor Version Description of Change 11-01-10 Xtrac 2.0 M3 x 0.5 added and M4 x 0.7 Modified 25-01-10 M.KERR 3.0 Additional notes to define limits of tightening torque for studs into casings and addition of loctite specification as standard. Verification note also added. 03-08-11 M.KERR 4.0 Nut / SHC bolt Tightening torques updated in line with Build 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 Revised tightening torques figures. Minimum length of thread engagement added. 09-02-15 M Arnold 5.1 Release of two controlled copies.

Document Distribution List

Copy Recipient Date Department No. 1 P.Fenner 9-2-2015 Build Shop 2 P.Fenner 9-2-2015 Build Shop

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. Torque figures stated are for tightening of nut onto stud, or bolt into casing. The torque values are not for use when tightening bottom fitting studs, shank fitting studs or thread inserts directly into the casing thread.

For all other applications, consideration should be given to the individual installation and a suitable tightening torque should be calculated using Xtrac program AE-5148, (available from the intranet in Reference Document / Verification Tools), and recorded as design verification against the assembly concerned.

3S.145D (Or Higher Grade Ti64 Studs / Screws Material) Studs / Screws Nm ft lbf Nm ft lbf 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 METRIC M10 x 1.5 50 37 44 32 M12 x 1.5 87 64 76 56 M12 x 1.75 85 63 74 55 1/4" UNF 13 10 11 8 1/4" UNF/UNC* 11 8 10 7 5/16" UNF 26 19 22 16 5/16" UNF/UNC* 23 17 20 15 3/8" UNF 45 33 40 30 3/8" UNF/UNC* 40 30 35 26

IMPERIAL 7/16" UNF 71 52 62 46 7/16" UNF/UNC* 64 47 55 41 1/2" UNF 106 78 92 68 1/2" UNF/UNC* 94 69 82 60

Notes on table:

° *Assumes UNF nut onto Steel or Titanium stud with UNC thread into Aluminium or Magnesium Alloy,

° All torque figures are based on calculations to give a safety factor of 2 when comparing the thread stress to the 0.2% proof stress of the material. The stress calculations were derived from the Machinery's Handbook 26, page 1482 and 1483. A friction coefficient of 0.12 was used. The inside and outside diameters of the bearing surface contact areas were extracted from Xtrac Standard XS006, XS007, XS008 and XS009.

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.

Internal thread length in casings shall be as per XS008 (Imperial) and XS009 (Metric ). The minimum length of engagement for mating threads quoted in the table below are in mm. They were calculated based on the Machinery's Handbook 26, page 1490 and 1491.

STUD INTERNAL THREAD MATERIAL MATERIAL RZ5 L169 3.2384.6 2014T6 7075T6 Ti64 17-4PH 3S.145D 7.5 5.5 5.0 3.5 3.0 2.0 2.0 M3x0.5 Ti64 6.0 4.0 4.0 2.5 2.5 2.0 2.0 3S.145D 10.0 7.0 6.5 4.5 4.0 2.5 2.5 M4x0.7 Ti64 7.5 5.5 5.0 3.5 3.0 2.5 2.5 3S.145D 12.5 9.5 8.5 5.5 5.0 3.0 3.0 M5x0.8 Ti64 9.5 7.0 6.5 4.5 3.5 3.0 3.0 3S.145D 15.0 11.0 10.0 6.5 5.5 3.5 3.5 M6x1.0 Ti64 11.5 8.5 7.5 5.0 4.5 3.5 3.5 3S.145D 18.5 13.5 12.5 8.0 7.0 4.5 4.5 M7x1.0 Ti64 14.0 10.0 9.5 6.0 5.5 4.5 4.5 3S.145D 20.5 15.0 13.5 9.0 7.5 5.0 5.0 M8x1.25 Ti64 15.5 11.0 10.5 7.0 6.0 5.0 5.0

METRIC 3S.145D 27.0 19.5 18.5 12.0 10.0 6.0 6.0 M10x1.25 Ti64 20.5 15.0 14.0 9.0 7.5 6.0 6.0 3S.145D 25.5 18.5 17.5 11.5 9.5 6.0 6.0 M10x1.5 Ti64 19.5 14.0 13.0 8.5 7.5 6.0 6.0 3S.145D 32.5 23.5 22.0 14.0 12.0 7.5 7.5 M12x1.5 Ti64 24.5 18.0 16.5 10.5 9.0 7.5 7.5 3S.145D 31.0 22.5 21.0 13.5 11.5 7.5 7.5 M12x1.75 Ti64 23.5 17.0 16.0 10.5 9.0 7.5 7.5 3S.145D 36.5 26.5 24.5 16.0 13.5 8.5 8.5 M14x2.0 Ti64 27.5 20.0 18.5 12.0 10.0 8.5 8.5 3S.145D 16.5 12.0 11.0 7.5 6.0 4.0 4.0 1/4" UNF Ti64 12.5 9.0 8.5 5.5 4.5 4.0 4.0 3S.145D 14.55 10.5 9.5 6.5 5.5 3.5 3.5 1/4" UNC Ti64 11.0 8.0 7.5 5.0 4.0 3.5 3.5 3S.145D 21.0 15.5 14.0 9.0 8.0 5.0 5.0 5/16" UNF Ti64 16.0 11.5 10.5 7.0 6.0 5.0 5.0 3S.145D 19.0 14.0 13.0 8.5 7.0 4.5 4.5 5/16" UNC Ti64 14.5 10.5 9.5 6.5 5.5 4.5 4.5 3S.145D 26.5 19.0 18.0 11.5 10.0 6.0 6.0 3/8" UNF Ti64 20.0 14.5 13.5 8.5 7.5 6.0 6.0 3S.145D 23.5 17.0 15.6 10.0 8.5 5.5 5.5 3/8" UNC Ti64 17.5 13.0 12.0 7.5 6.5 5.5 5.5 IMPERIAL 3S.145D 30.5 22.0 20.5 13.5 11.5 7.0 7.0 7/16" UNF Ti64 23.0 16.5 15.5 10.0 8.5 7.0 7.0 3S.145D 27.5 20.0 18.5 12.0 10.0 6.5 6.5 7/16" UNC Ti64 20.5 15.0 14.0 9.0 7.5 6.5 6.5 3S.145D 36.0 26.0 24.5 15.5 13.5 8.0 8.0 1/2" UNF Ti64 27.0 19.5 18.5 12.0 10.0 8.0 8.0 3S.145D 32.0 23.0 21.5 14.0 12.0 7. 5 7.5 1/2" UNC Ti64 24.0 17.5 16.5 10.5 9.0 7.5 7.5

Note: If the length of thread engagement is less than that specified in the table above, then a reduced tightening torque should be determined using Xtrac Program AE-5148, available from the intranet in Reference Document / Verification Tools.

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.

Issue 2.0 – 10/12/15 - 1152 Longitudinal Transaxle Sportscar Gearbox Manual © 2015 - Xtrac Limited, Gables Way, Kennet Park, Thatcham, Berkshire. RG19 4ZA. 50 Xtrac Inc, 6183 W. 80th Street, Indianapolis, IN 46278. United States

Product: P1152 Gearbox Date: 05/05/2015 To: All 1152 customers Ref: 1152 -00 01 From: Angelo Wilson Position: Design Engineer

Technical Bulletin Action Level

1 Requires Immediate Action 2 For Information Only

Ref Description 1 1152-420-000A CLUTCH SHAFT 1

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.

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 Ø15.799/15.773mm (ref. Figure 1.1).

Figure 1.1: Clutch Shaft Nose Journal Size

Figure 1.2: Issue number identification

All customers with clutch shafts at issue 3 or lower are asked to return them to Xtrac for modification. Ref. Figure 1.2 for issue number identification.

New clutch shafts supplied by Xtrac from 05/05/2015 will have the issue number 4 or higher and will be manufactured with the reduced nose journal diameter, unless otherwise 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: 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 [email protected] [email protected]

Prepared By: Angelo Wilson Signed: ANW Approved By: Mark Brogden Signed: MBB

Product: P1152 Gearbox Date: 07/07/2015 To: All 1152 customers Ref: 1152 -00 02 From: Angelo Wilson Position: Design Engineer

Technical Bulletin Action Level

1 Requires Immediate Action 2 For Information Only

Ref Description 1 1152-407-000A BELLHOUSING 2

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

Figure 1.2: Bellhousing Updates

These changes will be phased in imminently on LMP3 transmission builds.

2 1152-401-000A MAINCASE 2

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

This change will be phased in imminently on new builds and rebuilds.

3 1152-903-000A PUMP HOUSING ASSEMBLY 2

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 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 standard, unless otherwise notified.

4 1152-475WPB-1131 CROWNWHEEL & PINION SET 11:31 2

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.

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, unless otherwise notified.

5 600-449-000B DIFFERENTIAL BODY 2

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 Mark Brogden T: +44 1635 293 421 T: +44 1635 293 428 M: +44 7780 333 433 M: +44 7788 237 475 [email protected] [email protected]

Prepared By: Angelo Wilson Signed: ANW Approved By: Mark Brogden Signed: MBB

Product: P1152 Gearbox Date: 07/08/2015 To: All 1152 customers Ref: 1152 -00 03 From: Angelo Wilson Position: Design Engineer

Technical Bulletin Action Level

1 Requires Immediate Action 2 For Information Only

Ref Description 1 233-42M-3A-1730 – 233A GEAR SET COLLARED 17:30 1

The 233-42M-3A-1730 collared 3 rd gear set used in the 1152-996-000B cluster rd 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 st commencing 21 September 2015). From that time onwards, all new gearbox builds and rebuilds warranting a replacement 3 rd 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 3 rd gear sets before each prolonged period of running, in line with Xtrac’s general maintenance guidelines.

For further information or to order replacement gear sets, 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 [email protected] [email protected]

Prepared By: Angelo Wilson Signed: ANW Approved By: Mark Brogden Signed: MBB

Product: P1152 Gearbox Date: 09/11/2015 To: All 1152 customers Ref: 1152-0004 From: Tony Carrozza Position: Design Engineer

Technical Bulletin Action Level

1 Requires Immediate Action 2 For Information Only

Ref Description 1 1152-407-000A BELLHOUSING 2

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: Bellhousing Updates

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 42 8 M: +44 7780 333 433 M: +44 7788 237 475 [email protected] [email protected]

Prepared By: Tony Carrozza Signed: TZZ Approved By: Mark Brogden Signed: MBB