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
19
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 The mainshaft should be withdrawn from the top of the assembly, leaving the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 The layshaft can also be withdrawn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
, 5
th
, 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
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