6-SPEED TO 8-SPEED DCT

Additional Parts

1 7th speed input gear 17.84

2 7th speed output gear 17.84

3 7th speed gear synchronizer 14.35

4 7th speed gear hub, shift collar

5 7th speed gear shift hub

6 7th speed gear mis. parts

7 7th speed gear shift fork assemblies 9.55

8 (2) 7th speed gear shift fork piston assemblies 0.80

9 (2) 7th speed gear shift fork cylinder liners 3.00

10 7th speed spool valve 4.25

11 7th speed solenoid 9.00

12 8th speed input gear 17.84

13 8th speed output gear 17.84

14 8th speed gear synchronizer 14.35

15 8th speed gear hub, shift collar

16 8th speed gear shift hub

17 8th speed gear mis. parts

18 8th speed gear shift fork assemblies 9.55

19 (2) 8th speed gear shift fork piston assemblies 0.80

20 (2) 8th speed gear shift fork cylinder liners 3.00

21 8th speed spool valve 4.25

22 8th speed solenoid 9.00

23 misc. fasteners 0.15

Modified Parts/Assembly Operations Description of Modifications

1 transmission assembly assemble added components (gears, synchronizers, etc.) 2.75 add 2 minutes of assembly time @ 37.50/hr + $75.00/hr burden

2 case machined - front additional shift fork bores, modified valve body ports - estimated material + machining 8.91 add 1 lbs (est) @$1.10/lb + .5 minute machining time @ $35.70/60 + .5 minute burden @ 900/60

3 case assembly - front 2 added cylinder bore liners 1.38 add 1 minutes of assembly time @ 37.50/hr + $75.00/hr burden

4 case machined - rear additional 50mm longer, additional shift fork bores, modified valve body mount 12.20 add 4 lbs (est) @$1.10/lb + .5 minute machining time @ $35.70/60 + .5 minute burden @ 900/60

5 case assembly - rear 2 added cylinder bore liners 1.38 same as front case

6 valve body two additional valve bores, revised worm trails 3.36 add 1 lbs (guess) @ $1.10 + .50 minute machining time @ 35.70/60 + .50 minute burden$233.60/60

7 valve body assembly assemble 2 added spool valve, springs, clips, etc. 1.38 add 1 minutes of assembly time @ 37.50/hr + $75.00/hr burden

8 transfer plate worm trail revisions 1.10 add 1 lbs (guess) @ $1.10 

9 valve body gasket plate modified to accommodate the revised worm trails and porting 0.13 add material @ $.65/lb X .25 lbs

10 valve body cover larger stamping to accommodate the larger valve body 1.63 add material @ $.65/lb X 2.5 lbs

11 pump shaft longer by 50 mm 0.65 added material @ $.65/ lb X .1 lb

12 input shaft inner longer by 50 mm, additional spline for 7th gear 1.05 added material @ $.78/ lb X .15 lb + .5 minute machining time @ 37.50/60 + .5 X $75/60 burden

13 input shaft outer longer by 50 mm, add spline and press-fit 6th or 8th input gear 2.66 added material 1lb X $.78/lb + 1 minute X $37.50/60 + 1 minute X $75.00/60

14 upper output shaft longer by 50 mm, add splines for 7th and 8th gears 1.05 same as input shaft inner

15 lower output shaft longer by 50 mm, add spline 1.05 same as input shaft inner

16 reverse shaft longer by 50 mm 1.05 same as input shaft inner

17 oil pump squirter modified to accommodate the additional gears 3.00 add squiters and tubing for 4 additional gears

198.14

Process Steps for Gears raw material per gear set = ~4 lbs/2. net or 4.8 gross/2 = $3.75/2 + synchronizer @ $2.85 4.73

1 forge, trim, normalize 2/minute or 120/hr or .50 min X $38.52/60 + .50 minX$247/hr 2.38

2 CNC turn and face (two chuckings) 3/min or 180/hr or (.33 min/part X $35.70/60 + .33 X $75.00/60) X 2 machines 1.22

3 hob gear teeth 45 seconds/part or (.75/partX $35.70/60 + .75/part X $75.00/60) X 2machines 2.78

4 chamfer gear teeth 3/min or 180/hr or (.33 min/part X $35.70/60 + .33 X $75.00/60) X 1 machine 0.61

5 shave or roll gear teeth 3/min or 180/hr or (.33 min/part X $35.70/60 + .33 X $75.00/60) X 1 machine 0.61

6 press and weld synchronizer 2/minute or 120/hr or .50 min X $38.52/60 + .50 minX$150/hr 1.57

7 heat treat 0.80

8 grind i.d. 2/minute or 120/hr or .50 min X $38.52/60 + .50 minX$150/hr 1.57

9 grind taper on o.d. 2/minute or 120/hr or .50 min X $38.52/60 + .50 minX$150/hr 1.57

17.84

Process Steps for Input Shaft - Outer

1 forge, trim, normalize 

2 face ends, counter bore gear end

3 deep hole bore i.d. from each end

4 CNC turn and face, drill cross hole

5 roll spline

6 hob gear teeth - small gear

7 chamfer gear teeth
 6-SPEED TO 8-SPEED DCT

8 shave or roll gear teeth - small gear 9 hob gear teeth - large gear

10 chamfer gear teeth

11 shave or roll gear teeth - large gear

12 heat treat

13 grind o.d.'s

14 hard turn i.d.'s and face gear end

Process Steps for Input Shaft - Inner 1 forge, trim, normalize 2 face ends and centerdrill each end 3 deep hole drill i.d. 4 CNC turn and face 5 roll spline on small end 6 roll spline on mid area diameter 7 roll spline on gear end 8 hob gear teeth 9 chamfer gear teeth

10 shave or roll gear teeth 

11 heat treat

12 straighten shaft

13 grind o.d.'s (including splines)

14 hard turn i.d.'s and face gear end

Process Steps for Output Shaft 1/3/4/2 1 forge, trim, normalize 2 face ends and centerdrill each end 3 deep hole drill i.d. 4 CNC turn and face 5 drill cross holes 6 roll spline on small end 7 roll spline on mid area diameter 8 hob gear teeth 9 chamfer gear teeth

10 shave or roll gear teeth 

11 heat treat

12 straighten shaft

13 grind o.d.'s (incl. splines) and grind gear face

14 grind bearing journal

15 hard turn o.d. groove, faces and chamfer splines

16 hone gear teeth

Process Steps for Output Shaft 5/6/R 1 forge, trim, normalize 2 face ends and centerdrill each end 3 deep hole drill i.d. 4 CNC turn and face 5 roll spline on small end 6 roll spline on mid area diameter 7 hob gear teeth 8 chamfer gear teeth 9 shave or roll gear teeth 

10 heat treat

11 straighten shaft

12 grind o.d.'s (incl. splines) and grind gear face

13 grind bearing journal

14 hard turn o.d. groove, faces and chamfer splines

15 hone gear teeth
 6-SPEED TO 8-SPEED DCT

8th

7th
 6-SPEED TO 8-SPEED DCT
 6-SPEED TO 8-SPEED DCT

1 Design as sketched is functionally feasible

2 All gear sizes and ratios will change (funding is illustrated in the "stranded capital study")

3 Gear output shaft center distances will change to accommodate the additional splined attachments on the shafts

4 The 50 mm additional transmission length will package in the vehicle

5 The additional length required for the larger valve body will package within the vehicle

6 The transmission cases will accommodate the two additional shift forks