TRANSAXLE General Copyright © MILE 2011 MILE / XUV500 / TRANSAXLE 01/ VER 01 / JUL 2011
System Configuration XUV500 Is a Front Wheel Drive Vehicle. To transfer torque to the front wheels, Transaxle is used XUV500 also available in All Wheel Drive, where in PTU used to transfer torque to the IRDA through Propeller shaft & ITM Transaxle is a 6 forward & 1 Reverse Gear Cable operated Selector & Shifter Mechanism Fully Inhouse newly developed Cougar Transaxle
What is Transaxle Transaxle is a combination of transmission, the differential, and driven axle.
XUV500 - COUGAR Transaxle Weight 2WD - 61.2 Kg Weight AWD - 61.4 Kg Oil Capacity – 3.1 liters Oil Type Synthetic Oil, SAE 75W90, Castrol TAF-X
Different Views
Features 3 Shaft design 1st/2nd/3rd/4th – Countershaft 1 5th/ 6th / Rev – Countershaft 2 Rev separate shaft Centre rail shift system Two Final Drive ratios All ball / roller bearings Dual Mass Flywheel No poppet Springs & Balls
Transaxle Layout counter shaft I reverse axle input shaft counter shaft II output shaft
Transaxle Layout IV III II I R VI V counter shaft I (2) z11 z12 z13 z33 z14 z23 z32 z24 z25 z31 z41 z34 VI V z21 z22 z15 counter shaft I (2) counter shaft Il(3) input shaft (1) reverse axle (4) output shaft (5)
Transaxle Torque Max Design Torque – 400 Nm Vehicle Requirement – 320 Nm Torque Limitation 1st Gear – 280 Nm Rev Gear – 240Nm
Torque at O/P Shaft (Nm) Gear Ratios Gear Ratio Final Drive Input Torque (Nm) Torque at CS (Nm) Torque at O/P Shaft (Nm) 1st 4.154 4.05 280 1163.12 4710.64 2nd 2.143 400 857.20 3471.66 3rd 1.243 497.20 2013.66 4th 0.949 379.60 1537.38 5th 1.027 3.115 410.80 1279.64 6th 0.872 348.80 1086.51 Rev 4.961 240 1190.64 3708.84
Power Flow - 1st Gear IV III II I R VI V counter shaft II (3) z11 z12 z13 z33 z14 z23 z32 z24 z25 z31 z41 z34 VI V z21 z22 z15 counter shaft II (3) counter shaft I (2) input shaft (1) reverse axle (4) output shaft (5) 4WD output
Power Flow – 2nd Gear IV III II I R VI V counter shaft II (3) z11 z12 z13 z33 z14 z23 z32 z24 z25 z31 z41 z34 VI V z21 z22 z15 counter shaft II (3) counter shaft I (2) input shaft (1) reverse axle (4) output shaft (5) 4WD output
Power Flow – 3rd Speed IV III II I R VI V counter shaft II (3) z11 z12 z13 z33 z14 z23 z32 z24 z25 z31 z41 z34 VI V z21 z22 z15 counter shaft II (3) counter shaft I (2) input shaft (1) reverse axle (4) output shaft (5) 4WD output
Power Flow – 4th Speed IV III II I R VI V counter shaft II (3) z11 z12 z13 z33 z14 z23 z32 z24 z25 z31 z41 z34 VI V z21 z22 z15 counter shaft II (3) counter shaft I (2) input shaft (1) reverse axle (4) output shaft (5) 4WD output
Power Flow – 5th Speed IV III II I R VI V counter shaft II (3) z11 z12 z13 z33 z14 z23 z32 z24 z25 z31 z41 z34 VI V z21 z22 z15 counter shaft II (3) counter shaft I (2) input shaft (1) reverse axle (4) output shaft (5) 4WD output
Power Flow – 6th Speed IV III II I R VI V counter shaft II (3) z11 z12 z13 z33 z14 z23 z32 z24 z25 z31 z41 z34 VI V z21 z22 z15 counter shaft II (3) counter shaft I (2) input shaft (1) reverse axle (4) output shaft (5) 4WD output
Power Flow - Reverse IV III II I R VI V counter shaft II (3) z11 z12 z13 z33 z14 z23 z32 z24 z25 z31 z41 z34 VI V z21 z22 z15 counter shaft II (3) counter shaft I (2) input shaft (1) reverse axle (4) output shaft (5) 4WD output
Shifting Mechanism Cable Type 2 Cables - 1 for Selector 1 for Shifter
Shifting Mechanism 1/2 Rail end 3/4 Rail end REV Rail end 5/6 Rail end
Interlocking Mechanism 1/2 Rail end 3/4 Rail end REV Rail end 5/6 Rail end R 1 2 3 4 5 6
Shift System 2 Rail Design 3 Plastic Pad Sliding Fork on Rail SHIFTFORK PLASTIC PAD BUSHING REINFORCEMENT DRIVER SHAFT PTFE BUSH 2 Rail Design 3 Plastic Pad Sliding Fork on Rail
Drive Shaft Drive shafts transmit torque to the wheels. They are subject to torsion and stress because of turning and suspension action. CV Joints ensures smooth transfer of torque despite the wide range of angles they are bent in.
Molybdenum Grease is Packed Inside to reduce wear and Tear CV JOINTS The shaft fits in the center of a large, steel, star-shaped "gear" that nests inside a circular cage. The cage is spherical but with ends open, and it typically has six openings around the perimeter. This cage and gear fit into a grooved cup that has a splined and threaded shaft attached to it. Six large steel balls (2) sit inside the cup grooves and fit into the cage openings, nestled in the grooves of the star gear. Molybdenum Grease is Packed Inside to reduce wear and Tear
Video - CV JOINT WORKING
Thank You Copyright © MILE 2011 MILE / XUV500 / TRANSAXLE 01/ VER 01 / JUL 2011