All Wheel Drive Systems

One of our key areas of expertise is in the design and development of all wheel drive systems, especially where vehicles need to be adapted to perform in conditions or roles that exceed the capability of a mainstream production vehicle, and where innovative design solutions are required to overcome base vehicle packaging constraints.

AWD Transmission Assembly

One example of this is a hang-on front AWD system developed alongside the special vehicle engineering team of a leading OEM, where the brief was to turn the RWD base vehicle into an AWD vehicle, without changing any structural or mechanical components except the RWD transmission assembly. Our design solution required the power transfer unit, AWD coupling and front axle final drive to be integrated into a bespoke AWD transmission assembly. Several patents were granted during the process. The end result had so little impact on the base vehicle architecture that the AWD variant requires only the following AWD specific components: AWD transmission assembly, front drive shafts, wiring loom, AWD ECU and AWD specific ABS module.

High Ground Clearance 4x4

An example with less extreme packaging constraints, is a conventional high ground clearance 4x4 application, where a standard transfer box could be utilised. To keep the overall vehicle configuration close to the original, a new front axle and suspension sub-assembly was designed, to retain independent front suspension and utilise the original rack and pinion steering gear, rather than switch to a rigid beam axle and steering box.