1. TRANSAXLE
General
Copyright © MILE 2011 MILE / XUV500 / TRANSAXLE 01/ VER 01 / JUL 2011

2. 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

3. What is Transaxle
Transaxle is a combination of transmission, the differential, and driven axle.

4. 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

5. Different Views

6. 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

7. Transaxle Layout counter shaft I reverse axle input shaft
counter shaft II
output shaft

8. 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)

9. Transaxle Torque Max Design Torque – 400 Nm
Vehicle Requirement – 320 Nm
Torque Limitation
1st Gear – 280 Nm
Rev Gear – 240Nm

10. 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
2nd
2.143
400
857.20
3rd
1.243
497.20
4th
0.949
379.60
5th
1.027
3.115
410.80
6th
0.872
348.80
Rev
4.961
240

11. 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

12. 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

13. 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

14. 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

15. 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

16. 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

17. 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

18. Shifting Mechanism
Cable Type
2 Cables -
1 for Selector
1 for Shifter

19. Shifting Mechanism
1/2 Rail end
3/4 Rail end
REV Rail end
5/6 Rail end

20. Interlocking Mechanism
1/2 Rail end
3/4 Rail end
REV Rail end
5/6 Rail end R 1 2 3 4 5 6

21. 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

22. 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.

23. 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

24. Video - CV JOINT WORKING

25. Thank You Copyright © MILE 2011
MILE / XUV500 / TRANSAXLE 01/ VER 01 / JUL 2011