ZF Achieves Milestone with 40 Million Passenger Car Axle Drives Produced

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Image Courtesy: ZF

ZF has reached a major production milestone by manufacturing 40 million passenger car axle drives since 1997 for global automotive manufacturers. Including an additional 10 million bevel gear sets and differentials integrated into ZF’s automatic and dual-clutch transmissions, the total surpasses 50 million final drive systems delivered worldwide.

ZF has established itself as a market leader in axle drives for conventional internal combustion engine vehicles, particularly in front-engine, rear-wheel-drive configurations. The increasing demand for all-wheel-drive (AWD) applications, which offer enhanced traction, stability, and control, has significantly driven the growth of ZF’s axle drive production over the past two decades.

ZF’s journey with axle drives began in 1997 with the supply of front and rear axle drives for the Mercedes-Benz M-Class, produced at its Tuscaloosa, USA, facility. Over the years, ZF expanded its production footprint with facilities in Germany (Thyrnau and Gotha), the USA (Gainesville and Marysville), and China (Shenyang and Hangzhou). This growth enabled ZF to cater to a broader and more international customer base.

From the outset, ZF’s axle drives have featured lightweight aluminium housings, refined ground bevel gear sets, and application-specific designs that reduce noise levels and improve efficiency. Successive product generations further optimized weight through design enhancements and introduced low-friction bearings and low-viscosity oils, ensuring high performance and reliability.

In 2002, ZF introduced the electronically controlled differential lock in its rear-axle transmissions, enabling variable torque distribution between the wheels for improved traction, safety, and driving dynamics. This feature has evolved over four generations, incorporating mechatronic and software innovations for greater functionality.

For all-wheel-drive vehicles with front-transverse engine layouts, the company developed a rear-axle drive with an integrated AWD clutch. This comprehensive system combines mechanical, mechatronic, and software components to deliver superior AWD performance. Additionally, a power-take-off unit (PTO) directs torque from the front axle to the rear as required by the AWD clutch.

Kay Schmidt, Head of the Axle Drives Product Line, highlighted it’s commitment to modularity: “Our focus on standard components early on has enabled us to develop the world’s broadest range of axle drives. This flexibility allows us to deliver optimal performance across a wide range of applications.”

ZF has adapted its axle drive technology for hybrid applications, offering software-controlled solutions for mild hybrid (MHEV) and plug-in hybrid (PHEV) vehicles. These systems maintain the same advantages as it’s standard axle drives, including a low power-to-weight ratio, reduced noise, and high efficiency, making them ideal for modern hybrid powertrains. As demand for advanced drivetrain solutions continues to grow, it remains at the forefront of innovation, supporting the evolution of both conventional and electrified vehicles with cutting-edge axle drive technology.