Development of an Improved 5 Speed Manual Transmission to Increase the Maximum Torque Capacity

The introduction of new engines on the Ford Amazon vehicle family required a torque increase of the current 5 speed manual transmission. Therefore, an upgraded version of the current 5 speed manual transmission, so called IB5, was developed, which increased the maximum torque capacity from 145 Nm to 185 Nm.

This paper describes the required design changes necessary for torque capacity increase, involving several component upgrades, as well as the strategic targets to achieve a product with low cost, minimum investments and maximal manufacturing flexibility. Another important objective of the development program was to maintain the excellent shiftability and the good NVH of the current transmission.