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Global market review of OE gearbox clutches –
forecasts to 2011
2005 edition
3rd edition
Page i
Global market review of OE gearbox clutches – forecasts to 2011 3rd edition by Matthew Beecham
October 2005
Published by
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Page iii
Table of contents
Single-user licence edition............................................................................................................. ii Copyright statement .................................................................................................................. ii
Table of contents ........................................................................................................................... iii
List of tables .................................................................................................................................... v
List of figures ................................................................................................................................. vi
just-auto.com’s research portfolio .............................................................................................. vii Incredible ROI for your budget – single and multi-user licences..............................................vii
just-auto.com membership ......................................................................................................... viii
Chapter 1 Introduction.................................................................................................................... 1 Clutch systems take centre stage ............................................................................................. 1 Report coverage........................................................................................................................ 1
Chapter 2 The market ..................................................................................................................... 2 Market players........................................................................................................................... 2
LuK ................................................................................................................................... 2 Valeo ................................................................................................................................ 3 ZF Sachs .......................................................................................................................... 3
Market shares ........................................................................................................................... 3 Market forecasts........................................................................................................................ 5 Capital investments................................................................................................................. 10
Toyota............................................................................................................................. 10 Renault/Nissan ............................................................................................................... 11 Maruti.............................................................................................................................. 11 Ricardo ........................................................................................................................... 11
Chapter 3 Technical review.......................................................................................................... 12 Defining the elements ............................................................................................................. 12 Tomorrow’s gearboxes............................................................................................................ 16 CVTs ....................................................................................................................................... 17 Dual clutch transmission ......................................................................................................... 19 Motorsport innovations............................................................................................................ 26 New types of clutches and transmissions ............................................................................... 26
Chapter 4 Manufacturers.............................................................................................................. 30 Aisin Seiki................................................................................................................................ 30 Exedy ...................................................................................................................................... 31 FCC Co Ltd ............................................................................................................................. 34
Motorcycle clutches ........................................................................................................ 35
Page iv
Vehicle clutches.............................................................................................................. 35 LuK.......................................................................................................................................... 37 Valeo ....................................................................................................................................... 38 ZF Sachs................................................................................................................................. 41
Online sources of information ..................................................................................................... 46 Free email newsletters ............................................................................................................ 46 Other research reports ............................................................................................................ 46 Global news and feature articles............................................................................................. 46 Search the web ....................................................................................................................... 46
Your feedback ............................................................................................................................... 47
Page v
List of tables
Table 1: Manual transmission markets – percentage of fitment and numbers of units (‘000s) in
Western Europe, NAFTA, Eastern Europe, Asia, Japan, Mercosur, Other, 2000-
2005............................................................................................................................ 5
Table 2: Manual transmission markets – percentage of fitment and numbers of units (‘000s) in
Western Europe, NAFTA, Eastern Europe, Asia, Japan, Mercosur, Other, 2006-
2011............................................................................................................................ 6
Table 3: Manual gearbox OE clutch market values, Western Europe, NAFTA, Eastern Europe,
Asia, Japan, Mercosur, other regions, 2000-2011 (€’000) ......................................... 8
Table 4: Automated manual transmission markets (including twin-clutch) – Percentage of fitment
and numbers of units (‘000s) in Europe, NAFTA and Japan, 2000-2011................... 9
Table 5: Predicted market values of automated manual transmissions (including twin clutches),
Europe, NAFTA and Japan, 2000-2011 (€’000) ....................................................... 10
Table 6: Exedy Corporation’s sales by operating division, 2004-2005 (% of net sales) ................ 31
Table 7: Exedy Corporation’s sales by geographical region, 2004-2005 (% of net sales)............. 32
Table 8: Exedy Corporation’s overseas network............................................................................ 32
Table 9: FCC Co Ltd’s sales by product group, 2003-2005 (% of total sales) ............................... 36
Table 10: LuK’s clutch-related businesses worldwide.................................................................... 37
Table 11: Valeo Transmissions’ facilities worldwide ...................................................................... 39
Table 12: ZF Friedrichshafen’s key data, 2004.............................................................................. 43
Table 13: ZF Sachs’ key data, 2004 .............................................................................................. 44
Table 14: ZF Sachs’ selected key powertrain business production figures (Units)........................ 44
Page vi
List of figures
Figure 1: European clutch market shares for passenger cars and light commercial vehicles, 2004
(% of volume).............................................................................................................. 4
Figure 2: ZF Sachs’ 7 DCT 50 ....................................................................................................... 18
Figure 3: Q&A with BorgWarner..................................................................................................... 20
Figure 4: Q&A with LuK GmbH ...................................................................................................... 22
Figure 5: Q&A with Continental Automotive Systems.................................................................... 24
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Chapter 1 Introduction
Chapter 1 Introduction
Page 1
Clutch systems take centre stage
Of the three main vehicle markets of the developed world, Europe remains
unique in that nearly xx% of passenger cars are sold with manual
transmission. Europe’s sceptical consumers, however, may be persuaded to
embrace new technologies such as the dual-clutch transmission pioneered by
Volkswagen Group.
Although automatic transmissions are gaining a greater market share,
especially in northern Europe, consumer resistance remains strong. Motorists
with an interest in performance prefer changing gear for themselves, while
those more concerned with economy still believe that – quite apart from their
extra cost – automatic transmissions deliver inferior economy.
Emerging technologies include automatic clutches and electric manual
transmissions. Research into these technologies is particularly advanced in
Europe and Japan.
Report coverage
In this third edition reviewing the key market drivers for OE vehicle gearbox
clutches, just-auto updates the analysis of the impact of the ‘alternative’
transmissions types, such as belt-and-pulley continuously variable
transmission (CVT), the roller-in-toroid infinitely variable transmission and the
automated manual transmission (AMT). Our product fitment forecasts in
chapter two extends to xxxx, determi ning the market (by volume and value)
worldwide (and by major car-producing region) for manual transmissions and
AMTs. Chapter three reviews the technical advances in clutches, defining the
parts that make up the clutch itself as well as what we can expect to see in
tomorrow’s cars. This chapter includes exclusive interviews with BorgWarner,
Continental Automotive Systems and LuK. Chapter four provides brief profiles
of the major clutch manufacturers, namely, Aisin Seiki Exedy, FCC, LuK, Valeo
and ZF Sachs.
Chapter 2 The market
Chapter 2 The market
Page 2
Market players
The three main manufacturers of clutches for passenger cars and light
vehicles are LuK, Valeo and ZF Sachs.
LuK Headquartered in Bűhl, Germany, LuK’s clutch business employs 8,500 people
at 19 production sites in Germany, France, Brazil, UK, India, Korea, Mexico,
South Africa, Hungary and the US. In 2006, LuK will open its first production
site in China.
The company manufactures clutches, dual mass flywheels, hydraulic systems
and transmission parts. Its most recent innovations include components for
CVTs and AMTs. The company produces over xxm clutches annually for
passenger cars and tractors. In addition, the company produces some 3m
lock-up clutches and nearly xm dual mass flywheels for the OE and
aftermarket. This business generated sales of €x.xbn in 2004. LuK claims that
one in four cars worldwide is fitted with a LuK clutch as original equipment. As
far as the OE market for clutches for passenger cars in North America market
is concerned, a spokeswoman for the company told just-auto: “LuK is [the]
clear market leader in the comparably small segment of clutches for manual
transmission applications.”
LuK is relatively unknown, considering its products feature in one in four cars
built worldwide. However, the company has an interesting portfolio of products.
Its key transmission technologies include ECM (electronic clutch management,
which dispenses with the clutch pedal), ASG (autoshift gearbox, which
automates the gear shifting process) and USG (uninterrupted shift gearbox,
where an extra clutch partially fills the torque interruption during a shift). It has
also developed the ESG (electrical shift gearbox) in which a starter/generator
is coupled in parallel with one of the two input shafts. The PSG concept
(similar to Volkswagen’s DSG) is of particular importance to LuK.
Chapter 3 Technical review
Chapter 3 Technical review
Page 12
Defining the elements
Transmissions generally fall into one of two camps:
○ Manually-shifted transmissions with spur gears in a countershaft
arrangement.
○ Load-actuated automatic transmissions with planetary-gear sets.
According to Bosch, the basic elements of the manually-shifted transmission
are:
○ Single or multiplate dry clutch for interrupting and engaging the power flow;
actuation may be power-assisted to deal with high operating forces.
○ Variable-ratio gear transmission unit featuring permanent-mesh gears in
one of several individual assemblies.
○ Shift mechanism with shift lever.
A friction clutch consists of a pressure plate, a clutch disk – featuring bonded
or riveted friction surfaces – and the second friction surface represented by the
engine-mounted flywheel. The flywheel and pressure plate provide the thermal
absorption required for friction operation of the clutch; flywheel and pressure
plate are connected directly to the engine, while the clutch disk is mounted on
the transmission’s input shaft.
The pressure plate is basically the pressure mechanism that clamps the disc to
the flywheel to get the vehicle moving. Pressing in the pedal relieves the
pressure from the clutch disc to disengage the engine from the drivetrain for
shifting or stopping.
The clutch disc is the central connecting element of the clutch. Together with
the pressure plate, it disengages and engages the engine from and with the
drivetrain. The clutch disc transfers engine torque to the transmission input
shaft. The clutch disc is a flat plate with friction materials on both sides. As the
pressure plate is engaged (pedal let out), the clutch disc is clamped to the
flywheel. When the pressure plate is disengaged, (pedal pushed in) the clutch
Chapter 4 Manufacturers
Chapter 4 Manufacturers
Page 30
Aisin Seiki
Aisin Seiki is one of the leading manufacturers in terms of clutch sales,
although it is still mainly concerned with the Asian market. Its drivetrain
products group designs and produces automatic transmission; manual
transmissions; automated manual transmissions; continuously variable
transmission; clutch cover and discs. More specifically, its clutch products
include:
○ Clutch covers
○ Clutch discs (torsion rubber type)
○ Clutch discs (coil spring type)
○ Clutch disc (variable hysteresis type)
○ Flywheel with torsional damper
○ Torque converter
In Japan, Aisin produces clutch covers, discs and automatic transmissions at
its Ogawa plant, in Anjo prefecture. Aisin also produces and sells clutches at
the following sites:
○ Aisin (Australia) Pty Ltd – production of door latches and sales of clutches
and domestic sewing machines
○ PT Aisin Indonesia – clutch covers and other drivetrain related
components, door latches and other body related components, intake
manifolds and other engine related components
○ Liberty Mexicana SA de CV – production of water pumps and rebuilding of
clutch covers
○ Aisin Asia Pte Ltd, Singapore – sales of clutches for the aftermarket and
domestic sewing machines
Aisin’s strategic alliance with clutch maker, Exedy aims to provide a worldwide
network of drivetrain related products in North America and Asia. Aisin has a
xx.x% equity stake in Exedy, making it the company’s main shareholder. The
partners are using each other’s manufacturing facilities in North America to
increase local content and become more competitive.
Online sources of information Page 46
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