Sep 22, 2008

Tesla Sorts Out Gearbox Woes, Delivers Cars

Yes, the two-speed gearbox was a big bump in the road for electric automaker Tesla Motors, but now the company is putting that bump behind it. It has selected BorgWarner to build a single-speed gearbox for its Tesla Roadster, and it is initiating a ramped-up production rate with its production partner, Lotus. So far, 27 customers have taken delivery of Tesla Roadsters.

The new gearbox was designed for the higher peak torque levels of the new Roadster power train, which has increased from 211 foot-pounds to 280 foot-pounds of torque. It is an integral part of an enhanced power train that achieves an EPA combined range of 244 miles on a single charge -- up from Tesla’s previously announced EPA range of 221 miles.

“Last December, when the two-speed transmission designed by a previous supplier proved not to be durable, we announced we would modify our approach,” said JB Straubel, chief technology officer of Tesla Motors. “By using a more powerful inverter and an enhanced motor design, we were able to implement a single-speed gearbox and still achieve our original performance goals. In fact, the new setup is superior in almost every way.”

Production of Tesla Roadsters began in March, and the first vehicles were built with an interim transmission design. Customers who own Roadsters with the interim transmission can have their power train upgraded free of charge when the components become available.