Design of a spool and connection from the Twizy gearbox to the Pajero disconnect clutch.
Hello, and a long overdue update. One of the key difficulties with this project is the necessity of a disconnect clutch between the electric motor and final drive. Ideally this should be as close to the wheel hubs as possible. In the absence yet of designing a whole new custom free-wheeling hubs beam axle, i decided on a solution with using a dog-clutch disconnect mounted immediately after the reduction gearbox and upstream of the Pajero differential. The hardware i found suitable is the freewheel disconnect part from the front axle of a Pajero-io 4WD SUV. This was suitable because the clutched axle part is a separate module from the front diff body. A similar design exists in the larger Pajero gen.3 model front axle, but on that one the clutch assembly part is integral with the axle differential body, so the clutch can not be removed by itself. So the design problem has contained three elements, 1/ how to connect the output from the Twizy/Comex gearbox to this Pajero clutch shaft, 2/