Question about rear axle ratio and transmissions

   / Question about rear axle ratio and transmissions #21  
I had a Ram with 5.7 and 3:92 ratio. Ran great and would not want anything "higher speed" than that.
I ordered the Ram 1500 2014 specifically with the 3:92.
If your buying new, don't hesitate to order it. You get exactly what you want no more no less. Ram ordering is surprisingly fast.
I really liked the 3:73 many offered in the past with an overdrive transmission.
I'm back in a 2017 diesel F350.
I missed the diesel that much and will most likely never go gas again. That said, the new diesel are great,but very, very expensive to repair. Most people really can't justify them from an economical stand point.
 
   / Question about rear axle ratio and transmissions #22  
I'll toss my hat into the fray....

You asked two important questions; a) What does having more gears in the transmission change and b) How does that affect axle gearing.

As most would agree, OEMs spend MILLIONS of dollars and thousands of hours on R&D prior to product launch, so everything said in this thread is really arm-chair, this included - but math is still math ;)

With regard to transmission, when I was a pup, you had three speed autos and 4 speed manuals and gearing was somewhere between 3.08 and 4.10 in most every PU regardless of capacity. So what changed to cause more gears in the trans? Speed limits first and Fuel Economy!

3/4 gears covers the 0-55 MPH operating range pretty well, by the '80's 4 speed boxes were standard, which works out to ~14 MPH/gear. Of course even then FE was not a BIG concern for anyone despite the oil embargo of the mid '70's. Thru the '90's, CAFE was applied to pickups, specifically those at 8500# BVW and under, yup, that's the number. Over that GVW rating, the truck is considered a work vehicle and was not subject to CAFE reporting. I do not know if that number has changed, but if not, it would explain the severely reduced capacities on modern PUs that typically weigh about 6k-6.5k pounds in 4 door 4x4 configurations; it keeps then IN the CAFE reporting range. Now that speed limits are 70-80 MPH, 4 gears will not get the job done, because you still need 1st to get it moving and "OD" for highway cruising - that only leaves TWO gears to cover the 10-60 MPH spectrum :(

With 6/8 gears and a speed limit of say 75, you average ~11 MPH/gear. Importantly this does two VERY important things: 1) Keeps the engine speeds under control with smaller steps between gears, this leads to better performance and longer life and 2) Allows calibration of the system to optimize both pulling power AND fuel economy by electronically adjusting shift points to very closely match engine load. You would "short shift" at light loads keeping engine RPMs down and therefore volumetric efficiency high and "power shift" at high loads to keep the engine at peak power, which is also enabled by the smaller steps between gears.

As for axle ratios, you can only effectively add so many "OD" gears and without adding serious engineering and material cost, two OD gears is considered a practical maximum. If you need to keep the engine at 1800 RPM at cruise speed (say 75 MPH) and you have a top gear ratio in the box of 0.64:1 (TG - 1 = 0.822, TG - 2 = 1:1) and typical 17" tires with a Rolling radius of 31" which equates to about 640 Revs/mile.

As 75mph = 60mph*1.25, 640 Revs/mile (tire) turns into 800 RPM (tire) @ 75 MPH. Since RPM (engine) = 1800 and trans ratio = 0.64:1 (actually 1:0.64) we know Driveshaft speed is more than the engine speed (hence "OverDrive", or 1800/0.64 = 2813rpm(ds). What axle ratio will allow 2813rpm(ds) and 800rpm (tire)? That is: 2813/800 = 3.52:1

Engineers choose the ratio for 1st gear and high gear based on mission requirements , then optimize how many are in between based on cost/benefit, RAM chose 8.

The peak Tq available to the axle shafts is a function of: Peak Tq(engine)*TC(typically 2.3:1)*ratio is low*RAR. We can see that assuming 440lb-ft peak (eng)*2.3*1st gear* = driveshaft Tq. DS Tq * RAR = Axle Tq > With a stated 3.21 axle Tq this is 5060*3.21 = 16243lb-ft, with a 3.73 this becomes 18874lb-ft!

The AXLES are only so strong, so engineers need to limit the torque to them, selecting rear axle ratios that will not exceed design limits of the axles is one effective method.
 
   / Question about rear axle ratio and transmissions #23  
You are correct, higher numbered rear ratios do take a lot of shock out. Commercial trucking has had to work around lower numbered ratios for a while since OEM's are wanting to dramatically down speed engines and going to direct drive final transmission ratios. That has meant diff ratios of around 2.47 to 2.64. Even down to 2.21. Really takes a toll on drive lines.

It's NOT the OEMs, it is the CUSTOMERS, but they want to have their cake - and eat it too, without paying for any of it!

Downspeeding the engine has HUGE impacts on FE, BUT there is a cost! You CANNOT get acceptable performance from 0 to 70 MPH with a 10 speed trans and a down-sped engine. The gear jumps are just too great for acceptable performance and FE. 10 years ago when BB diesels would operate well from 1400-2200 RPM, 10 speeds in the box would get you 70 MPH, at a modest FE and performance cost. Drop the engine operating speeds down 600 RPM (into the 900-1400 range) to MAXIMIZE FE and all that math is out the window.

How do you fix it? More gears in the box, guess what? That is COSTLY, Eaton, ZF, Allison, etal are NOT in the habit of losing money and more parts in the component is more cost. OEMs, pinched between completely conflicting REQUIREMENTS from customers for FE and COST are forced to spec low numbered diffs so customers are insulated from the cost of their demands on the industry.

Lower numbered RAR moves stresses normally taken by the axle shafts to the drive shaft, you are 100% spot on in that regard. Since no truck OEM has complete control over their products (if you won't build it "THIS WAY" -insert chosen language-, we won't buy it), they are forced to use the tools and components available to meet customer demands.
 

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