Bugatti Veyron Drivetrain
The Bugatti Veyron is one of the fastest street legal production cars in the world. The Bugatti Veyron is powered by a 7-speed dual-clutch gearbox that is comprised of two clutches with four gears each. One of the clutches is for the even and reverse gears, and the other clutch is for the odd gears.
The specific Veyron of this case was countering three problems with his drivetrain.
1. Rear limited-slip differential had a malfunction in his torque distribution.
2. DCT clutch was slipping at high torque power demands.
3. Front driveshafts boots were encountering fracture problems causing leaking grease.
Find the causes of these problems and the best solutions within the customer’s budget.
The Limited Slip Differential:
The housing of the clutch package piston was almost completely cracked around his diameter. Thereby several high- and low-pressure seals were split into pieces or totally worn out.
These part failures were preventing the control of the Bugatti Veyron limited-slip differential, to distribute desired amounts of the supercar’s (1001 hp!) power to the wheels. To solve this problem, KMP was able to remake the replacement parts of the highest available grade materials which also improved the performance of the parts.
The Veyron DCT clutch:
Searching for the nature of the Veyron DCT slippage problem at high power ratings, we found ‘dished’ clutch plates (which need to be totally flat). The ‘dished’ clutch plates were found in the primary clutch package for the even gears 2,4 and 6 and R. Too much slippage at high RPMs generated excessive heat, which in this case caused the clutch plates to deform into a dish shape.
Replacing the clutch plates with fresh new flat ones of even stronger material solved the slippage problem and will withstand the high loads in the future.
The Driveshaft boots:
The outboard tripod boots of the Veyron front driveshaft were fractured at the inside of a boot lobe causing the grease to fly out through this tear by the centrifugal forces.
Analyzing the boot material resulted in the ability to apply an enhanced stronger rubber compound for a boot remake to improve the resistance against fracture.
Done all this, the drivetrain parts can spin around safely again while hitting speeds at 400km/h maybe?