Flanged Nissan Leaf motor coupler

Description

Nissan uses a very capable motor in their Leaf and eNV200. The later model, the EM57 is capable of 160 kW in an e+ Leaf (with a different inverter compared to the 110 kW version). It is relatively compact and there are various aftermarket Vehicle Control Units (VCU’s) to use them outside of a Nissan. However, if you don’t use the Nissan reduction gearbox, mating the motor to your gearbox might be a challenge. The spline of the Nissan motor is quite specific and there are no clutches available that really fit.

The Leaf motor has a rolled spline which is cheaper to produce than our cut spline. Downside is that it is less accurate. We have managed to improve the fit compared to the original Leaf gear coupler, but due to the above there will always remain some slight play.

Flanged Nissan Leaf motor coupler

We have sourced and invested in a spline cut tool for the Nissan EM57 spline. Various couplers will be produced. For now there are dedicated couplers for the Volvo M47 and a Volvo M40 gearbox. These couplers are dual spline. One side is the Leaf spline and the other side is the Volvo spline (coarse or fine depending on the model/gearbox). This ensures a perfect alignment. The coupler is hardened as a whole.

While this is a very nice approach it requires expensive spline cut tools. Therefore is it not very cost effective to develop these kind of couplers for many car types. This is where our flanged Nissan Leaf motor coupler comes in.

You can ask a machine shop to fabricate a core often taken from a clutch disc of the car you want to mate to or choose from one of our plug and play spline cores. Since these are an aftermarket solution and turn out of vary slightly in tolerances these are made to order and not always in stock. So the “ships in 1-3 days” status is only valid for the coupler. Planning for counter flange and expected shipping timing will be provided after ordering.

The list of possible counter flanges :

• Audi 23-splines
• Audi 24-splines
• Audi 28-splines
• BMW 10-splines, 29 mm
• BMW 10-splines, 35 mm
• BMW 22-splines, 28,6 mm
• BMW 26-splines, 35 mm
• Chevrolet 26-splines
• Ford 23-splines
• Mercedes 26-splines
• Mitsubishi 23-splines, 25,4 mm
• Opel 14-splines
• Saab 14-splines
• Saab 17-splines
• Toyota 14-splines
• Toyota 21-splines
• Volvo M50 / M51
• Volvo M90 20-splines
• Volvo 850 / V70 20-splines
• Volvo whiteblock 23-splines
• Volkswagen Golf (type 1-4) and Beetle, 24 splines, 20,6 mm
• Volkswagen Golf II 16v, 28 splines, 22,2 mm

The above list is subject to change due to the fact that I have not been able to validate all of them for usability with my flanged adapter.

Unfortunately I do not know what exact models these splines fit. Feedback / input is welcome. If a type is not listed above I cannot supply a standard counter flange and you need to make one / have one made for example using a clutch disc.

In the below drawing you will find the measurement details of the mating face of the flanged adapter.

Adapter plates are currently under development and being tested and will be available as well.