Jaguar independent rear suspension
Encyclopedia
Jaguar's independent rear suspension (IRS) unit has been a common component of a number of Jaguar production cars
Automobile
An automobile, autocar, motor car or car is a wheeled motor vehicle used for transporting passengers, which also carries its own engine or motor...

 since 1961, passing through three major changes of configuration up to 2003 and still used in the full-sized Jaguar XJ (in third generation form). This article concentrates on the first generation Jaguar IRS, which firmly established the marque's reputation for suspension sophistication, combining as it did smooth ride with excellent roadholding and low levels of noise, vibration and harshness (NVH
Noise, Vibration, and Harshness
Noise, vibration, and harshness , also known as noise and vibration , is the study and modification of the noise and vibration characteristics of vehicles, particularly cars and trucks...

). The three generations overlap in time due to their being used in both full size
Full-size car
A full-size car is a marketing term used in North America for an automobile larger than a mid-size car. In the United States, the EPA uses "large car" to denote full-size cars....

 and sports
Sports car
A sports car is a small, usually two seat, two door automobile designed for high speed driving and maneuverability....

 models that were updated at different times. The modern S-Type
Jaguar S-Type
The Jaguar S-Type was a mid-size luxury/executive car that debuted at the 1998 Birmingham Motor Show and went on sale in spring 1999. The name is a revival of a previous Jaguar model, the S-Type introduced in 1963.-Overview:...

 and XF
Jaguar XF
The Jaguar XF The Jaguar XF The Jaguar XF (type (X250) is a mid-size luxury car / sports saloon produced by British car manufacturer Jaguar. The car, which replaced the Jaguar S-Type, was launched at the 2007 Frankfurt Motor Show following the public showing of the C-XF concept in January 2007 at...

 models, although they are also rear wheel drive with independent suspension, use the Ford DEW98 platform so are not covered in this description of Jaguar's in-house suspension systems.

Development

When first introduced, it was relatively rare for British
Great Britain
Great Britain or Britain is an island situated to the northwest of Continental Europe. It is the ninth largest island in the world, and the largest European island, as well as the largest of the British Isles...

 cars to have independently sprung rear wheels, most production cars of the time using live axle
Live axle
A live axle, sometimes called a solid axle, is a type of beam axle suspension system that uses the driveshafts that transmit power to the wheels to connect the wheels laterally so that they move together as a unit....

s. Independent suspension systems offer the advantage of lower unsprung weight
Unsprung weight
In a ground vehicle with a suspension, the unsprung weight is the mass of the suspension, wheels or tracks , and other components directly connected to them, rather than supported by the suspension...

 to improve roadholding, and when properly designed, the ability to maintain the roadwheels perpendicular to the road surface during cornering and in response to uneven road surfaces, further improving roadholding. The reduction in transfer of vertical undulations in road surface to the vehicle body also provides a smoother ride.

Jaguar's first IRS system took five years to develop. A Mark 2
Jaguar Mark 2
The Jaguar Mark 2 is a medium sized saloon car built from 1959 to 1967 by the Jaguar company in Coventry, England, as successors to the Jaguar 2.4 and 3.4 models, manufactured between 1957 and 1959...

 saloon fitted with a prototype IRS demonstrated a reduction in unsprung weight of 190 lb (86 kg) compared with a live axle. Its first production application was in the E-Type
Jaguar E-type
The Jaguar E-Type or XK-E is a British automobile, manufactured by Jaguar between 1961 and 1975. Its combination of good looks, high performance, and competitive pricing established the marque as an icon of 1960s motoring...

 from its launch in 1961. The assembly was manufactured in three different sizes with differing track widths to suit different models. The first generation Jaguar IRS continued to be updated and used until production of the XJS
Jaguar XJS
The Jaguar XJ-S is a luxury grand tourer produced by the British manufacturer Jaguar from 1975 to 1996. The XJ-S replaced the E-Type in September 1975, and was based on the XJ saloon. It had been developed as the XK-F, though it was very different in character from its predecessor...

 ended in 1996, though a derivative of the IRS continued to be used by Aston Martin in the DB7 until 2004.

The IRS is built around a fabricated steel crossbeam
Subframe
A subframe is a structural component of a vehicle, such as an automobile or an aircraft, that uses a discrete, separate structure within a larger body-on-frame or unit body to carry certain components, such as the engine, drivetrain, or suspension. The subframe is bolted and/or welded to the vehicle...

 that allows it to be relatively easily removed from the vehicle as a complete assembly. This feature has made it suitable for adaptation as a non-standard component on other vehicles.

Overview

The complete rear suspension assembly is carried in a steel crossbeam (shown ghosted in the diagram below), which is attached to the vehicle body via four rubber vee-blocks and also carries the differential (blue) and inboard brakes (red). The rear wheels are located transversely by top links and wheel carriers (green) and lower links (cyan). The top link is the driving half-shaft with a universal joint at each end. The lower link pivots adjacent to the differential casing at its inboard end and where it meets the wheel carrier at the wheel hub casting (violet) at its outboard end. The pivot bearings at each end of the lower link are widely spaced so as to provide maximum longitudinal rigidity. Suspension is provided by two coil spring and damper units (yellow) on each side of the differential casing (four in total), the spring and damper units attaching to the crossbeam at the top and the lower link at the bottom. The crossbeam is located by two radius arms (see photo above) each of which runs forward from the lower link to a point on the vehicle body and is pivoted at each end via rubber bushings.

Crossbeam

In order to insulate the passenger compartment from noise, vibration and harshness (NVH
NVH
NVH is a three-letter abbreviation with multiple meanings, including:*National R.V. Holdings*Noise, vibration, and harshness*Norwegian School of Veterinary Science...

), the independent rear suspension was designed to be carried in a separate crossbeam assembly attached to the vehicle body by four rubber vee-blocks. The only other points of contact with the vehicle body (i.e. the radius arms) are by means of metal sleeved (Metalastik) rubber bushes, so there is no metal-to-metal contact between the suspension and vehicle body. The fabricated steel crossbeam carries the differential and inboard brakes (if fitted).

Differential

The differential is a Salisbury 4HU unit with a hypoid spiral bevel gear. It provides final drive reduction ratios ranging from 2.88:1 to 3.54:1, depending upon the Jaguar model. The bolts that attach the differential to the subframe have small holes through their heads so that they can be safety wire
Safety wire
Safety wire or lockwire is common in the aircraft and racing industries as an extra precaution to keep vital fasteners from unintentionally loosening and parts from falling off due to vibration or other forces. The use of safety wire is a type of positive locking device. It also allows rapid and...

d to prevent them coming undone, which would otherwise be difficult to detect since they can only be accessed when the whole suspension assembly is removed from the car. A limited slip differential was standard on some models and optional on others. The first generation IRS always had the disc brakes mounted inboard, the brake units being located immediately adjacent to the differential and braking its output shafts.

Top link and wheel carrier

The top link is a fixed-length half-shaft universally jointed at each end. The universal joint
Universal joint
A universal joint, universal coupling, U joint, Cardan joint, Hardy-Spicer joint, or Hooke's joint is a joint or coupling in a rigid rod that allows the rod to 'bend' in any direction, and is commonly used in shafts that transmit rotary motion...

s act as inner and outer pivots for the top link, which rotates to transmit drive from its inner pivot at the output of the differential/brake unit to its outer pivot at the wheel carrier. The wheel carrier takes the form of a splined stub axle (for knock-off wheels) or a stub axle and hub plate (for 5-lug wheels). In later XJS models with outboard rear brakes, the wheel carrier, brake discs and parking brake drum were a single cast steel unit. In all cases the wheel carrier runs in bearings mounted in a large cast aluminium hub carrier.

Lower link and hub carrier

Each lower link is fabricated from a steel tube with a two-pronged fork welded to each end. The outer end of the lower link pivots about a fulcrum shaft, which runs longitudinally through the bottom of each hub carrier. The inner fulcrum mounting is adjacent to the bottom of the differential casing. Wide spacing of the pivot bearings provides both torsional and fore-and-aft rigidity to the hub carrier. This prevents the hub carrier from twisting relative to the differential and is also necessary because, with driveshafts acting as the upper suspension links, the hub carrier has no other way of resisting fore-and-aft movement.

Bearings and bushes

The top and lower link pivots use roller bearings
Rolling-element bearing
A rolling-element bearing, also known as a rolling bearing, is a bearing which carries a load by placing round elements between the two pieces...

, reducing friction relative to plain bearings and improving both the smoothness and speed of suspension response. The position and shape of the rubber vee-blocks and Metalastik bushes are designed to ensure sufficiently rigid suspension mounting for good control whilst successfully isolating the body from NVH.

Radius arms

The crossbeam itself is not designed to carry normal acceleration and braking forces, so it is located by two radius arms that run forward from each lower link to points on the (unitary construction) vehicle body, beneath the rear passenger compartment. Each radius arm attaches to its lower link at a point just outboard of the bottom spring mountings and pivots vertically about its fixing bolt. The fixing bolts pass through a small Metalastik bush, which consist of a metal sleeve held within a rubber bush. Where the radius arm meets the vehicle body, it is attached by a vertical bolt passing through a large Metalastic bush that is pressed into the forward end of the radius arm. Safety straps retain the radius arms in proximity to the vehicle body should one of the front securing bolts happen to come loose.

As a consequence of the radius arm forward attachments not being on the axis of the lower link arm inner pivots, it would appear at first glance that free movement of the suspension would be impossible without some components bending, or the trailing arm elastomeric bushes being compressed unduly. However, as described above, the crossbeam is rubber mounted to the body. The crossbeam and lower links maintain the correct toe angle of one wheel relative to the other, however due to the relative angles of the trailing radius arms, body roll results in the entire cross-beam and lower links pivoting slightly about the crossbeam's mounting points, thus inducing a small amount of passive rear wheel steering, which may result in significantly improved handling. When the Jaguar components are re-used in other vehicles, the differential is often rigidly mounted to the chassis, different radius arm configurations are used, and the passive rear wheel steering effect is lost.

Springing and damping

Springing and damping are provided by four coilover
Coilover
A coilover is an automobile suspension device. "Coilover" is short for "coil spring over strut". It consists of a shock absorber with a coil spring encircling it. The shock absorber and spring are assembled as a unit prior to installation, and are replaced as a unit when the shock absorber has...

 spring and damper units which attach to the crossbeam at the top and the lower links at the bottom. The use of two spring and damper units on each side is unusual and allows the use of smaller springs, taking up less space and protruding less into the luggage area. It also equalises the load transmitted to the front and rear of the crossbeam

Anti-roll bar

Some models were also fitted with an anti-roll bar, a torsion bar arrangement intended to reduce body roll on cornering.

Brakes

For the first 32 years of production of the first generation IRS, the disc brake
Disc brake
The disc brake or disk brake is a device for slowing or stopping the rotation of a wheel while it is in motion.A brake disc is usually made of cast iron, but may in some cases be made of composites such as reinforced carbon–carbon or ceramic matrix composites. This is connected to the wheel and/or...

s were mounted at the inboard ends of the driveshafts in order to minimise unsprung weight at the outboard end. The hydraulic
Hydraulics
Hydraulics is a topic in applied science and engineering dealing with the mechanical properties of liquids. Fluid mechanics provides the theoretical foundation for hydraulics, which focuses on the engineering uses of fluid properties. In fluid power, hydraulics is used for the generation, control,...

 brake calipers were mounted directly onto the differential. Care was taken to prevent heat generated by the brakes from damaging the differential output seals, although this was never totally successful. The parking brake used separate mechanical calipers acting on the discs.
For the 1993-1996 model XJS
Jaguar XJS
The Jaguar XJ-S is a luxury grand tourer produced by the British manufacturer Jaguar from 1975 to 1996. The XJ-S replaced the E-Type in September 1975, and was based on the XJ saloon. It had been developed as the XK-F, though it was very different in character from its predecessor...

, the brakes were moved to the outboard position. This was achieved using the hub carriers from the Second Generation IRS, which by that time had already been in production for seven years for the XJ6 (XJ40)
Jaguar XJ (XJ40)
The Jaguar XJ is a luxury sedan manufactured by Jaguar Cars between 1986 and 1994. It was an all-new redesign of the XJ to replace the Series III, although the two model ranges were sold concurrently until the Series III was discontinued in 1992...

. Moving the rear brakes outboard eliminated the heat transfer problem and allowed for easier servicing. The parking brake then used brake shoe
Brake shoe
A brake shoe is the part of a braking system which carries the brake lining in the drum brakes used on automobiles, or the brake block in train brakes and bicycle brakes.-Automobile drum brake:...

s inside a brake drum
Drum brake
A drum brake is a brake in which the friction is caused by a set of shoes or pads that press against a rotating drum-shaped part called a brake drum....

 in the centre of the disc rotor.

Original applications

The following Jaguar cars were fitted with the first generation IRS as part of their original specification. The second column indicates the vehicle's approximate rear track
Wheelbase
In both road and rail vehicles, the wheelbase is the distance between the centers of the front and rear wheels.- Road :In automobiles, the wheelbase is the horizontal distance between the center of the front wheel and the center of the rear wheel...

, according to whether the narrow, medium, or wide version of the suspension assembly was used.
Model Track
E-Type
Jaguar E-type
The Jaguar E-Type or XK-E is a British automobile, manufactured by Jaguar between 1961 and 1975. Its combination of good looks, high performance, and competitive pricing established the marque as an icon of 1960s motoring...

 Series 1 & 2
50 in (1,270 mm)
E-Type
Jaguar E-type
The Jaguar E-Type or XK-E is a British automobile, manufactured by Jaguar between 1961 and 1975. Its combination of good looks, high performance, and competitive pricing established the marque as an icon of 1960s motoring...

 Series 3
54 in (1,372 mm)
S-Type
Jaguar S-Type (1963)
The Jaguar S-Type was produced from 1963–68 as a technically more sophisticated development of the Jaguar Mark 2, offering buyers a more luxurious alternative to the Mark 2 without the size and expense of the Mark X. It sold alongside the Mark 2, as well as the Jaguar 420 following its release in...

 
54 in (1,372 mm)
420  54 in (1,372 mm)
Mark X
Jaguar Mark X
The Jaguar Mark X was the top-of-the-range saloon car built by the British manufacturer Jaguar, originally aimed at the United States market. The Mark X succeeded the Mark IX as the company's large saloon model.-Body:...

 
58 in (1,473 mm)
420G
Jaguar Mark X
The Jaguar Mark X was the top-of-the-range saloon car built by the British manufacturer Jaguar, originally aimed at the United States market. The Mark X succeeded the Mark IX as the company's large saloon model.-Body:...

 
58 in (1,473 mm)
XJ6 & XJ12 Series 1,2,3
Jaguar XJ
Jaguar XJ is the designation that has been used for a series of luxury saloon cars sold under the British Jaguar marque. The first XJ was launched in 1968 and the designation has been used for successive Jaguar flagship models since then. The original model was the last Jaguar saloon to have had...

 
58 in (1,473 mm)
XJS
Jaguar XJS
The Jaguar XJ-S is a luxury grand tourer produced by the British manufacturer Jaguar from 1975 to 1996. The XJ-S replaced the E-Type in September 1975, and was based on the XJ saloon. It had been developed as the XK-F, though it was very different in character from its predecessor...

 
58 in (1,473 mm)
Daimler DS420
Daimler DS420
The Daimler DS420, popularly known as the Daimler Limousine, is a large limousine produced by Daimler Motor Company between 1968 and 1992. The vehicles are used extensively as official state cars in several countries, including by the British and Danish Royal Families...

 
58 in (1,473 mm)

Non-original applications

The first-generation IRS has been fitted as a modification to a number of other vehicles, including the following:
  • AC Cobra
    AC Cobra
    The AC Cobra, also known colloquially as the Shelby Cobra in North America, is an Anglo-American sports car that was produced during the 1960s.-History and development:...

     replicas

  • Ford Mustang
    First-generation Ford Mustang
    The first-generation Ford Mustang is the original pony car, manufactured by Ford Motor Company from 1964 until 1973.It was initially introduced as a hardtop and convertible with the fastback version put on sale the following year...


  • MG MGB
    MG MGB
    The MGB is a sports car launched by MG Cars in May 1962 to replace the MGA. Introduced as a four-cylinder roadster, a coupé with 2+2 seating was added in 1965...


  • Panther J.72
    Panther J72
    The J.72 was the first product of the Panther Westwinds company, sold from 1972 through 1981. It was an ultra-exclusive luxury roadster, intended to compete with the best of the 1970s motor industry. It used mechanicals from the XJ12, including the 5.3 L Jaguar V12 engine, and was styled like...


  • Panther Lazer
    Panther Lazer
    The Lazer was an open roadster sports car produced by the UK's Panther Westwinds company in 1974. Only one was ever sold. The Canadian importer for Panther wanted Robert Jankel to build a unique automobile as a surprise present for his wife...


  • Panther De Ville
    Panther De Ville
    The Panther De Ville was a neo-classic luxury model from Panther Westwinds, the British specialty maker. Offered from 1974 to 1985, the De Ville was conceived by Robert Jankel to appeal to the taste of nouveau riche customers, including singer Elton John and actor Oliver Reed...


  • Reliant Scimitar
    Reliant Scimitar
    Reliant's first Scimitar was a coupé based upon the styling of a Daimler SP250 prototype and the chassis of a Reliant Sabre. It was first displayed in 1964. It was powered by a 2.6 L Ford straight six from the Ford Zephyr / Ford Zodiac...


  • Toyota Hilux
    Toyota Hilux
    The Toyota Hilux is a series of compact pickup trucks produced and marketed by the Toyota Motor Corporation. Most countries used the Hilux name for the entire life of the series but in North America, the Hilux name was retired in 1976 in favor of Truck, Pickup Truck, or Compact Truck...


  • Triumph TR7
    Triumph TR7
    The Triumph TR7 is a sports car manufactured from September 1974 to October 1981 by the Triumph Motor Company in the United Kingdom. It was initially produced at the Speke, Liverpool factory, moving to Canley, Coventry in 1978 and then finally to the Rover plant in Solihull in 1980...


Second generation IRS (1986-2006)

Jaguar made several fundamental changes to the design of the IRS for the new XJ40 model, launched in 1986.

The shape of the subframe changed to an approximate triangle, bolted to the front of the differential and attached to the car at approximately the same points as the radius arms of the first generation IRS. The rear of the differential was further supported by a pair of link rods attaching it to the car's rear floor structure. Rubber bushes at the attachment points provided the necessary levels of NVH
Noise, Vibration, and Harshness
Noise, vibration, and harshness , also known as noise and vibration , is the study and modification of the noise and vibration characteristics of vehicles, particularly cars and trucks...

 suppression.

The fixed-length driveshaft as the upper suspension link remained, but the lower wishbone became a fabricated steel box section with a much wider base. Putting the front and rear pivots of the wishbones so far apart meant that the radius arms could be eliminated.

The original twin springs on each side were replaced by a single spring and damper, acting against the car's body instead of the rear subframe. The brakes were moved to the outboard ends of the driveshafts to enable better heat dissipation and easier servicing.

Original applications

The following Jaguar cars were fitted with the second generation IRS as part of their original specification:
  • Jaguar XJ (XJ40)
    Jaguar XJ (XJ40)
    The Jaguar XJ is a luxury sedan manufactured by Jaguar Cars between 1986 and 1994. It was an all-new redesign of the XJ to replace the Series III, although the two model ranges were sold concurrently until the Series III was discontinued in 1992...

  • Jaguar XJ (X300)
    Jaguar XJ (X300)
    The Jaguar XJ is a luxury sedan manufactured by Jaguar Cars between 1994 and 1997. It was the first XJ produced entirely under Ford ownership, and can be considered an evolution of the outgoing XJ40 generation. Like all previous XJ generations, it features the Jaguar independent rear suspension...

  • Jaguar XJ (X308)
    Jaguar XJ (X308)
    The Jaguar XJ is a luxury sedan manufactured by Jaguar Cars between 1997 and 2002. It is an evolution of the outgoing X300 platform, and the exterior styling is nearly identical between the two generations. The major change was the introduction of Jaguar's AJ-V8 as the only available engine...

  • Jaguar XK (X100)
    Jaguar XK (X100)
    The Jaguar XK8 is a grand tourer car that was launched by Jaguar Cars in 1996, and was the first generation of a new XK series. The XK8 was available in coupé or convertible body styles and with the new 4.0 litre Jaguar AJ-V8 engine. In 1998 the XKR was introduced with a supercharged version of...


Third generation IRS (2003 onward)

For the launch of the aluminium
Aluminium
Aluminium or aluminum is a silvery white member of the boron group of chemical elements. It has the symbol Al, and its atomic number is 13. It is not soluble in water under normal circumstances....

-bodied Jaguar XJ (X350) model, Jaguar developed a new and complex multi-link suspension
Multi-link suspension
A multi-link suspension is a type of vehicle suspension design typically used in independent suspensions, using three or more lateral arms, and one or more longitudinal arms....

 unit. The driveshafts had now ceased to be a structural part of the suspension, so they could be fitted with constant-velocity joint
Constant-velocity joint
Constant-velocity joints allow a drive shaft to transmit power through a variable angle, at constant rotational speed, without an appreciable increase in friction or play. They are mainly used in front wheel drive and all wheel drive cars...

s that allowed their length to vary with suspension travel. This system was also incorporated into the revised Jaguar XK (X150) sports coupe in 2006.
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