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Major German car parts maker ZF Friedrichshafen is investing a hefty $500 million into its transmission plant in South Carolina – all to transform it into a “flexible manufacturer of parts” for both ICE and plug-in hybrids, and for both passenger cars and large commercial vehicles by launching production of its PowerLine transmission in the US.

In a release, ZF said it will add new product lines over the next few years at its massive 1.7 million-square-foot Gray Court plant just south of Greenville, South Carolina. The company will also produce in North America for the first time its fourth-gen eight-speed transmission for plug-in hybrids, which ZF supplies in Germany for the BMW 7 Series and X5.

ZF’s PowerLine transmission has a modular design that the company says can save up to 10% in fuel compared to other transmissions. And the PowerLine’s flexible design can accommodate both ICE and plug-in hybrid variants for a range of vehicle types, from lightweight passenger cars to trucks, buses, and commercial vehicles. One of the better aspects of the PowerLine is that it is designed for class 5 vehicles to class 8 semi-trucks, with the gear ratios stepped to deliver increased torque at launch and a higher top gear for better fuel savings – so any step in the direction of reducing CO2 emissions from the heavy-duty trucking industry is a positive.

“ZF Gray Court is our North American premier flex manufacturing facility, producing technologies for today and tomorrow,” ZF’s Stephan von Schuckmann said in the release. “This site is our first ever to mirror the transition that the industry and the world is now navigating.”

The company plans to hire 400 workers for new jobs at the plant.

The factory targets a production capacity of 200,000 transmissions annually by 2025, and is dedicating about 50,000 square feet of the factory to make that happen.

The move comes after a $200 million investment aimed at supporting three “major US commercial vehicle manufacturers.” The company says that it too is seeking federal incentives to support investment plans, although where this stands is not yet clear.

Last year, ZF announced its plan to expand its parts offering to more than 73 million more vehicles in North America by adding 285 new products to its lineup – including brake pads, suspension, and steering components for Tesla, Hyundai, Ford, BMW, and Mercedes-Benz. Back in 2019, ZF signed BMW onto its roster and began producing its eight-speed automatic transmission for the German automaker at ZF’s Gray Court site, which is about 30 miles from BMW’s plant in Spartanburg, South Carolina.

ZF Group is reportedly also investing millions to pump up production at its Mexico facilities, pouring $194 million to build a new facility in Juarez, and nearly $40 million to expand its Toluca facility.

ZF Friedrichshafen, which makes transmissions, shock absorption systems, and chassis components for more than 55 auto brands and is Germany’s second-largest supplier after Bosch, said recently that it could lay off as many as 12,000 people in a “worst-case scenario” by 2030. The company employs 165,000 people around the world.

Photo: ZF Gray Court/Courtesy of ZF


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Watch Kia’s new EV4 hatch carve up the Nurburgring, nearly on two wheels [Video]

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Watch Kia's new EV4 hatch carve up the Nurburgring, nearly on two wheels [Video]

Kia’s upcoming entry-level EV has finally made its way to the famous Nurburgring for testing. The EV4 hatch was spotted ripping across the track, nearly on two wheels at one point, as Kia preps for its big debut.

According to Kia, the EV4 is “an entirely new type of EV sedan. ” It was first unveiled last October during Kia’s first annual EV Day, alongside the EV3 and EV5 as part of its new low-cost lineup.

The EV5 launched in China last year, while the EV3 is already rolling out in Korea and Europe. Next up, we will finally see the production version of the EV4.

Although its four-door format suggests it’s a sedan, Kia said the EV4’s bold design is a symbol of the company’s innovation. Its low nose, long-tail silhouette, and added roof spoiler give it an almost racecar-like feel.

With its official debut approaching, Kia’s EV4 has been spotted out in the wild several times. Last week, it was caught testing in the US for the first time.

A hatchback model has also been spotted. It was first caught on European roads this summer and in the US earlier this month.

Kia-EV4-Nurburgring
Kia EV4 (back) showcased alongside EV9 (left) EV3 (middle), and EV5 (right) (Source: Kia)

Kia EV4 hatch takes on the Nurburgring as debut looms

After the EV4 was spotted racing across the Nurburgring for the first time, we are getting our best look yet at the upcoming Kia model.

The video from CarSpyMedia shows the EV4 hatch carving up sections of the track. Several times, you can see the EV4 is being pushed to the limits, nearly going up on two wheels.

Kia EV4 hatch testing at Nurburgring (Source: CarSpyMedia)

However, with a low center of gravity and likely added stabilization tech, the EV4 appears to handle it with ease. You can also see the difference between the sedan model and the hatchback, with the bulky backside.

As it takes on the track, it almost looks like the 576 hp EV6 GT, Kia’s fastest and most powerful car. At least for now.

Kia-EV4-hatchback
Kia EV4 sedan concept (Source: Kia)

Kia is expected to officially reveal the EV4 by the end of the year, with deliveries starting in 2025. Prices are expected to be in the $30,000 to $40,000 range. The hatchback model is likely aimed at Europe, but it could also find a market in the US as buyers drift toward more efficient options.

Ahead of the LA Auto Show later this week, Kia is teasing five new vehicles for the US, at least one being an EV. Will it be the EV4? EV3?

Source: CarSpyMedia

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Elon Musk hints at Tesla making bigger electric cars, but don’t hold your breath

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Elon Musk hints at Tesla making bigger electric cars, but don't hold your breath

Elon Musk is hinting at Tesla making bigger electric cars, but you shouldn’t hold your breath as it’s not the first time he said that.

In the last few hours, Musk responded to two fans on X, asking Tesla to build bigger vehicles to support larger families.

Musk often promotes the idea of having bigger families as he is afraid of declining populations due to low birth rates in some countries.

With the first one, the CEO responded with a simple “OK,” and with the other, he elaborated a bit more by referencing the recently unveiled Tesla Robovan and “some other things”:

Musk appears to be hinting at Tesla’s work on a bigger electric vehicle that has yet to be unveiled.

While interesting, it’s hard to give too much weight to the comment, considering Musk claimed that Tesla has been working on a higher passenger capacity vehicle for years.

A “high passenger-density urban transport” vehicle has been in Tesla’s official product roadmap since 2016 and has yet to be unveiled, unless you count the Robovan unveiled last month, but that’s completely attached to Tesla’s self-driving effort as the vehicle has no steering wheel or pedals.

As part of Tesla’s shift toward autonomous driving, the automaker has pulled back plans for several new electric vehicle programs in favor of those without any driver inputs, like Cybercab and Robotvan.

Musk has also discussed the possibility of Tesla making an electric van on several occasions in the last few years.

Tesla is expected to soon unveil two new vehicles to be launch next year, but those are based on the Model 3 and Model Y and therefore, they aren’t likely to be bigger vehicles.

Electrek’s Take

Like most things Elon says lately, it goes in my “I’ll believe it when I see it” folder.

That said, I think an electric van that can be configured for cargo, camper, or passenger, would make a ton of sense in Tesla’s vehicle lineup.

Of course, it’s harder to get the greenlight for a vehicle program like that if your CEO is perpetually convinced that the company is on the verge of achieving self-driving and making steering wheels obsolete.

I’m more of the opinion that Tesla should have played it more careful and continue working on growing its human-driveable EV lineup while working on self-driving.

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Penske Truck Leasing kicks off a US rooftop solar rollout in Illinois

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Penske Truck Leasing kicks off a US rooftop solar rollout in Illinois

Penske Truck Leasing is rolling out rooftop solar on its US truck leasing, rental, and maintenance buildings, starting in Illinois.

Penske Truck Leasing, which offers an electric truck fleet leasing program, wants to cut emissions and save energy, so it’s activated its first rooftop solar system at its new facility in Channahon, Illinois (pictured). The 200 kW system is expected to generate about 80% of the building’s energy needs, and the rest will be supplied by the local utility.

The next Penske Truck Leasing rooftop solar system to come online will be in Grand Rapids, Michigan, “in the coming months,” followed by another in Linden, New Jersey, in 2025. All three of these new buildings are part of Penske’s LEED building program, which is designed to reduce energy use and promote sustainability.

Seven of Penske’s existing facilities in California will also get solar retrofits. These locations, which include Fresno, Hayward, La Mirada, National City, Riverside, San Diego, and San Leandro, are expected to generate about 600 kW of renewable energy in total.

Penske has teamed up with Sunrock Distributed Generation under a power purchase agreement to make the California upgrades happen. The company is also working with ForeFront Power, based in San Francisco, as its lead consultant for the solar rollout.

On average, these solar-powered Penske facilities will generate around 1 million kWh of renewable energy each year, preventing about 442 metric tons of CO2 emissions annually. That’s equivalent to the amount of energy needed to power nearly 90 homes for a year.

Drew Cullen, senior vice president of fuels and facility services at Penske, highlighted the significance of this move, noting:

Our solar program is an important piece of our renewable energy strategy, and ForeFront Power continues to be an outstanding partner in helping us bring these projects to fruition.

These investments will allow us to directly generate our own renewable energy to power our locations and continue to support our customers with sustainable solutions.

Penske Truck Leasing, part of Penske Transportation Solutions, is headquartered in Reading, Pennsylvania, and operates over 437,000 vehicles across North America, with nearly 1,000 maintenance facilities and more than 2,500 rental locations. Its investment in solar power is a key part of its broader sustainability strategy to cut emissions and reduce reliance on traditional energy sources.

Read more: Penske and Hitachi just launched a big electric truck charging pilot


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