HORSE begins production of new DB49 transmission in Seville plant

HORSE, a division of Horse Powertrain and a leader in innovative and low-emission powertrain systems, has started production of the new ‘DB49’ transmission at its plant in Seville, Spain.

The new transmission is the first to be designed in-house by HORSE, and can be applied to plug-in hybrid passenger vehicles. The DB49 gearbox is a clutchless, 15-speed unit, producing a maximum torque of 470Nm and a peak output of 35kW. It features two electric motors for maximum versatility across a range of driving conditions.

Weighing just 99kg, the new transmission will first feature in the plug-in hybrid models of the Renault Rafale SUV.

The new DB49 is controlled via HORSE’s Power Electronics Box (PEB), a cutting-edge integrated electronics unit. The PEB, produced at HORSE’s Aveiro plant, includes optimized hardware and software to significantly reduce the use of battery charge.

Patrice Haettel, Chief Executive Office at HORSE, said: “The start of DB49 production in Seville is more than just a technological milestone; it reaffirms the strategic role HORSE plays in the global mobility ecosystem. The DB49 is a hybrid gearbox—a progression of the DB35—designed for the engine used in the Renault Rafale. It is the result of relentless innovation aimed at developing technological solutions for a more responsible and sustainable future while meeting the demands of the global market.This is innovation that doesn’t just seek to invent but to continuously improve what we are already doing.”

Javier Bernaldez Garcia, Plant Director at HORSE Seville, said: “Our Seville team continues to push at the forefront of transmission innovation, and DB49 is no exception. Matching performance and efficiency, this new transmission will be a benchmark for transmission systems for many years to come. We’ve invested resources to ensure the plant remains state-of-the-art, ensuring quality and durability of every unit manufactured.”

The new transmission will be produced at HORSE’s Seville plant. Employing over 1,000 technicians and engineers, HORSE Seville is the company’s main plant for hybrid transmission production – while also producing critical units for the ICE value chain. More than 60% of the plant’s output is exported beyond Spain.

The plant has produced transmissions for more than 60 years and built more than 32 million units over its lifetime. In 2024, HORSE Seville produced 666,670 transmissions. This includes the first generation of the plant’s hybrid gearboxes, including DB49.

Shifting to hybrid gearbox production represented one of the biggest transformations in the plant’s history, requiring the creation of two new assembly lines and the adaptation of several machining lines.

To ensure stringent quality control, HORSE Seville has also invested in a state-of-the-art test bench to provide world-class acoustic, vibrational, and functional analysis of mechanical and electronic components. The plant has also adopted a number of ‘data-centric’ processes to streamline access to documentation, testing data, and individual unit information.