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Why is there a huge bulge in 2021 Lexus IS 300 AWD's driver footwell? We explain

After an initial turn a few weeks ago for the 2021 Lexus IS first drive review, the revised luxury sedan has returned to the Autoblog garage for a second look. This middle-of-the-road IS 300 AWD pairs a 260-horsepower V6 with a six-speed automatic transmission and four driven wheels, and frankly it's the least interesting way to spec out the redesigned sedan. While there are cars in this segment designed to get a performance boost from their all-wheel-drive systems even in dry conditions, the IS isn't one of them. Adding insult to injury, you get stuck with a cramped driver-side footwell care of the engineering shenanigans that went into making this system possible.  While we've mentioned this particular compromise before, we rarely touch on the reasons why it exists in the first place. The fundamentals are fairly obvious; the standard IS utilizes a longitudinal, rear-wheel-drive powertrain. As is typical with this configuration, the transmission sits in a tunnel beneath the center console. This arrangement works just fine, provided you don't need to power the front wheels.  To do so in a traditional car like the IS requires a literal end-around maneuver involving the engine and transmission, which we've diagrammed for you below care of MSPaint. This is a bit simplified for the sake of this write-up, and it should be noted that this is not the only way to implement AWD in an inherently RWD platform, but it illustrates how the power for the front axle (red) and rear axle (blue) flows from the transmission to the drive wheels. To get juice flowing to the front axle, Lexus had to add a parallel output shaft, exiting the transmission from the front with enough clearance for the bell housing and engine, which sits between the transmission and the front differential. This requires quite a bit of lateral reach, meaning the housing has to extend much farther out than usual to accommodate it (yellow arrow). As a result, the all-wheel-drive transmission looks a lot like a sci-fi gun with a chunky drum magazine hanging off the side of it. The hump (above right) in the footwell is there to clear this protrusion. This basic configuration isn't unique to Lexus. In fact, if you look at a BMW xDrive cutaway, it's similar. So, why no "hump" in other cars? There are multiple factors, but to boil it down to what is most relevant, it's a combination of the resulting shape of the Lexus transmission housing and the size of the IS chassis.

Growing demand could bring more body-on-frame off-roaders to the Lexus range

Car-based crossovers are outselling truck-derived SUVs by a wide margin, but Lexus still sees a strong demand for models that offer true off-road capability. It hinted that it could soon increase its presence in this segment. Toyota's luxury division entered 2021 with two body-on-frame SUVs in its range: the Land Cruiser-based LX (pictured) and the smaller, more affordable GX. Neither is a high-volume model, but both fared shockingly well in 2020. LX sales in the United States fell by 4.4% to 4,512 units, which is a great result in a year when double-digit declines were common, and GX sales increased by 9.9% to 28,519 units. Clearly, off-roaders are in demand. "What we have seen at Toyota is that there's so much of an appetite for [off-roading] that I see that [moving into] the Lexus brand as well. There is an appetite, a customer desire, a customer push to see all brands giving them more options. I think it would be silly for Lexus not to travel down that path," explained Jack Hollis, the head of automotive operations for Toyota's North American division, in an interview with Automotive News. He added that his team has identified a "white space" in the Lexus range that could be filled with an additional body-on-frame off-roader. He didn't reveal precisely what he has in mind, but there are a few possibilities we can rule out. We know Toyota is wrapping up the development of the next-generation Land Cruiser, even if the SUV might not be sold in America, and seeing a next-generation LX seems like a given, but we don't think that's what Hollis was referring to. Moving into the space above the LX with an even bigger truck is highly unlikely. Similarly, the idea of a Lexus-badged SUV aimed at the Jeep Wrangler and the Ford Bronco is neat but unrealistic. Ford's hotly-anticipated born-again off-roader has captured the attention of executives, however. "Holy cow! They sold out that thing, and I think there's a strong market out there for authentic off-road chops and credibility. We're seeing that with [the Toyota] 4Runner as well. I don't think it's any secret that [the 4Runner] is not all that new, but it continues to set records, and it continues to grow volume," pointed out Lexus brand head Andrew Gilleland in a separate interview with Automotive News. Could we see a Lexus-specific version of the 4Runner? We certainly wouldn't rule it out, especially because making an upmarket variant of the SUV would help Toyota leverage the benefits of economies of scale.

Toyota investing $750M, adding 600 jobs at 5 U.S. plants

BUFFALO, W.Va. — Toyota on Thursday announced it is investing an additional $750 million at five U.S. plants that will bring nearly 600 new jobs, including the production of two hybrid vehicles for the first time at its Kentucky facility. It marks yet another expansion of the Japanese automaker's U.S. presence, bringing to nearly $13 billion the amount it will spend by 2021. The latest investments are at facilities in Alabama, Kentucky, Missouri, Tennessee and West Virginia. Those same facilities were part of a 2017 announcement by Toyota for a $374 million investment to support production of its first American-made hybrid powertrain. Toyota Motor North America CEO Jim Lentz said the latest investments "represent even more examples of our long-term commitment to build where we sell. By boosting our U.S. manufacturing footprint, we can better serve our customers and dealers and position our manufacturing plants for future success with more domestic capacity." Toyota's Georgetown, Kentucky, facility will get a $238 million infusion to produce hybrid versions of Lexus ES 300 sedans starting in May and the Rav4 SUV starting in January 2020, the company announced. It also includes $288 million to increase annual engine capacity at Toyota's Huntsville, Alabama, facility. The plant will add 450 jobs to accommodate new four-cylinder and V6 engine production lines. Last year Toyota and Mazda announced plans to build a $1.6 billion joint-venture plant in Huntsville that will eventually employ about 4,000 people. Toyota also is spending $62 million on equipment to boost production of Toyota and Lexus cylinder heads at its Bodine Aluminum facility in Troy, Missouri, as part of its cost-saving New Global Architecture production strategy to share common parts and components among different vehicles. A $50 million expansion and equipment upgrade at its Bodine plant in Jackson, Tennessee, will add 13 jobs and produce engine blocks while doubling the capacity of hybrid transaxle cases and housings. And Toyota will add 123 jobs and spent $111 million to expand its plant and purchase equipment in Buffalo, West Virginia, to double the capacity of hybrid transaxles. Previously, Toyota also announced a $600 million investment at its Princeton, Indiana, plant to increase the capacity of its Highlander SUV and to incorporate the new production strategy, and $170 million to launch the 2020 Corolla on a new production line in Blue Springs, Mississippi.