Sr. Chassis Driveline Engineer

Sr. Chassis Driveline Engineer

Hyundai America Technical Center, Inc (HATCI) is seeking a Senior Chassis Engineer specializing in driveline systems for U.S. pickup trucks and off-road vehicles.

In this role, one will lead the design, development, and validation of critical driveline components and systems – including 4WD/AWD systems, solid axles, half-shafts, driveshafts (prop shafts), and advanced differentials (such as torque vectoring systems and electronic locking differentials). The ideal candidate is a seasoned engineer with 8–10 years of experience in automotive chassis/driveline engineering, capable of taking concepts from initial design through production launch. One will utilize their expertise in CATIA V5 and industry standards to ensure robust, innovative solutions that meet performance, safety, and durability requirements for rugged truck and off-road applications. This position also demands strong leadership skills, cross-functional collaboration, and a passion for mentoring junior engineers while remaining open to continuous learning and development.

Candidates applying for positions with Hyundai-Kia must be legally authorized to work in the United States, verification of employment eligibility will be required at the time of hire.

WHAT YOU WILL DO

• Driveline Design & Development: Lead the engineering of driveline systems and components for 4WD and AWD vehicles, including transfer cases, power transfer units, and related mechanisms, to achieve performance and reliability targets.
• Axles and Shaft Components: Design and develop axle assemblies and shaft components (e.g. solid rear axles, front/rear half-shafts, prop shafts and driveshafts), ensuring they can withstand high torque loads and off-road conditions while meeting weight and durability goals.
• Differentials & Torque Management: Engineer advanced differential systems (front and rear), including limited-slip units, torque vectoring differentials, and electronic locking differentials, to optimize traction, handling, and stability for both on-road and extreme off-road use.
• Validation & Testing: Define, Support and execute comprehensive DVP&R (Design Verification Plan & Report) test plans for driveline components. Support bench tests, dynamometer tests, and vehicle field tests (on-road and off-road) to validate performance, durability, and NVH characteristics. Analyze test data and drive iterative design improvements based on results.
• Problem Solving: Monitor and troubleshoot driveline issues throughout the development cycle. Conduct root cause analysis for any failures or performance gaps (using tools like 5-Why, Fishbone, etc.) and implement effective design or process changes to resolve issues promptly.
• Cross-Functional Collaboration: Work closely with cross-functional teams – including Vehicle Dynamics, Suspension, Powertrain, NVH, Manufacturing, and Quality – to ensure seamless integration of the driveline systems into the overall vehicle. Coordinate packaging studies, interfaces, and systems integration to avoid conflicts and achieve performance objectives.
• Supplier Coordination: Liaise with OEM and Tier 1 suppliers for driveline components. Review and approve supplier designs or design changes, ensuring they meet all specifications and quality standards. Oversee supplier development activities and support the sourcing and manufacturing process for driveline parts.
• Standards & Compliance: Ensure all designs comply with relevant regulatory and industry standards, including Federal Motor Vehicle Safety Standards (FMVSS) and applicable SAE standards for chassis and driveline systems. Incorporate these requirements into the design specifications and validation plans.
• Documentation & CAD Modeling: Create and maintain detailed engineering documentation. Develop 3D models and 2D drawings in CATIA V5 for all components and assemblies, including applying GD&T as needed. Author and update technical specifications, DFMEAs (Design Failure Mode and Effects Analysis), design review materials, and engineering reports to support program milestones and production readiness.
• Leadership & Mentoring: Mentor junior engineers by sharing best practices and guiding them through problem-solving. Foster a culture of knowledge-sharing and continuous improvement. Demonstrate a willingness not only to teach others but also to be trained – staying receptive to new ideas, tools, and methodologies that can enhance team capabilities.
• Innovation & Continuous Improvement: Stay up-to-date with emerging technologies and trends in driveline and off-road vehicle systems. Drive innovation by proposing new solutions or improvements (such as novel torque management systems or lightweight materials) to keep the company’s truck and off-road platforms at the forefront of performance and reliability. 

• Travel up to 20% of the time, both domestically and internationally

WHAT YOU WILL BRING TO THE ROLE

• Basic Qualifications:
• Bachelor's degree in mechanical, automotive, or a related field of engineering
• 8-10 years of experience in chassis and suspension design, with a focus on driveline systems
• Proficiency with 3D modeling and drafting via CATIA V5. Able to create complex part models, assemblies, and engineering drawings with proper GD&T annotation. Familiarity with PLM systems to manage CAD data and BOMs.
• Proven experience in an automotive OEM or Tier-1 supplier environment, following formal development processes (APQP, DFMEA, PFMEA, PPAP, etc.)
• Deep knowledge of driveline components and principles – including four-wheel-drive/all-wheel-drive systems, axle design, driveshaft/prop shaft engineering, and differential gearing (open, limited-slip, locking, torque vectoring). Capable of performing detailed component design and analytical calculations for strength, fatigue, and performance.
• Familiarity with FMVSS (Federal Motor Vehicle Safety Standards) and relevant SAE standards as they apply to chassis and driveline components (e.g., safety, durability, and noise standards). Ability to design components that meet or exceed these regulatory requirements and industry best practices.
• Experience developing and executing component and system validation tests (DVP&R). Strong analytical skills in interpreting test results and correlating them with simulations or expected performance. Knowledge of CAE tools (FEA, multi-body dynamics, or drivetrain simulation software) to support design decisions is a plus.
• Excellent troubleshooting and problem-solving abilities. Proficient in root cause analysis techniques for addressing engineering issues in prototypes or production (e.g., failure analysis, FMEA updates, 8D problem resolution).
• Demonstrated ability to interpret test data, perform data-driven design decisions, and apply engineering analysis
• Flexibility with program and process changes, as Hyundai/Kia/Genesis is willing to make late changes to satisfy customer needs
• Good written, oral, interpersonal, and leadership skills
• Proficiency in Microsoft programs, such as Excel, Outlook, PowerPoint, and Word
• Excellent time management, self-management, and organization skills
• Ability to remain current with new technologies and best practices
• Willingness to attend training, workshops, or conferences to enhance skills
• Ability to diagnose and resolve complex, section-related issues 
• Valid Driver's License and a satisfactory driving record

• Preferred Qualifications:
• Master's degree in mechanical, automotive, or a related field of engineering
• Experience working on pickup trucks, SUVs, or off-road vehicles and knowledge of their specific driveline systems, durability, set up, articulation, etc.
• Experience working on electrucal or hybrid vehicle suspension systems
• Experience performing advanced suspension modeling, simulations, and optimization via CAE tools (e.g., ANSYS, Nastran, MATLAB/Simulink, etc.)
• In-depth understanding of vehicle ride & handling, off-road performance, and NVH considerations specific to heavy-duty trucks and SUVs
• Knowledge of solid axle and independent suspension systems in off-road conditions
• Familiarity with CATIA V6 and PDM (i.e., ENOVIA V6) or Windchill PLM systems
• Professional Engineer (PE) license or Six Sigma certification

WHAT HYUNDAI CAN OFFER YOU

• Zero-dollar Employee Premiums on Medical, Dental, and Vision for You and Your Family
• 100% Employer-paid Disability and Life Insurance
• Generous Paid Time Off, Including Vacation, Sick, and Abundant Holidays
• Hybrid Work Schedule
• Competitive Salaries
• A Global Environment that Fosters Diversity
• Retirement Savings and Planning Benefits
• Access to Health Savings Accounts and Flexible Spending Accounts 
• Flexible Work Hours

OTHER DETAILS

• Candidates applying for positions with Hyundai KIA must be legally authorized to work in the United States. Verification of employment eligibility will be required at the time of hire.
  • HATCI is an Equal Opportunity Employer including Disabled and Veteran. VEVRM Federal contractor.