At Ti Automatic Transmission Fluids: Mti TBB Martin Tabbey

Automatic Transmission Fluids
Automatic A t ti Transmission Fluids

Martin T bb M ti Tabbey
2 ATI Confidential
201 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 1 1

ATF- Allison Transmission Fluids

Topics
ATF Function & Characteristics ATF Basestocks ATF Additives ATF Degradation ATF Types Transmission Fluid Analysis
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ATF Function And Characteristics

Transfer of hydraulic pressure Actuation of valves & clutch systems Sufficient kinematic viscosity Flow at low temperatures Foam & aeration control Control of wear, corrosion, and seal swell Friction balance for smooth shifts (function of slip speed) Friction durability Thermal stability/Oxidation Resistant
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Protection of mechanical components
Transfer of torque Control of clutch friction Dissipation of heat from clutches, torque converters, and retarders


Topics
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API Basestock Categories

The American Petroleum Institute (API) has grouped base oils by % Saturates, Viscosity Index and Sulfur Content
GROUP I Mineral based; refined from crude
Solvent dewaxed
GROUPS II & III Mineral based; refined from crude

Hydro-cracked, hydro-treated and isomerized
GROUP IV - Synthetics
Constructed from simple hydro-carbons reacted together to form decene chains. Pure H-C structure (PAO - polyalphaolefin) Excellent oxidation resistance and low temperature properties
GROUP
I II III IV
Saturates(%)
<90 >90 >90 PAO
ViscosityIndex
80 120 80 120 >120
SulfurContent(%)
>0.03 <0.03 <0.03
6 ViscosityIndex(VI)=rateofchangeinviscositywithagivenchangeintemperature.
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Formulating to Viscosity Targets

Decreasein Viscosity@40C 36kcP 35kcP
(<10,000cPusually requiresGroupIV)
Base Stock Type Group I Group II p Group III Group IV (PAO)
DecreaseinVI Improvers ~20% ~10% NoVIImprovers
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Topics
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ATF: Generic Composition

Note: TES 295 oils do not contain Viscosity Index (VI) Improvers
Inhibitors Inhibitors b o s
Oxidation
Base Oils (80 90%) (80-90%) VI Improver (5-15%) Dispersants (2-8%) Inhibitors (0.5-2.5%) Seal Swell Agents (0-3%) Friction Modifiers (0.2-0.8%)
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Rust Corrosion Wear EP Wear Foam/Air Entrainment
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ATF fluid specifications are established by OEMs and define performance criteria. criteria Additives are blended with base oils to meet desired performance
ATF Additives
Viscosity Index Improvers F i ti M difi Friction Modifiers
Polymers added to increase viscosity at higher temperatures Control the transfer of torque in clutches/shift feel
Rust And Corrosion Inhibitors

Prevent corrosion of metal components from oxidation
Anti-Wear
Chemically react with metal surfaces to form protective film
Dispersant , Detergents & Anti-Oxidants

Sludge and varnish control; oxidation control
Seal Swell Agents g

Control swelling, hardness, tensile strength of elastomers
Anti-Foam Agent
Prevents excessive foaming and air entrainment Its a balancing act! Too little or too much of any one component can 10 mean the difference between success and failure of the ATF
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Topics
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ATF Degradation g
Oxidation Chemical Change
Fluid oxidation is a chemical reaction
Much like rust is a chemical reaction between iron and oxygen Base oil breaks down
Air mix and temperature accelerate the reaction Fluid thickens and becomes more acidic Primary indicator
TAN (Total Acid Number) increase measured in Mg KOH/g M KOH/
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1 201 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 1 1

ATF Degradation g
Oxidation Effects Of Oxidation
Increased sludge and varnish deposits
Cl Clogged filt / l d filters/solenoids id
Decreased shift quality and clutch durability I Increased component wear d t Rule of thumb:
O id ti rate (reaction rate) doubles for every Oxidation t ( ti t ) d bl f 10 degree Celsius increase in sump temperature
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Oxidation
FluidA
TotalAcidNu umber (TAN)
Rate is a function of time, temperature (duty cycle), and fluid quality l ) d fl id lit
Used Fluid
Initial (fresh fluid)
FluidB
TimeinService (DrainInterval) Time in Service (D i I t l)

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Physical Changes
Viscosity Index (VI) Improver Sheardown

Viscosity Index (VI) Improvers are polymers added to base mineral oils to maintain viscosity at higher temperatures These polymers are tightly coiled at low temperatures and have little affect on the base stock oil viscosity and uncoil as temperature increases to increase viscosity If not present: Oil would thin out at high temperature or not flow in very cold environments
With VI Improver
Viscosity
VI = 110 VI = 90
40 100
Viscosity Gain
Temperature (C)
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Viscosity Index (VI) Improver Sheardown Physical Changes

(contd)
Kinematic viscosity decreases with extended use y

VII polymers are physically cut up in gear meshes, bearing contact areas, torque converter vanes, pump vanes, etc. vanes etc Sheardown - permanent viscosity loss (caused by shearing of VII polymers)
Oil shear reduces oil pump efficiency resulting in reduced cooler flow Oil shear reduces fluid film resulting in reduced Oil gear and bearing life
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Viscosity Index (VI) Improver Sheardown
Viscosity at 100C (c cSt)
High stress zone g st ess o e (gear mesh, bearing contact zone)
VI Sheardown (30% - 40% loss)
VII polymer (intact)
Scissored polymer Time
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TES 389/TES 295 Performance Comparison

TES295ApprovedProducts TES295ApprovedProducts
(shearandoxidationstable)
V Viscosit ty
Sheardown Sh d
(viscosity loss; thinning)
TES389ApprovedProducts TES389ApprovedProducts TES 389 Approved Products
Oxidation
(viscosity growth; thickening)
TimeinService(DrainInterval)
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TES 295 Fluids 295

Outperforms Other Fluids On Every Level
No shear down Protects transmission components Resists oxidation Extremely good low temperature properties Extends drain intervals Improves vehicle uptime Increases life cycle value Extended Transmission Coverage
Only valid with a TES 295 fluid
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TES 295 Approval Number
AN-011001 AN-031002 AN-031003 AN-031004 AN-051005 AN 071006 AN-071006 AN -101007
Approved Marketer
Castrol Heavy Duty Lubricants BP Lubricants Cognis Corporation International Truck & Engine Company ExxonMobil Lubricants and Petroleum Specialties Company John Deere & Company Volvo Trucks North America
Product Brand Name

TranSynd Autran Syn 295 Emgard 2805 Fleetrite Synthetic ATF Mobil Delvac Synthetic ATF HD SynTran Bulldog Synthetic ATF
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Topics
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ATF Types
DEXRON
General Motors specification
DEXRON III & VI are no longer approved fluids l d fl id in any Allison products due to seal compatibility issues
MERCON
Ford Motors specification
TO-4
Caterpillar Specification
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Allison Specifications TES 228 (C4) TES 439

Off-Highway transmissions only. No longer accepting new fluids R l Replaces TES 228
ATF Types yp
Heavy duty diesel engine oil & higher viscosity ATFs
TES 353
Synthetic fluid Off-Highway only fluid, Off Highway

TES=TransmissionEngineeringSpecification
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Allison Specifications (contd) TES 389

Mineral based fluid for On-Highway transmissions only Acceptable non-TES 295 fluids Synthetic fluid for On-Highway transmissions only y Synthetic fluid for Hybrid transmissions
TES=TransmissionEngineeringSpecification
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ATF Types
TES 295 295 TES 468


Topics
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Transmission Fluid Analysis y

Overview Fluid Analysis Evaluates Overall Health Of Transmission Fluid And Transmission System Allison Recommends Fluid Analysis As Primary Method To Determine Fluid Change Intervals I t l Fluid Change Intervals May Differ Due To:
Local conditions Severity of operation/duty cycle
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Overview SIL 17 TR 96 17-TR-96
Provides oil sampling procedures/guidelines
I Th Ab In The Absence Of A Fl id A l i Fluid Analysis Program:

Follow fluid change intervals Use prognostics if enabled p g
SIL 10-TR-99
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Overview GN2055EN
Technicians Guide; Automatic Transmission Fluid Understanding/Analysis Understanding/Analysis

Use this document as a fluid analysis reference
Allison Uses Fluid Analysis Kits Provided By Polaris Laboratories LLC

P/N 29537805
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Polaris Laboratories Metal Analysis
24 elements analyzed
Wear metals Contaminant metals Additi metals Additive t l
Reported in parts per million (ppm)
Water Content
R Reported i percent (%) d in
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Overview Viscosity
Reported in Centistokes (cSt)
TAN (Total Acid Number)

R Reported i M KOH/ t d in Mg KOH/g
At 40 C and 100 C
Glycol Test All Samples Comments And Severity Status

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Sample Report
Severity is based on report Comments not on individually flagged results
Customer inputs
Condition based standardized comments Metal Analysis
Physical & Chemical Tests 100% Glycol Test
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Condition Base Standardized Comments
Polaris Report Customer Feedback

Computer generated comments from Polaris are based on ATD limits for oil degradation (TAN (TAN, viscosity, and glycol/water content) Oil change recommended if: T Transmission teardown recommended if i i t d d d if:
Glycol is positive and/or Water 0.2%
TAN 4.0 (both TES 389 and TES 295 fluids) 100C Viscosity 6.0 cSt TES 295 & 5.5 cSt TES 389
Note:PerAllisonpolicy,wearmetalsaremeasuredandreportedbutarenotused N P Alli li l d d db d toassessthequalityofthetransmissionfluidortheconditionofthetransmission

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Glycol T L b R Gl l Test Lab Results l Background
Glycol
T i l ingredient i antifreeze Typical i di t in tif Typically mixed with water 50/50
Forms a liquid coolant coolant
Glycol additives
Includes various potassium and sodium compounds
Indicators that glycol may be present in ATF Both shown on the Polaris report
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Glycol Test Lab Results Background (contd)
Risk of sodium and potassium precipitating out of fluid Early 2010

Subsequently removed by transmission filter
Transmission fluid sampling and analysis kit revised to include glycol check on every oil sample
ASTM D2982 Glycol Test
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Glycol Test Lab Results False Positive Glycol Lab Results
ASTM D2982 test for glycol is inherently susceptible to false positive results New oil chemistry may cause false positives
Associated with oil additive manufacturing Associated with base oil refining
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Glycol Test Lab Results False Positive Glycol Lab Results (contd)
Additives often burn off during service
Later tests come back negative
New ATF placed into service for a short time may initially test positive for glycol
If an oil analysis report shows glycol is positive, plus sodium and potassium readings are < 10ppm
Check new/unused fluid sample for glycol
Determines if fluid is susceptible to false positive reading
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Glycol Test Lab Results Negative Glycol/Water Lab Results With Known Glycol And/Or Water Content
S Several field instances where fl id analysis l fi ld i t h fluid l i indicated negative glycol/water results
Subsequent transmission teardown and inspection revealed obvious contamination
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Glycol Test Lab Results Negative Glycol/Water Lab Results With Known Glycol And/Or Water Content (contd)
P Possible causes ibl
Oil sampling procedure error
Glycol/water had time to separate from ATF System should be operating or immediately after shut down
Water may burn off during use/evaporate Error in interpreting lab results
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Glycol Test Lab Results Negative Glycol/Water Lab Results With Known Glycol And/Or Water Content (contd)
If oil analysis shows glycol i negative plus il l i h l l is ti l sodium and/or potassium readings are greater or equal to 10ppm
Inspect the unit for rusted hardware
If evidence of rust is present, unit has most likely been p , y contaminated with glycol
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Reportbelowshowsnegativeglycol/waterresult Transmissioninspectionshowsobviousglycol/watercontamination
Transmission Fluid Analysis
NegativeglycolreadingwithNa i l l di ih &K10ppm
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Glycol/Water Mixed With ATF
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Automatic Transmission Fluids

Automatic A t ti Transmission Fluids

Automatic Transmission Fluids

ATF- Allison Transmission Fluids

Automatic Transmission Fluids

ATF Function And Characteristics

Protection of mechanical components

Automatic Transmission Fluids

ATF- Allison Transmission Fluids

Automatic Transmission Fluids

API Basestock Categories

GROUPS II & III Mineral based; refined from crude

Automatic Transmission Fluids

Formulating to Viscosity Targets

Base Stock Type Group I Group II p Group III Group IV (PAO)

DecreaseinVI Improvers ~20% ~10% NoVIImprovers

Automatic Transmission Fluids

ATF- Allison Transmission Fluids

Automatic Transmission Fluids

ATF: Generic Composition

Rust Corrosion Wear EP Wear Foam/Air Entrainment

Automatic Transmission Fluids

Viscosity Index Improvers F i ti M difi Friction Modifiers

Rust And Corrosion Inhibitors

Dispersant , Detergents & Anti-Oxidants

Seal Swell Agents g

Automatic Transmission Fluids

ATF- Allison Transmission Fluids

Automatic Transmission Fluids

Automatic Transmission Fluids

Automatic Transmission Fluids

TotalAcidNu umber (TAN)

Initial (fresh fluid)

TimeinService (DrainInterval) Time in Service (D i I t l)

Automatic Transmission Fluids

Viscosity Index (VI) Improver Sheardown

Automatic Transmission Fluids

Viscosity Index (VI) Improver Sheardown Physical Changes

Kinematic viscosity decreases with extended use y

Automatic Transmission Fluids

Viscosity Index (VI) Improver Sheardown

Viscosity at 100C (c cSt)

High stress zone g st ess o e (gear mesh, bearing contact zone)

VI Sheardown (30% - 40% loss)

VII polymer (intact)

Scissored polymer Time

Automatic Transmission Fluids

TES 389/TES 295 Performance Comparison

(viscosity loss; thinning)

TES389ApprovedProducts TES389ApprovedProducts TES 389 Approved Products

(viscosity growth; thickening)

Automatic Transmission Fluids

TES 295 Fluids 295

Automatic Transmission Fluids

Product Brand Name

Automatic Transmission Fluids

ATF- Allison Transmission Fluids

Automatic Transmission Fluids

Automatic Transmission Fluids

Allison Specifications TES 228 (C4) TES 439

Heavy duty diesel engine oil & higher viscosity ATFs

Synthetic fluid Off-Highway only fluid, Off Highway