1、 ENGINEERING MATERIAL SPECIFICATIONFLUID, AUTOMATIC TRANSMISSION, WSS-M2C919-E FRICTION MODIFIED, RED 1. SCOPE The material defined by this specification is a factory fill automatic transmission fluid composed of base fluids and additives. 2. APPLICATION This specification was released originally fo
2、r fluid used as a power transmission, hydraulic control, heat transfer and general lubricant in automatic transmissions requiring specific clutch and band frictional characteristics, specifically intended for engagement noise reduction and improved frictional retention characteristics. 3. REQUIREMEN
3、TS 3.0 STANDARD REQUIREMENTS FOR PRODUCTION MATERIALS Material suppliers and part producers must conform to the Companys Standard Requirements for Production Materials (WSS-M99P1111-A) 3.3 COLOR Dyed red (ISO 2049/ASTM D 1500 or DIN 51-578) Color Rating 6 - 7.5 Use the weight percent of Morton Chemi
4、cal Companys Automate Red B (or equivalent) necessary to produce a distinct red hue when one drop of fluid is placed on plain white paper. Perform similar test on fluid after 20,000-cycle durability test. Color number after 20,000-cycle test must match or exceed unused fluid color number by no more
5、than 1 whole number. 3.4 MISCIBILITY TEST No separation (FLTM BJ 120-03) 3.5 VISCOSITY 3.5.1 New Fluid kinematic viscosity at 100 C 7.2 8.2 mm2/s (ISO 3104 / ASTM D 445) 3.5.2 After 20 hrs KRL, kinematic 6.0 mm2/s, min viscosity at 100 C (ASTM D 445 / DIN 51350) 3.5.3 New Fluid Brookfield viscosity
6、at -40 C 10,000 +/- 3,000 mPa.s (ASTM D 2983) Date Action Revisions 2004 08 10 Revised Para 3.0 inserted; paras 3.1, 3.2, 3.23 paras 3.17 torque as a function of rpm and temperature. TABLE I BREAK-IN APPLY PRESSURE kg/cm20 SLIDING SPEED 180 RPM DURATION 20 min TEMPERATURE Test Head 120 +/- 2 C AERAT
7、ION RATE, cc/min 50 +/- 5 cc BATH TEMPERATURE 120 C TABLE II DURABILITY APPLY PRESSURE, kg/cm210 SLIDING SPEED 180 RPM DURATION To Failure TEMPERATURE TEST HEAD 155 +/- 2 C AERATION RATE cc/min 50 +/- 5 cc DURATION 50 mins BATH TEMPERATURE 145 C APPLY PRESSURE Kg/cm210 TABLE III DYNAMIC BATH TEMPERA
8、TURE C 145 +/- 5 C TEST HEAD TEMPARATURE C 155 +/- 5 C APPLY PRESSURE Kg/cm210 AERATION RATE cc/min 50 RPM 3600 ENERGY 20 KJ INTERVAL 20 DYNAMIC ENGAGEMENTS EVERY 50 mins TABLE IV TYPICAL CONDITIONS FOR micro-V DATA COLLECTION TEMPERATURE, BATH 120 C APPLY PRESSURE 10 Kg/cm2SLIDING SPEED 0-220 INTER
9、VAL - HRS. 4 hrs DATA ACQUISITION 1.90 SEC WITHIN 2.0 SEC. WINDOW TEMPERATURE, TEST HEAD 120 C NOTE: CLUTCH PLATE MEAN RADIUS IS 56.90 mm Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 8 of 20 ENGINEERING MATERIAL SPECIFICATIONWSS-M2C919-E 3.14.8 Summarized sequen
10、ce of operations: 1. Break-in for 20 mins. 2. Slipping mode for 50 mins. 3. 20 dynamic engagements. 4. Slipping mode for 50 mins. 5. 20 Dynamic engagements. 6. Slipping mode for 50 mins. 7. 20 Dynamic engagements. 8. vs. V data collection. 9. 6 Dynamic engagements. 10. Repeat sequence. 3.14.9 Failur
11、e Criteria: d/dv x 1000 -12 for a total of 250 hrs minimum. 3.15 CLUTCH FRICTION EVALUATION AND DURABILITY TESTS 3.15.1 Evaluation And Durability: Using friction plates with waffle-groove SD-1777 friction material, run six 4-plate packs, 200 cycles each, for evaluations and three 4-plate packs, 2000
12、0 cycles for durability, according to the procedure below. One pack is considered to be four steels and two friction plates arranged according to Figure 1 and referred to as the 4-plate pack. All torque trace information must be obtained using digitized data acquisition and must be acquired without
13、filtering or signal modification at no less than 1000 points per second. Part No. Friction Material XP-142976 Supplier BW SD-1777 C8AP-7B442-A (XP-143218) BW plates available from: Separator Plates available from: Request plates “_“ Request Steels “_“ Borg Warner Corp. Steel Part Corporation 700 S.
14、25th Ave. Attn: James Baldwin Bellwood, IL 60104 (734) 953-2410 Attn: Bruce Clay (708) 547-2744 Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 9 of 20 ENGINEERING MATERIAL SPECIFICATIONWSS-M2C919-E 3.15.2 Cleaning Procedure Prior to each durability test, the fixtu
15、re must be cleaned. After removing the front cover, the Spacer, Retainer Ring and Hub are removed. These parts are cleaned with Stoddards solvent, scrubbed with a non-metallic bristle brush or non-metallic scouring pad and rinsed. The inside of the test housing, attached ports and thermocouple conne
16、ctions are flushed with Stoddards solvent using a squeeze bottle. Thoroughly clean all crevices and ports in the housing where lubricant is likely to be trapped. Air-blow dry the cleaned parts and test housing. 3.15.3 Assembly Procedure. (See machine set up parameters) 3.15.3.1 Inspect rotating shaf
17、t seal (National No. 4471887) for deterioration and replace if necessary. Indication of seal failure or loss of flexibility is the escape of air past the seals. If this seal is replaced, also replace lip seals No. 1366236 and 3-21196 (both supplied by Greening Associates, Inc.) 3.15.3.2 Install clut
18、ch plate hub, snap ring, and clutch plate retainer. 3.15.3.3 Inspection of clutch plates prior to testing. A. Find the thickest spot of each plate and arrange the plates so the thick spots are distributed around the pack, for minimum thickness. B. Identify each plate by marking the top tooth with a
19、number, one through six in the sequence shown in the sketch. This number will be at the top when each plate is installed for test. C. Mark a tooth at approximately 120each way around from the numbered tooth on each plate. Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC
20、Page 10 of 20 ENGINEERING MATERIAL SPECIFICATIONWSS-M2C919-E D. Measure and record average overall pack thickness under a 14 kg load. E. Measure plate thickness as follows: At each of the three locations, 120apart, measure at two places, one near the inside, and one near the outside diameter. These
21、measurements will be labeled “initial“. F. Use micrometer, and keep the entire anvil within the friction contact area for each measurement. G. After the durability test repeat these measurements in the same order and at the same places, beginning at the numbered tooth. These measurements are labeled
22、 “final“. H. Subtract the “final“ measurements from the “initial“ measurements. Wear limit at any of the six places is 0.1524 mm. Average wear per plate is not to exceed 0.0762 mm. 3.15.3.4 Presoak clutch plates in test fluid for 5 minutes minimum and then install clutch plates in the test head in t
23、he order prescribed with plate rounded side facing operator. 3.15.3.5 Install packs into test head. Thermocouple is to be located at the mid point of the back-to-back plates of the 4-plate pack. 3.15.3.6 Install two spacers only between the cover and the outermost clutch plate to locate the thermoco
24、uple at the center of the test pack. 3.15.3.7 Check clutch plate pack free movement. Clearance is 0.70 +/- 0.13 mm. This measurement, made with a depth micrometer, is made between the head and outermost clutch plate while the pack is pressed into the head with finger pressure (about 1 kg) at the sit
25、es of measurements. 3.15.3.8 Install thermocouple between the 4 and 5 oclock position to within 1.0 mm of steel clutch plate annulus O.D. (without touching clutch plate). 3.15.3.9 Install new 0-rings on cover, if necessary. Print 134-D8 o-rings are Precision Seal No. 265 and No. 272 or equivalent. 3
26、.15.3.10 Attach cover and fasten with Ring-Bearing Support and Cover Retainer print 134-D18. 3.15.4 Lubricant Installation Attach reservoir line to housing port at 12 oclock position. Close all other housing ports. For SD-1777, the fill volume is 305 +/-5 mL. Open valve at 11 oclock position to allo
27、w air venting during filling. Close this valve when oil begins to overflow. Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 11 of 20 ENGINEERING MATERIAL SPECIFICATIONWSS-M2C919-E 3.15.5 Test Start-Up 3.15.5.1 Connect the instrumentation for measuring torque, press
28、ure, motor-speed, and thermocouple. Calibrate torque, pressure, and speed signals. (Note, if compression type load cell is used, calibrate torque with lever-arm tare included in calibration). 3.15.5.2 Set apply pressure to 275 +/- 5 kPa for SD-1777 3.15.5.3 Set release pressure to 75 kPa min. 3.15.5
29、.4 Open cooling fluid valve. 3.15.5.5 Set Timer to provide the following test-cycle sequence: SEQUENCE Event Duration Cumulative Time, s Operation 1 10.0 (T1)* 0 to 10.0 High speed (HS) motor on (force released) 2 5.0 (T1 + T2)* 10.0 to 15.0 Motor off, force applied 3 5.0 (T4)* 15.0 to 20.0 Motor of
30、f, force released 4 0.5 20.0 to 20.5 Static Drive (SD) motor on to engage static drive5 5.0 20.5 to 25.5 SD motor off, force released 6 0.5 25.5 to 26.0 SD motor off, force applied 7 5.0 26.0 to 31.0 SD motor on, force applied 8 5.0 31.0 to 36.0 SD motor off, force released * = Reference SAE Frictio
31、n Nomenclature Specification (SAE J1646) 3.15.5.6 Start temperature recorder 3.15.5.7 Start the timer (this engages the motor). 3.15.5.8 Check for leaks, operation of transducers and cycling event times. 3.15.6 Test Start-Up After Unscheduled Shutdown. 3.15.6.1 Repeat Test Start-Up sequence 3.15.4 w
32、ith fresh fluid and a new clutch pack. Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 12 of 20 ENGINEERING MATERIAL SPECIFICATIONWSS-M2C919-E 3.15.7 Test Operation. 3.15.7.1 Continue to repeat test cycle sequence for 20000 cycles (item 3.15.4.6). 3.15.7.2 Maintain
33、 fluid temperature during operation at 135 +/- 2 C. 3.15.7.3 Record Static Breakaway torque after clutch pack has been released (allowed to separate) for a 5 second soak time. Static breakaway speed to be 4.37 +/- 0.1 RPM 3.15.7.4 Two static breakaway measurements are required. Measure the first sta
34、tic breakaway 0.25 seconds after beginning of zero time. Zero time begins at threshold torque plus 5 N-m positive torque. Static breakaway torque shall be the mean of torque obtained during 50 ms interval centrally located about the 0.25 +/- 0.02-second point. Report the first torque as well as the
35、maximum torque measured between zero time and the 0.25 +/- 0.02-second time. 3.15.8 Required Recordings. 3.15.8.1 Record fluid temperature continuously. 3.15.8.2 Record apply pressure, and motor speed at 5 cycles to confirm proper test operation. 3.15.8.3 Record torque, apply pressure, and motor spe
36、ed during test cycle sequence at intervals indicated in Table I. 3.15.9 Test Results Required for Review. 3.15.9.1 Torque, apply pressure and motor-speed records per item 3.15.7.2 and 3.15.7.3. 3.15.9.2 Friction Data Requirement Sheet - see Table I. 3.15.9.3 Graph Static Breakaway, Low Speed Dynamic
37、, Dynamic coefficients and stop times per Table I as function of cycles. 3.15.9.4 Temperature chart obtained per para. 3.15.4.6. 3.15.9.5 Provide all torque traces required per Table I, page 8. 3.15.10 Test Criteria (Evaluation of 12 packs and Durability of 3 packs) 3.15.10.1 All required coefficien
38、ts shall be calculated using the mean of 5 measured values taken +/- 2 cycles around the specified cycle. The maximum and minimum torque of each range is to be reported with the coefficient of the specified cycle. Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 13
39、of 20 ENGINEERING MATERIAL SPECIFICATIONWSS-M2C919-E 3.15.10.2 All required midpoint dynamic coefficients measured at 1800 RPM shall fall within a range specified in TABLE V. Midpoint dynamics torque is to be a mean of torque obtained during the 50 ms interval centrally located about the 1800-RPM sp
40、eed. Upper and lower control limits to be established after review of data and data to be revisited annually for revisions. d1800 for SD-1777 = SEE TABLE V 3.15.10.3 All required low speed dynamic peak coefficients, calculated from the dynamic torque trace) shall fall within a range specified in TAB
41、LE V. The low speed dynamic measurement shall be the highest value for torque obtained within the last 50 ms of the torque measurement. The time of the measurement must be reported. SEE FIGURE 3, PAGE 18. - 0.05d max for SD-1777 = SEE TABLE V 3.15.10.4 Between 400 and 20000 cycles of operation, all
42、static breakaway coefficients must fall within the range specified in TABLE V. Static breakaway torque must be obtained after the clutch pack has been opened for 5 seconds following the dynamic engagement to allow the friction surfaces to attain temperature equalization. The static breakaway torque
43、values are to be measured at .25 seconds after the beginning of the static engagement. SEE FIGURE 4, PAGE 18. 0.25s 4.37 for SD-1777 = SEE TABLE V 0.0s 4.37 for SD-1777 = Rate & Report* * = Reference SAE Friction Nomenclature Specification (SAE J1646) 3.15.10.5 All required ratios of the low speed d
44、ynamic coefficient to the midpoint dynamic coefficient E/M, both obtained from the same dynamic engagement trace, shall fall in the range specified in Table V. Ratios between the static breakaway coefficient and the mid-point dynamic coefficient B/M are to be “rate and report“. Printed copies are un
45、controlled Copyright 2004, Ford Global Technologies, LLC Page 14 of 20 ENGINEERING MATERIAL SPECIFICATIONWSS-M2C919-E (- 0.05)d max E/M = * (d 1800) (0.25)s 4.37 B/M = * (d 1800) *= Reference SAE Friction Nomenclature Specification (SAE J 1646) Specification TABLE V for SD-1777 Mid-point Dynamics Lo
46、w speed Dynamics Static Breakaway S/D Stop Times Cycles Max Min Max Min Max Min Max Min Max Min 5 R & R R & R R & R R & R R & R R & R R & R R & R R & R R & R 25 R & R R & R R & R R & R R & R R & R R & R R & R R & R R & R 100 0.16 0.13 0.16 0.13 0.15 0.10 1.15 0.90 0.90 0.75 200 0.16 0.13 0.16 0.13 0
47、.15 0.10 1.15 0.90 0.90 0.75 600 0.16 0.13 0.16 0.13 0.15 0.10 1.15 0.90 0.90 0.75 1000 0.16 0.13 0.16 0.13 0.15 0.10 1.15 0.90 0.90 0.75 5000 0.16 0.13 0.16 0.13 0.15 0.10 1.15 0.90 0.90 0.75 10000 0.16 0.13 0.16 0.13 0.15 0.10 1.15 0.90 0.90 0.75 15000 0.16 0.13 0.16 0.13 0.15 0.10 1.15 0.90 0.90
48、0.75 20000 0.16 0.13 0.16 0.13 0.15 0.10 1.15 0.90 0.90 0.75 3.15.10.6 Between 100 and 20,000 cycles of operation, all stop times must fall within the range specified in TABLE V for SD-1777. 3.15.10.7 Viscosity Change after 20,000 cycles from original 22% viscosity at 100 C, max. Printed copies are
49、uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 15 of 20 ENGINEERING MATERIAL SPECIFICATIONWSS-M2C919-E SAE NO. 2 MACHINE SET-UP PARAMETERS Perform evaluation at the following schedule: SD-1777 Temperature: 135 +/- 3 C Pressure: 275 +/- 5 kPa Velocity: 3600 rpm Energy: 20740 +/- 100 J Fill Volume: 305 mL +/- 5 mL Total Cycles: 400 for each evaluation pack 20000 for each durability pack Printed copies are uncontrolled Copyright 2004, Ford Global Technologies, LLC Page 16 of 20 ENGINEERING MATERIAL SPECI
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