NAVISTAR MPAPS P-9542-2018 Quality Requirements For Manual Automated Manual Dual Clutch and Automatic Transmissions.pdf

1、This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2018 by Navistar, Inc. JANUARY 2018 Page 1 of 7 NAVISTAR, INC. Material, Parts, and Process Specification

2、 (MPAPS) NUMBER: MPAPS P-9542 Former Designation: TMS-9542 TITLE : Quality Requirements For Manual, Automated Manual, Dual Clutch and Automatic Transmissions CURRENT REV. No.: 1801 DATE: Jan. 2018 WRITTEN/EDITED BY: W. Cook / A. Mirza APPROVED BY: R. Goluch SUPERSEDES: Rev. 1506 June 2015 PRINTED CO

3、PIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health

4、 practices and to determine the applicability of regulatory limits prior to use. 1.0 APPLICATION This specification covers quality control requirements for purchased transmission assemblies provided as completed units to Navistar Assembly Plants. 2.0 SCOPE This specification covers the transmission

5、noise requirements, the quality plan, quality control, source approval, suppliers reports, and shipping and identification requirements. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of t

6、he MPAPS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified the latest issue of all referenced standards shall apply. The following specifications, standards, and regulations are referenced in this specification: ISO 9001/TS 16949 Quality Management Systems- Requirements CFR Titl

7、e 29, Part 1910 Occupational Health and Safety Standards NAVISTAR ISQ-001-QM Integrated Suppler Quality Requirements NAVISTAR EDS-A16 Key Control Characteristics (KCC) NAVISTAR MPAPS B-50 Restricted Chemical Substances NAVISTAR D-13 Supplier Packing and Shipping Standard. CFR Title 40, Part 205 (SAE

8、 J366) - Transportation Equipment Noise Emission Controls NAVISTAR MPAPS P-9543 Engineering Test Report Requirements SAE J617 - Engine Flywheel Housing and Mating Transmission Housing Flanges SAE J1463 - Pull-Type Clutch Transmission Installation Dimensions 4.0 GENERAL REQUIREMENTS 4.1 Noise Require

9、ment - All Transmissions 4.1.1 Drive-by-Noise The noise level contribution of the transmission measured during a drive-by test, or equivalent approved laboratory test, conducted as per CFR Title 40, Part 205.54 (SAE J366), shall not exceed 72 dBA. In order to verify compliance with this requirement,

10、 the transmission shall be tested in all possible drive-by gear ratios and the transmission contributed noise level of each gear ratio shall be measured and recorded. The average contributed noise level, plus two standard deviations, shall not exceed 72.0 dBA for each of the gear ratios measured dur

11、ing the drive-by test. If a small statistical sample is tested, the average transmission contributed noise level measured in each of the possible NUMBER: MPAPS P-9542 Quality Requirements For Manual, Automated Manual, Dual Clutch, and Automatic Transmissions REVISION: 1801 This document is restricte

12、d and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2018 by Navistar, Inc. JANUARY 2018 Page 2 of 7 drive-by gear ratios shall not exceed 70.0 dBA. The supplier shall submit a report

13、(see Suppliers Report, Section A.1) detailing the drive-by noise level measurements, or equivalent approved laboratory simulation measurements, to the Vehicle Acoustical Group at Navistar as a part of the qualification procedure for each transmission model. 4.1.2 Cab Interior Noise The contribution

14、of an isolated transmission gear shift lever to the interior cab noise, as measured at a point 6 inches to the right of the drivers right ear (approximately 2 feet from the knob), shall not exceed 49 dBA when the vehicle is stationary, with engine at idle, transmission in neutral and the clutch enga

15、ged. The contributed noise level of the transmission gearshift lever to the interior cab noise in any operating condition in any gear ratio shall not exceed 62 dBa. A test to evaluate the gearshift lever contribution to interior cab noise will be developed and the test procedures agreed to between t

16、he Vehicle Acoustics Group at Navistar and the transmission supplier. The test shall be run by Navistar once a vehicle is available. 5.0 QUALITY All transmissions shall be supplied in a clean and dry condition. All transmission assembly or test fluids/oils that may remain or leave a residue inside t

17、he transmission must be compatible with Navistar factory fill oils/fluids. Splines shall be free of dirt, paint, rust, pits, gouges, nicks, and scratches. 5.1 Quality Control Plan A Quality Control Plan for this product will be established by mutual agreement between Navistar and the supplier. The f

18、ollowing items, where applicable,* will be included in the control plan as dimensional features for management by statistical process control.* Applicability table for Eaton AMT, DCT, Eaton Manual, and Tremec Manual 5.1.1.1 AMT, DCT, Eaton Manual, and Tremec Manual 5.1.1.2 AMT, DCT, Eaton Manual, an

19、d Tremec Manual 5.1.1.3 AMT and Manual 5.1.1.4 AMT and Manual 5.1.1.5 AMT and Manual 5.1.1.6 AMT and Manual 5.1.1.7 AMTs, Eaton Manuals, and DCTs 5.1.1.8 AMT and Manual 5.1.1.9 AMT, Eaton Manuals, and DCTs 5.1.1.10 AMT and Manual 5.1.1.11 AMT and Manual 5.1.1 Manual and Automated Manual Transmission

20、s Navistar releases transmissions with an Attribute Based Release (ABR) release system. For manual and automated manual transmissions, there are up to 11 ABR features that make up one full complete transmission depending on the suppler to be delivered to Navistar. Not all ABR features have controlle

21、d NUMBER: MPAPS P-9542 Quality Requirements For Manual, Automated Manual, Dual Clutch, and Automatic Transmissions REVISION: 1801 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assu

22、me all patent liability. 2018 by Navistar, Inc. JANUARY 2018 Page 3 of 7 dimensioned features on them. A prime example of this is the Reverse Switch category there are only two possibilities, does the supplier install the switch, which is supplier controlled, or not install the switch. Dimensions of

23、 the switch itself are controlled by supplier. These ABR features exist solely for the benefit of Navistar assembly plants and customers who can order options provided by the transmission supplier. A full list of possible ABR features, as well as the Key Critical Characteristics (KCC) within those A

24、BR features is detailed herein. 5.1.1.1 Base Transmission Each base transmission released is part of a family. A family can consist of any number of transmission feature codes. The definition of a family shall be transmissions that share the same basic design and external dimensions. A drawing will

25、be generated for each family, detailing the ABR categories applicable to the family. There are no KCCs on this ABR category. However, any changes to the Base Transmission from the supplier affecting “form, fit, or function” such as transmission size impacts or transmission mount changes must be appr

26、oved by Navistar through the SREA Process. The specific distance from front of case to PTO bolt pattern (433 mm for Tremec/446.4 mm for Eaton) must be maintained for all product. 5.1.1.2 Shift Controls Applicable to manual transmissions only. Some suppliers have the ability to have the shifter tower

27、 in a forward, or center/standard position. Some transmission families may also have full lower stub levers installed by the transmission supplier and shipped to Navistar plants in that configuration. Whether the shift tower is shipped to our factory installed on the transmission or shipped in separ

28、ately, the shift tower will have a released Navistar print that controls the shift lever length and bend points. The mating surface of the transmission to the shift bar housing is a supplier controlled mating surface. There are no KCCs for this ABR category. A subsection of this ABR will be applicab

29、le to AMTs and DCTs only. Controls CAN Communication Rate will define the baud rate (250k vs. 500k) at which the J1939 network communicates at. 5.1.1.3 Output Shaft Speed Sensor This ABR category defines the number and type of Output Shaft Speed Sensors to be installed by the transmission supplier p

30、rior to delivery to Navistar. The sensor itself is controlled by the transmission supplier. There are no KCCs for this ABR category. However, any changes to the Output Shaft Speed Sensor from the supplier affecting “form, fit, or function” must be approved by Navistar through the SREA Process. 5.1.1

31、.4 Reverse Switch This ABR category defines if a Reverse Switch is installed by the transmission supplier prior to delivery to Navistar. The switch itself is controlled by the transmission supplier. There are no KCCs for this ABR category. However, any changes to the Reverse Switch from the supplier

32、 affecting “form, fit, or function” must be approved by Navistar through the SREA Process. 5.1.1.5 Neutral Start Switch This ABR category defines if a Neutral Start Switch is installed by the transmission supplier prior to delivery to Navistar. The switch itself is controlled by the transmission sup

33、plier. There are no KCCs for this ABR category. However, any changes to the Neutral Start Switch from the supplier affecting “form, fit, or function” must be approved by Navistar through the SREA Process. NUMBER: MPAPS P-9542 Quality Requirements For Manual, Automated Manual, Dual Clutch, and Automa

34、tic Transmissions REVISION: 1801 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2018 by Navistar, Inc. JANUARY 2018 Page 4 of 7 5.1.1.6 Rear Bearing Ret

35、ainer This ABR category defines the number and type of ports available on the Rear Bearing Retainer for the installation of Transmission Output Shaft Speed Sensors (TOSS). There are no KCCs for this ABR category. However, any changes to the Rear Bearing Retainer from the supplier affecting “form, fi

36、t, or function” must be approved by Navistar through the SREA Process. 5.1.1.7 Transmission Output Yoke / Flange Assembly This ABR category defines if a yoke or flange is installed by the transmission supplier prior to delivery to Navistar. The output shaft dimensions are defined by the supplier in

37、their design and the supplier must approve the yoke / flange possibilities. The yoke / flange selection will be done by the Navistar Driveline Group and will be released on the ABR by the Transmission Group. There are no KCCs for this ABR category. 5.1.1.8 Internal Lube Pump Provision This ABR categ

38、ory defines if an internal lube pump is installed by the transmission supplier prior to delivery to Navistar. The internal pump is designed and released by the transmission supplier and is part of the suppliers assembly. The transmission supplier must inform Navistar what possibilities exist so Navi

39、star can release ABR codes based on the suppliers design. There are no KCCs for this ABR category. 5.1.1.9 Clutch Housing This ABR category defines which clutch housing will be installed by the transmission supplier prior to delivery to Navistar. The clutch housing is designed and released by the tr

40、ansmission supplier in accordance with SAE standard J1463 and is part of the suppliers assembly. The transmission supplier must inform Navistar what possibilities exist so Navistar can release ABR codes based on the suppliers design. The KCCs for the Clutch Housing are: 1. Engine Mounting diameter 2

41、. Alignment of Pedal Shaft Bore (Only applicable for manual transmission with mechanical clutch linkage) 5.1.1.10 Input Spline This ABR category defines which input spline will be installed by the transmission supplier prior to delivery to Navistar. The input spline is designed and released by the t

42、ransmission supplier in accordance with SAE standard J617 and is part of the suppliers assembly. The KCCs for the Input Spline are: 1. Pilot Diameter 2. Tooth Thickness and Spacing (Composite Gauging is Acceptable) 5.1.1.11 Thru-Shaft PTO This ABR category defines if a thru shaft PTO provision is in

43、stalled by the transmission supplier prior to delivery to Navistar. The thru-shaft PTO provision is designed and released by the transmission supplier and is part of the suppliers assembly. The transmission supplier must inform Navistar what possibilities NUMBER: MPAPS P-9542 Quality Requirements Fo

44、r Manual, Automated Manual, Dual Clutch, and Automatic Transmissions REVISION: 1801 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2018 by Navistar, Inc

45、. JANUARY 2018 Page 5 of 7 exist so Navistar can release ABR codes based on suppliers design. There are no KCCs for this ABR category. DCT/AMT/Manual transmission ABR features diagram T r a n s m i s s i o nY o k eC l u t c h H o u s i n g ( S A E J 1 4 6 3 )I n p u t S h a f t( S A E J 6 1 7 )5.1.2

46、 Torque Converter Automatic Transmissions 5.1.2.1 Base Transmission Each transmission released is part of a family. A family can consist of any number of transmission feature codes. The definition of a family shall be transmissions that share the same basic design and external dimensions. A drawing

47、will be generated for each family, detailing the ABR categories applicable to the family. There are no KCCs on this ABR category. However, any changes to the Base Transmission from the supplier affecting “form, fit, or function” such as transmission size impacts or transmission mount changes must be

48、 approved by Navistar through the SREA Process. 5.1.2.2 Torque Converter This ABR category defines what torque converter shall be installed by the transmission supplier prior to delivery to Navistar. The torque converter is designed and released by the supplier and is part of the suppliers assembly. The transmission supplier must inform Navistar what possibilities exist so Navistar can release ABR codes based on the suppliers design. The KCCs for this ABR category are 1. Pilot Diameter 2. Studs/Lugs/Bolt Holes - Location