1、 WORLDWIDE ENGINEERING STANDARDS Material Specification GMW16444 DEXRON - VI Automatic Transmission Fluid Copyright 2011 General Motors Company All Rights Reserved August 2011 Originating Department: North American Engineering Standards Page 1 of 93 Scope Note: Nothing in this standard supercedes ap
2、plicable laws and regulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Material Description. This specification covers DEXRON-VI Automatic Transmission Fluid (ATF) primarily for use in General Motors automatic transmis
3、sions. This specification describes, in terms of laboratory and simulated service test results, the requirements for a minimum-performance fluid. The primary requirement is satisfactory performance in normally functioning transmissions under normal and severe conditions. 1.2 Symbols. Not applicable.
4、 1.3 Typical Applications. This lubricant is to be used in GM Automatic Transmissions and other specified applications. 1.4 Remarks. 1.4.1 This specification may involve hazardous materials, operations, and equipment. This specification does not purport to address all of the safety problems associat
5、ed with its use. It is the responsibility of the user of this specification to establish appropriate safety and health practices and to determine the applicability of regulatory limitations prior to use. 1.4.2 This specification uses the International System of Units (SI) as standard per IEEE/ASTM S
6、I 10, except for certain components, which are commercially available only in American conventional units. 1.4.3 This specification uses the Rounding-Off Method per ASTM E29 for significant figures to determine conformance to specification requirements. 1.4.4 Unless otherwise noted, part numbers of
7、this specification refer to those of General Motors Powertrain. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. ASTM D92 ASTM D1193 ASTM D4289 ASTM D6082 ASTM D130 ASTM D1500 ASTM D4629 ASTM D6443 ASTM D445 ASTM
8、D1748 ASTM D4683 ASTM D6922 ASTM D471 ASTM D2240 ASTM D4927 ASTM D7043 ASTM D664 ASTM D2270 ASTM D4951 ASTM E29 ASTM D665 ASTM D2983 ASTM D5185 ASTM E168 ASTM D892 ASTM D3182 ASTM D5293 FVA No.2/IV ASTM D893 ASTM D4052 ASTM D5800 IEEE/ASTM SI 10 2.2 GM Standards/Specifications. GMW3059 2.3 Additiona
9、l References. 2.3.1 Society of Automotive Engineers (SAE) Papers. x Caracciolo, F. Development of a Sprag Wear Test Procedure for Evaluating the Antiwear Performance of ATFs, SAE Paper 902149. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo
10、reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16444 Copyright 2011 General Motors Company All Rights Reserved August 2011 Page 2 of 93 x Jones, C. and Linden, J. L. Development of a Vehicle Test for Determining ATF Performance in an Electroni
11、cally Controlled Capacity Clutch. SAE Paper 982667. x Morgan, C., Cummings, J.M., Fewkes, R., Jackson, J.M. A New Method of Measuring Aeration and Deaeration of Fluids, SAE Paper 2004-01-2914. (See Appendix K.) x Morgan, C., Fewkes, R., McCombs, T., Tersigni, S.H., Jackson, J.M. Low-Speed Carbon Fib
12、er Torque Capacity and Frictional Properties Test for ATFs, SAE Paper 2004-01-3026. 2.3.2 Test Method Sources. x ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA, 19428-2959, USA. (available at: www.enterprise.astm.org.) x EHDPROC_11 is available from Southwest Researc
13、h Institute, 6220 Culebra Road, San Antonio, TX, USA. x LR4 procedure is available from Southwest Research Institute, 6220 Culebra Road, San Antonio, TX, USA. x MERCON SP procedure 3.14 Specification. Ford Motor Company, ATF Committee, 36200 Plymouth Road, Livonia, MI, 48150, USA. x Test Methods CEC
14、 L-45-99 Co-ordinating European Council, Madou Plaza, 25th Floor, Place Madou 1, B-1030 Brussels, Belgium. (available at: www.cectests.org.) 2.3.3 Forms. x A spreadsheet is available from the GM ATF Committee that contains all report formats. (See Appendix K.) x All GM DEXRON testing forms including
15、 Form A are available from the Team Leader for Service Parts Engineering and DEXRON Licensing or the GM ATF and Gear Oil Committee Chairman, via GM Supply Power. Folders/ENGINEERING/Powertrain Product Engineering/Transmission. ( 4h Pass M. Rust Protection Test ASTM D1748 a) Sandblasted surface b) 40
16、 C c) 50 h d) New coupon for each test No rust or corrosion on any test surface N. W ear Test ASTM D7043 Modified: a) 80 r 3 C b) 6.9 MPa c) 11.356 L (3 gal) d) Conestoga pump parts 10 mg weight loss (maximum) O. Cold Crank Simulation ASTM D5293: -30 C 3200 cP (maximum) P. High Temperature, High She
17、ar ASTM D4683: 150 C 2.00 cP (minimum) Q. Noack Evaporation ASTM D5800 10% evaporation (maximum) 1 h at 200 C R. Film Thickness EHDPROC_11 at Imperial College Equal to or better than Reference Fluid S. Tapered Roller Bearing Shear CEC L-45-99 Modified: 3 480 000 revolutions (40 h) KV100, 5.5 cSt (mi
18、nimum) at EOT, 10% decrease (maximum) at EOT (BOV + EOTV)/2 5.0 cSt at 100 C Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16444 Copyri
19、ght 2011 General Motors Company All Rights Reserved August 2011 Page 4 of 93 TEST METHOD REQUIREMENT T. Foam Test Appendix A ASTM D892 Modified New fluid: a) Sequence I, ASTM D892; 50/0 (maximum) b) Sequence II, ASTM D892; 50/0 (maximum) c) Sequence III, ASTM D892; 50/0 (maximum) d) Sequence IV, AST
20、M D6082; 50/0 (maximum) After cycling test filtered fluid: a) Sequence I, ASTM D892; 50/0 (maximum) b) Sequence II, ASTM D892; 50/0 (maximum) c) Sequence III, ASTM D892; 50/0 (maximum) d) Sequence IV, ASTM D6082; 150/0 (maximum) U. Elastomer Test Appendix B Pass V. Plate Friction Test Appendix C 1)
21、Satisfactory operation for 200 h 2) No unusual wear or flaking on test parts 3) Between 10 and 200 h of operation: a) Midpoint dynamic torque between 80 and 105 Nm b) Maximum Torque 90 Nm c) Delta Torque 200 Nm c) Delta Torque 5.0 cSt 6) Used fluid viscosity at -20 C 5.0 cSt 6) Used fluid viscosity
22、at -20 C 90 200 120 15.7 - 16.30.1 101 2402 4803 720 Three Three Three Three4 960 Point Point Point Point5 1,200 Average Average Average Average10 2,40015 3,60020 4,80025 6,00030 7,20035 8,40040 9,60045 10,80050 12,00055 13,20060 14,40065 15,60070 16,80075 18,00080 19,20085 20,40090 21,60095 22,8001
23、00 24,000105 25,200110 26,400115 27,600120 28,800125 30,000130 31,200135 32,400140 33,600145 34,800150 36,000DEXRON-VI Band Friction - 150 HOURSStop TimesMidpoint Torque NmEnd TorqueNmMax - MidTorqueNmCopyright General Motors Company Provided by IHS under license with General Motors CompanyNot for R
24、esaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16444 Copyright 2011 General Motors Company All Rights Reserved August 2011 Page 26 of 93 Figure D1: Band Head Cover for Band Release Measurement (all dimensions are in millimeters (mm) Fi
25、gure D2: Installation of Micrometer for Band Release Measurement Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16444 Copyright 2011 Gen
26、eral Motors Company All Rights Reserved August 2011 Page 27 of 93 Appendix E: Oxidation Test E1 Objective E1.1 To determine the automatic transmission fluid oxidation resistance, thermal stability, material compatibility, and transmission cooler braze joint corrosion protection characteristics. E2 T
27、est Equipment E2.1 A GM Powertrain 4L60-E transmission available from GM Racing (Flint, MI), and a flex-plate, Part Number 471529. The transmission sump pan and the filter, GM Customer Care and Aftersales (CCA) 24200796, are from a 2004 or later 4L60-E. Figures E1, E2 and Table E3 show a 4L60-E Cuta
28、way View, Internal Components, and Internal Components Part List, respectively. E2.2 A 7.5 kW electric motor, Dayton Model Number 2N986K, or equivalent, capable of driving the GM Powertrain 4L60-E transmission, modified as described herein, at 1755 10 min-1 (1755 10 rpm). This motor should be equipp
29、ed with bearings that will withstand axial and lateral thrust and rotate such that attached transmission rotates in the same direction as when mounted in a vehicle. E2.3 Water-Cooled Heat Exchanger. ITT Standard Company, Part Number 5-160-02-008-002, or equivalent. Cooling water should be flowed in
30、a countercurrent direction when compared to the transmission fluid flow. E2.4 Cooler. Harrison Radiator, Division of General Motors, Part Number 3096410. Installed as described in Figure E3. E2.5 The fluid flow outside the transmission shall be as diagrammed in Figures E3 through E8. These diagrams
31、include mechanism for adjusting main line pressure. Control duty cycle to give specific main line pressure. E2.5.1 Three-Way Valve with Cv greater than 1.6, equally sized orifices in both fluid paths greater than or equal to 6.35 mm and a temperature rating equal to or better than 200 C at 690 kPa.
32、E2.5.2 Two 6.35 mm (1/4 in) National Pipe Tapered Thread (NPT) iron valves for throttling the fluid flow. Both valves must have Cvs greater than 0.60, orifice size equal to or greater than 6.35 mm. Both valves must have a temperature rating equal to or better than 200 C at 690 kPa. Locate one valve
33、at the heat-exchanger-to-transmission in-port. Locate second valve in the line which fluid flow rate is determined. E2.5.3 Stainless steel tubing, 8 mm, and appropriate fittings to assemble the items in Steps E2.5.1 and E2.5.2. E2.5.4 Teflon-Lined, Stainless Steel-Sheathed Hose. Aeroquip, Part Numbe
34、r 2807-6 and fittings, Part Number 190600-6C, or equivalent, as shown in Figures E3 through E8. E2.6 A dipstick tube and associated hardware as shown in Figures E10 and E11, and a dipstick, GM CCA Part Number 1239014. E2.7 A quick disconnect fitting between the air flow controller and the dipstick t
35、ube to allow for temporary use of calibration unit by disconnecting the controller from the dipstick tube. E2.8 Diaphragm Control Valve. Research Controls, Inc., Type 75S, Trim J, Action ATO, Diaphragm 3-15, or equivalent. E2.9 Air Flow Control Device. Sierra Instruments, Series Number 840, or equiv
36、alent, with maximum flow control set to 100 mL/minute at standard temperature and pressure. E2.10 Cylinder of hydrocarbon-free dry (minimum -59 C dew point) compressed air with regulator controls. E2.11 Temperature Measurement. Thermo-sensor, Iron-Constantan thermocouples, Type 2J34-E-6-TP, or equiv
37、alent. Chino Recorder, Model Number ES800-01, or equivalent. If using a digital recorder, data will be collected at 1 Hz. E3 Transmission Modification and New Parts Replacement E3.1 Remove parking pawl activating arm. E3.2 Seal the transmission extension end and speedometer cable hole by welding as
38、shown in Figure E12. The speedometer hole may also be sealed by leaving the speedometer sensor in the hole. E3.3 Drill and tap the Fourth oil hole in the servo cover as shown in Figure E9. E3.4 Remove the existing transmission vent from the case and tap the vent hole 1.587 mm (1/16 in) NPT for the i
39、nstallation of a pipe plug. Drill vertically and tap a 3.175 mm (1/8 in) NPT hole from the top of the case into Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE EN
40、GINEERING STANDARDS GMW16444 Copyright 2011 General Motors Company All Rights Reserved August 2011 Page 28 of 93 the vent passage. Install a 90 degree elbow into the case. Attach 215 mm of 9.5 mm stainless steel tubing bent 90 degrees with a 108 mm radius as shown in Figure E6. E3.5 Use petrolatum a
41、nd/or an additive-free, solvent neutral base oil to aid assembly. No other lubricants are allowed. E3.6 The bottom pan is modified to accommodate two Iron-Constantan thermocouples and a fluid level sight glass as shown in Figure E13. E3.7 New Parts for Transmission Rebuild. E3.7.1 Hughes Performance
42、 Converters, Inc., 4L60-E stator-locked torque converter. E3.7.2 Unused fiber 3rd and 4th clutch plates, reverse input clutch plates, overrun clutch plates, forward clutch plates, low and reverse clutch plates obtainable from GM Racing (Flint, MI) as Part Number CAH0404. E3.7.3 New seals and gaskets
43、 from 4L60-E Gasket Kit GM Customer Care and Aftersales (CCA) Part Number 24221347. E3.8 Bell Housing Modification for Temperature Control. E3.8.1 Drill two holes, 5.7 cm diameter, through the top of the bell housing, as shown in Figure E16. E4 Test Procedure E4.1 Transmission Cleaning. E4.1.1 Disas
44、semble new 4L60-E transmission (except pump and valve body). Clean metal parts with Stoddard solvent and air blow dry the parts. E4.2 Transmission Rebuilding. E4.2.1 Use petrolatum and/or an additive-free, solvent neutral base oil to aid assembly. No other lubricants are allowed. E4.2.2 Rebuild 4L60
45、-E using specified parts (see E3.7) according to the latest repair manual. E4.3 Clean all test equipment that contacts test fluid thoroughly with Stoddard solvent before test. E4.4 Measure the motor end-play by first mounting a dial indicator to the test stand. Place the pointer of the indicator on
46、the motor shaft hub. Set the indicator dial to read zero. Using a pry bar, apply moderate pressure between the hub and the transmission case support plate. The end-play should be less than or equal to 0.38 mm. E4.5 Measure the motor run-out using the fixture shown in Figure E15, or equivalent. The r
47、un-out should be less than or equal to 0.30 mm. E4.6 Bolt the flex-plate on the motor shaft hub. Adjust the hubs position on the shaft so that the distance between the flex-plate and the transmission case support plate is 14.29 mm at the ring gear. E4.7 Measure flex-plate warpage by first mounting a
48、 dial indicator to the test stand. Place the pointer of the dial indicator on one of the flex-plate bolt pads. This pad is the reference pad. Set the dial indicator to read zero. The flex-plate is turned so that the dial indicator meets one of the other pads in approximately the same area of the pad
49、 as that of the reference pad. Measure the third pad similarly. The maximum allowable deviation from the reference pad is 0.38 mm. E4.8 Mark the torque converter bolt pads 1, 2, and 3. Mark the flex-plate pads 1, 2, and 3. Bolt the torque converter to the flex-plate so that the numbers on the torque converter and the f
