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Automatic Transmission Fluids ©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 1 A t t i A u t o m a t i c T r a n s m i s s i o n F l u i d s M ti T bb Martin T abbey 2 A TI Confidential

ATF Fluids

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Page 1: ATF Fluids

Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 1

A t ti Automatic Transmission

FluidsM ti T bbMartin Tabbey

22

ATI Confidential

Page 2: ATF Fluids

Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 2

Automatic Transmission Fluids

ATF- Allison Transmission Fluids

• ATF Function & CharacteristicsTopics

• ATF Function & Characteristics• ATF Basestocks• ATF Additives• ATF Degradation• ATF Degradation• ATF Types• Transmission Fluid Analysis

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Page 3: ATF Fluids

Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 3

Automatic Transmission Fluids

ATF Function And Characteristics

Transfer of hydraulic pressureTransfer of hydraulic pressureActuation of valves & clutch systemsActuation of valves & clutch systems

Sufficient kinematic viscositySufficient kinematic viscosityFlow at low temperaturesFlow at low temperaturesFoam & aeration controlFoam & aeration control

Protection of mechanical componentsProtection of mechanical components Control of wear, corrosion,Control of wear, corrosion,and seal swelland seal swell

Transfer of torqueTransfer of torqueControl of clutch frictionControl of clutch friction

Friction balance for smooth shifts Friction balance for smooth shifts (function of slip speed)(function of slip speed)

Friction durabilityFriction durabilityFriction durabilityFriction durability

Dissipation of heat from clutches, torque Dissipation of heat from clutches, torque converters, and retardersconverters, and retarders Thermal stability/Oxidation ResistantThermal stability/Oxidation Resistant

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Page 4: ATF Fluids

Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 4

Automatic Transmission Fluids

ATF- Allison Transmission Fluids

• ATF Function & CharacteristicsTopics

• ATF Function & Characteristics• ATF Basestocks• ATF Additives• ATF Degradation• ATF Degradation• ATF Types• Transmission Fluid Analysis

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Page 5: ATF Fluids

Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 5

API Basestock CategoriesThe 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– Excellent oxidation resistance and low temperature properties

GROUP Saturates (%) Viscosity Index Sulfur Content (%)

I < 90 80 – 120 > 0.03II > 90 80 – 120 < 0.03III > 90 >120 < 0.03

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IV  PAO

Viscosity Index (VI) = rate of change in viscosity with a given change in temperature.

Page 6: ATF Fluids

Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 6

Formulating to Viscosity Targets

Base Stock Type Decrease in VI Decrease in 

Group I Improvers

~20%

Viscosity@‐40C

3‐6 kcPGroup II

Group III~10%3‐5 kcP

p

Group IV (PAO) No VI Improvers(< 10,000 cP usuallyrequires Group IV)

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Page 7: ATF Fluids

Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 7

Automatic Transmission Fluids

ATF- Allison Transmission Fluids

• ATF Function & CharacteristicsTopics

• ATF Function & Characteristics• ATF Basestocks• ATF Additives• ATF Degradation• ATF Degradation• ATF Types• Transmission Fluid Analysis

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Page 8: ATF Fluids

Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 8

ATF: Generic CompositionNote: TES 295™ oils do not contain

Viscosity Index (VI) Improvers

InhibitorsInhibitorsb o s

Base Oils (80-90%)

Oxidation

Rust

CorrosionBase Oils (80 90%)VI Improver (5-15%)Dispersants (2-8%)Inhibitors (0.5-2.5%)

Corrosion

Wear

EP Wear

Foam/Air Entrainment

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Seal Swell Agents (0-3%)Friction Modifiers (0.2-0.8%)

Page 9: ATF Fluids

Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 9

ATF AdditivesATF fluid specifications are established by OEMs and define performance criteria Additives are blended with base oils to meet desired performancecriteria. Additives are blended with base oils to meet desired performance • Viscosity Index Improvers

– Polymers added to increase viscosity at higher temperaturesF i ti M difi• Friction Modifiers

– 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 Agentsg

– Control swelling, hardness, tensile strength of elastomers• Anti-Foam Agent

– Prevents excessive foaming and air entrainment

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It’s a balancing act! Too little or too much of any one component can mean the difference between success and failure of the ATF

Prevents excessive foaming and air entrainment

Page 10: ATF Fluids

Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 10

Automatic Transmission Fluids

ATF- Allison Transmission Fluids

• ATF Function & CharacteristicsTopics

• ATF Function & Characteristics• ATF Basestocks• ATF Additives• ATF Degradation• ATF Degradation• ATF Types• Transmission Fluid Analysis

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Page 11: ATF Fluids

Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 11

Automatic Transmission Fluids

ATF Degradationg

• Chemical Change

Oxidation

• Chemical Change– Fluid oxidation is a chemical reaction

• Much like rust is a chemical reaction between iron • 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 M KOH/

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Mg KOH/g

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Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 12

Automatic Transmission Fluids

ATF Degradationg

• Effects Of Oxidation

Oxidation

• Effects Of Oxidation– Increased sludge and varnish deposits

Cl d filt / l id• Clogged filters/solenoids– Decreased shift quality and clutch durability

I d t – Increased component wear– Rule of thumb:

O id ti t ( ti t ) d bl f • Oxidation rate (reaction rate) doubles for every 10 degree Celsius increase in sump temperature

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Page 13: ATF Fluids

Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 13

Oxidation

Fluid A

Used FluidRate is a function of time, temperature (duty

l ) d fl id litumbe

r

Fluid B

cycle), and fluid quality

 Acid Nu

(TAN)

Initial (fresh fluid)

Total

Time in Service (D i I t l)

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Time in Service (Drain Interval)

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Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 14

• Physical ChangesViscosity Index (VI) Improver Sheardown• Physical Changes

– 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 viscositytemperature increases to increase viscosity

– If not present: Oil would “thin out” at high temperature or not flow in very cold environments

ty

With VI Improver

Visc

osi

VI = 90

VI = 110Viscosity Gain

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Temperature (°C)40 100

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Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 15

Viscosity Index (VI) Improver Sheardown•Physical Changes (cont’d)

–Kinematic viscosity decreases with extended usey• VII polymers are physically “cut up” in gear meshes,

bearing contact areas, torque converter vanes, pump vanes etcvanes, etc.

• “Sheardown” - permanent viscosity loss (caused by shearing of VII polymers)

–Oil shear reduces oil pump efficiency resulting in reduced cooler flowOil shear reduces fluid film resulting in reduced –Oil shear reduces fluid film resulting in reduced gear and bearing life

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Page 16: ATF Fluids

Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 16

Viscosity Index (VI) Improver Sheardown

High stress zone

ty a

tcS

t)

VI Sheardown(30% - 40% loss)

88

g st ess o e(gear mesh, bearing

contact zone)

Visc

osi

100C

( c

44

VII polymer Scissored polymer

Time(intact)

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Page 17: ATF Fluids

Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 17

TES 389/TES 295™ Performance Comparison

TES 295™ TES 295™ Approved ProductsApproved Products

Sh d

(shear and oxidation stable)

ty Sheardown(viscosity loss; thinning)

Viscosit

Oxidation

V

TES 389TES 389 Approved ProductsApproved Products(viscosity growth; thickening)

Time in Service (Drain Interval)

TES 389 TES 389 Approved ProductsApproved Products

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Page 18: ATF Fluids

Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 18

Automatic Transmission Fluids

TES 295™ Fluids

• Outperforms Other Fluids On Every Level

TES 295 Fluids

• Outperforms Other Fluids On Every Level– No shear down

Protects transmission components– Protects transmission components– Resists oxidation– Extremely good low temperature properties– Extremely good low temperature properties– Extends drain intervals– Improves vehicle uptimeImproves vehicle uptime– Increases life cycle value– Extended Transmission Coverage

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Extended Transmission Coverage• Only valid with a TES 295™ fluid

Page 19: ATF Fluids

Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 19

TES 295™ Approval Number

ApprovedMarketer

ProductBrand Name

AN-011001 Castrol Heavy Duty Lubricants TranSynd™

AN-031002 BP Lubricants Autran Syn 295AN-031003 Cognis Corporation Emgard 2805

AN-031004 International Truck & Engine Company Fleetrite Synthetic ATF

AN-051005ExxonMobil Lubricants

and Petroleum Specialties Company

Mobil Delvac Synthetic ATF

AN-071006 John Deere & Company HD SynTranAN 071006 John Deere & Company HD SynTran

AN -101007 Volvo Trucks North America Bulldog Synthetic ATF

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Page 20: ATF Fluids

Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 20

Automatic Transmission Fluids

ATF- Allison Transmission Fluids

• ATF Function & CharacteristicsTopics

• ATF Function & Characteristics• ATF Basestocks• ATF Additives• ATF Degradation• ATF Degradation• ATF Types• Transmission Fluid Analysis

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Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 21

Automatic Transmission Fluids

ATF TypesATF Types

• DEXRON®• DEXRON®

– General Motors specificationDEXRON® III & VI l d fl id • DEXRON® III & VI are no longer approved fluids in any Allison products due to seal compatibility issues

• MERCON®

– Ford Motors specificationFord Motors specification• TO-4

Caterpillar Specification2222

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– Caterpillar Specification

Page 22: ATF Fluids

Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 22

Automatic Transmission Fluids

ATF Typesyp

TES 228 (C4)

Allison Specifications

• TES 228 (C4)– Off-Highway transmissions only.

No longer accepting new fluids – No longer accepting new fluids • TES 439

R l TES 228– Replaces TES 228• Heavy duty diesel engine oil & higher

viscosity ATFsviscosity ATFs• TES 353

– Synthetic fluid Off-Highway only2323

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Synthetic fluid, Off Highway onlyTES = Transmission Engineering Specification

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Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 23

Automatic Transmission Fluids

ATF Types

• TES 389

Allison Specifications (cont’d)

• TES 389– Mineral based fluid for On-Highway

transmissions onlytransmissions only– Acceptable non-TES 295™ fluids

• TES 295™• TES 295– Synthetic fluid for On-Highway

transmissions onlyy• TES 468

– Synthetic fluid for Hybrid transmissions

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Synthetic fluid for Hybrid transmissionsTES = Transmission Engineering Specification

Page 24: ATF Fluids

Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 24

Automatic Transmission Fluids

ATF- Allison Transmission Fluids

• ATF Function & CharacteristicsTopics

• ATF Function & Characteristics• ATF Basestocks• ATF Additives• ATF Degradation• ATF Degradation• ATF Types• Transmission Fluid Analysis

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Page 25: ATF Fluids

Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 25

Automatic Transmission Fluids

Transmission Fluid AnalysisyOverview

• Fluid Analysis Evaluates Overall “Health” Of Transmission Fluid And Transmission System

• Allison Recommends Fluid Analysis As Primary Method To Determine Fluid Change I t lIntervals

• Fluid Change Intervals May Differ Due To:– Local conditions– Severity of operation/duty cycle

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Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 26

Automatic Transmission Fluids

Transmission Fluid Analysisy

• SIL 17 TR 96

Overview

• SIL 17-TR-96– Provides oil sampling procedures/guidelines

I Th Ab Of A Fl id A l i • In The Absence Of A Fluid Analysis Program:

Follow fluid change intervals– Follow fluid change intervals• SIL 10-TR-99

– Use prognostics if enabledp g

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Automatic Transmission Fluids

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Automatic Transmission Fluids

Transmission Fluid Analysisy

• GN2055EN

Overview

• GN2055EN– “Technicians Guide; Automatic Transmission

Fluid Understanding/Analysis”Fluid Understanding/Analysis• Use this document as a fluid analysis reference

• Allison Uses Fluid Analysis Kits Provided By Allison Uses Fluid Analysis Kits Provided By Polaris Laboratories LLC– P/N 29537805

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Automatic Transmission Fluids

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Automatic Transmission Fluids

Transmission Fluid Analysisy

• Metal Analysis

Polaris Laboratories

• Metal Analysis– 24 elements analyzed

• Reported in parts per million (ppm)• Reported in parts per million (ppm)– Wear metals– Contaminant metals

Additi t l– Additive metals

• Water ContentR d i (%)– Reported in percent (%)

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Automatic Transmission Fluids

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Automatic Transmission Fluids

Transmission Fluid Analysisy

• Viscosity

Overview

• Viscosity– Reported in Centistokes (cSt)

• At 40º C and 100º C• At 40º C and 100º C

• TAN (Total Acid Number)R t d i M KOH/– Reported in Mg KOH/g

• Glycol Test – All Samples• Comments And Severity Status

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Automatic Transmission Fluids

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Sample ReportSeverity is based on report Comments not onComments – not on individually flagged results

Customer inputs

Metal Analysis

Condition based standardized comments

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Physical & Chemical Tests

100% Glycol Test

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Automatic Transmission Fluids

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Automatic Transmission Fluids

Transmission Fluid Analysisy

Polaris Report Customer Feedback

Condition Base Standardized Comments

Polaris Report Customer Feedback• Computer generated comments from Polaris are

based on ATD limits for oil degradation (TAN based on ATD limits for oil degradation (TAN, viscosity, and glycol/water content)

• Oil change recommended if:Oil change recommended if:– TAN ≥ 4.0 (both TES 389 and TES 295™ fluids)– 100ºC Viscosity ≤ 6.0 cSt TES 295™ & ≤ 5.5 cSt TES 389

T i i t d d d if• Transmission teardown recommended if:– Glycol is “positive” and/or Water ≥ 0.2%

N P Alli li l d d d b dN P Alli li l d d d b d

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Note: Per Allison policy, wear metals are measured and reported but are not used Note: Per Allison policy, wear metals are measured and reported but are not used to assess the quality of the transmission fluid or the condition of the transmissionto assess the quality of the transmission fluid or the condition of the transmission

Page 32: ATF Fluids

Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 32

Automatic Transmission Fluids

Transmission Fluid AnalysisGl l T L b R l

y

• Background

Glycol Test Lab Results

• Background– Glycol

T i l i di t i tif• Typical ingredient in antifreeze• Typically mixed with water 50/50

– Forms a liquid “coolant”– Forms a liquid coolant– Glycol additives

• Includes various potassium and sodium Includes various potassium and sodium compounds

– Indicators that glycol may be present in ATF

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» Both shown on the Polaris report

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Automatic Transmission Fluids

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Automatic Transmission Fluids

Transmission Fluid Analysisy

• Background

Glycol Test Lab Results

• Background (cont’d)

– Risk of sodium and potassium precipitating out of fluidout of fluid• Subsequently removed by transmission filter

– Early 2010Early 2010• Transmission fluid sampling and analysis kit

revised to include glycol check on every oil sample– ASTM D2982 Glycol Test

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Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 34

Automatic Transmission Fluids

Transmission Fluid Analysisy

• False Positive Glycol Lab Results

Glycol Test Lab Results

• False Positive Glycol Lab Results– ASTM D2982 test for glycol is inherently

susceptible to false positive resultssusceptible to false positive results– New oil chemistry may cause false

positivespositives• Associated with oil additive manufacturing• Associated with base oil refiningAssociated with base oil refining

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Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 35

Automatic Transmission Fluids

Transmission Fluid Analysisy

• False Positive Glycol Lab Results

Glycol Test Lab Results

• False Positive Glycol Lab Results (cont’d)

– Additives often burn off during service• New ATF placed into service for a short time may • New ATF placed into service for a short time may

initially test positive for glycol– Later tests come back negative

– 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

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Determines if fluid is susceptible to false positive reading

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Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 36

Automatic Transmission Fluids

Transmission Fluid Analysisy

• Negative Glycol/Water Lab Results With

Glycol Test Lab Results

• Negative Glycol/Water Lab Results With Known Glycol And/Or Water Content

S l fi ld i t h fl id l i – Several field instances where fluid analysis indicated negative glycol/water results• Subsequent transmission teardown and inspection • Subsequent transmission teardown and inspection

revealed obvious contamination

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Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 37

Automatic Transmission Fluids

Transmission Fluid Analysisy

• Negative Glycol/Water Lab Results With

Glycol Test Lab Results

• Negative Glycol/Water Lab Results With Known Glycol And/Or Water Content (cont’d)

P ibl – Possible causes• Oil sampling procedure error

Glycol/water had time to separate from ATF– 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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Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 38

Automatic Transmission Fluids

Transmission Fluid Analysisy

• Negative Glycol/Water Lab Results With

Glycol Test Lab Results

• Negative Glycol/Water Lab Results With Known Glycol And/Or Water Content (cont’d)

If il l i h l l i ti l – If oil analysis shows glycol is negative plus sodium and/or potassium readings are greater or equal to 10ppmor equal to 10ppm• Inspect the unit for rusted hardware

– If evidence of rust is present, unit has most likely been p , ycontaminated with glycol

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Automatic Transmission Fluids

©2011 Allison Transmission, Inc. All rights reserved. (Confidential Document) Page 39

Transmission Fluid AnalysisReport below shows negative glycol/water result

Transmission inspection shows obvious glycol/water contamination

i l l di i hNegative glycol reading with Na & K ≥ 10 ppm

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Glycol/Water Mixed With ATF

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