A STUDY ON AUTOMATIC TRANSMISSION OVERHEATING PROBLEM By SHAROUL JAMBARI A dissertation submitted in partial fulfilment of the requirements for the degree of Master of Science (Automotive Engineering) Kulliyyah of Engineering International Islamic University Malaysia MARCH 2009
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A STUDY ON AUTOMATIC TRANSMISSION OVERHEATING PROBLEM
By
SHAROUL JAMBARI A dissertation submitted in partial fulfilment of the
requirements for the degree of Master of Science (Automotive Engineering)
Kulliyyah of Engineering International Islamic University Malaysia
MARCH 2009
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ABSTRACT
In this dissertation a study of heating problem in automatic transmission is investigated and discussed. Two important parameters that are temperature and pressure are measured. The possibility of using additives and oil coolers to reduce the temperature in automatic transmission is explored. In addition to that, the effect of pressure on the heating problem is also investigated. The testing procedure involved taking the measurements of pressure and temperature at four different points in the gearbox using the pressure and temperature sensors. Seven different types of testing were performed. Three tests were performed comparing different types of additives, two for comparing different types of oil coolers and two for comparing the new and old standard ATF. The results have shown that testing using additive reduced the temperature and maintained the pressure in automatic transmission. Testing using oil coolers also reduced the temperature and also reduced the pressure in automatic transmission. Therefore, we can conclude that using the additive is better than using oil cooler because of the pressure is maintained while reducing the temperature during the operating of automatic transmission.
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البحث ملخص
مت قياس عاملني مهمني ومها . ة إرتفاع احلرارة يف ناقل احلركة اآليل للسيارات يف هذه االطروحةمت دراسة ظاهر
. تبحث هذه الدراسة إمكانية إستخدام بعض االضافات ومربدات الزيت لتقليل احلرارة. احلرارة والضغط
رارة والضغط يف اربع مواقع مت أخذ قراءات احل. باالضافة اىل ذلك، مت أخذ التأثري على الضغط بنظر االعتبار
هناك سبعة طرق للفحوصات، ثالثة منها مع . خمتلفة يف صندوق التروس باستخدام جمس الضغط وجمس احلرارة
أي (وإثنان مع أنواع خمتلفة من مربدات الزيت ومت املقارنة مع املواصفات القياسية .أنواع خمتلفة من االضافات
. لنتائج، أنه باالمكان تقليل احلرارة والضغط باستخدام االضافاتأظهرت ا. احلديثة والقدمية) يت أف
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APPROVAL PAGE
I certify that I have supervised and read this study and that in my opinion; it conforms to acceptable standards of scholarly presentation and is fully adequate, in scope and quality, as a dissertation for the degree of Master of Science in Automotive Engineering. ……………………………………... Waleed Fekry Faris
Supervisor I certify that I have read this study and that in my opinion it conforms to acceptable standards of scholarly presentation and is fully adequate, in scope and quality, as a dissertation for the degree of Master of Science in Automotive Engineering. ….…………………………………… Kassim A. Abdullah Internal Examiner …….………………………………… Raed I.M.Kafafy Internal Examiner The dissertation was submitted to the Advanced Engineering and Innovation Centre and is accepted as a partial fulfilment of the requirements for the degree of Master of Science in Automotive Engineering. ……..…………………………………… Waleed Fekry Faris Director, Advanced Engineering and Innovation Centre
The dissertation was submitted to the Kulliyah of Engineering and is accepted as a partial fulfilment of the requirements for the degree of Master of Science in Automotive Engineering. ………………………………………….. Ahmad Faris Ismail Dean, Kulliyyah of Engineering
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DECLARATION
I hereby declare that this dissertation is the result of my own investigations, except
where otherwise stated. I also declare that it has not been previously or concurrently
submitted as a whole for any other degrees at IIUM or other institutions.
Sharoul Bin Jambari Signature.................................................. Date . ……………………….
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INTERNATIONAL ISLAMIC UNIVERSITY MALAYSIA
DECLARATION OF COPYRIGHT AND AFFIRMATION OF FAIR USE OF UNPUBLISHED
No part of this unpublished research may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without prior written permission of the copyright holder except as provided below.
1. Any material contained in or derived from this unpublished research may only be used by others in their writing with due acknowledgement.
2. IIUM or its library will have the right to make transmit copies (print of
electronic) for institutional and academic purposes. 3. The IIUM library will have the right to make, store in a retrieval system
and supply copies of this unpublished research if requested by other universities and research libraries.
Affirmed by Sharoul Bin Jambari.
…………………………….. ………………………….. Signature Date
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In dedication to my beloved wife and children
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ACKNOWLEDGEMENTS
Bismillahirrahmaanirrahim, In the name of Allah, the most compassionate and the merciful. First and foremost, I am thankful and grateful to Allah SWT, the Creator and Sustainer of this whole universe, the Most Beneficent and the Most Merciful, for His guidance and blessings, and for granting me knowledge, patience and perseverance to accomplish this dissertation successfully. I take a great pride to express my sincere appreciation and gratitude to my supervisor, Asst Prof. Dr Waleed Fekry Faris, for his invaluable support, constant inspiration, expert guidance, encouragement and constructive criticism throughout this work. I have been fortunate to work under his guidance. I did learn a lot from his constant monitoring and his passion for perfection. It has been a wonderful experience working with him. I also would like to thank and appreciate to MARA and UniKL who support my studies. At last but not least, I also extend my thanks to my beloved wife and daughters who were the source of my motivation to work hard. Last but not least, I would like to thank all engineering faculty members especially Sister Rohamah for her support throughout the completion of my studies in IIUM.
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TABLE OF CONTENTS
Abstract ……………………………………………………………….................... ii Abstract in Arabic ………………………………………………………………… iii Approval Page …………………………………………………………..………… iv Declaration Page ………………………………………………………………….. v Copyright Page…………………………………………………………………….. vi Dedication ………………………………………………………………………………………….. vii Acknowledgements………………………………………………………………… viii Table of Contents………………………………………………………………….. ix List of Tables …………………………………………………………………….... xii List of Figures ……………………………………………………………………. xiii
2.4.1 Torque converter…………………………………………………. 12 2.4.2 Planetary gear set………………………………………………… 14 2.4.3 Multiple clutches and brakes…………………………………..… 16 2.4.4 One way clutch……………………………………………………17 2.4.5 Kickdown band brake……………………………………………..18 2.4.6 Hydraulic control system………………………………………… 18 2.4.7 Electronic control system………………………………………… 20 2.4.8 Non Electronic control system…………………………………… 21 2.4.9 Seal and Gasket………………………………………………….. 22 2.4.10 Common problem in automatic transmission………………….. 23
2.5 Automatic Transmission Cooling Technique………………………….. 25 2.5.1 Additive as the Cooling Agent…………………………………... 26 2.5.2 Oil Cooler as the Auxiliary Cooling system…………………….. 26 2.5.3 Transmission Oil Pan Special Design …………………………... 28
2.6 Previous Research on the Cooling Methods…………………………… 29 2.6.1 Additives inside Automatic Transmission…..…………………… 30 2.6.2 Viscosity Effect inside Automatic Transmission ……………….. 31 2.6.3 Auxiliary Oil Cooler ……………………………………………. 31 2.6.4 Control and prediction of transmission temperature…………….. 35 2.6.5 A shift control system for an automatic transmission…………… 38
3.3 Experimental Materials………………………………………………… 50 3.3.1 Different types of Additives……………………………………… 50 3.3.2 Aluminum and Steel types of Oil Coolers……………………..… 51 3.3.3 Standard Automatic Transmission Fluid………………………… 53
3.4 Experimental Method…...…………….……………………………….. 54 3.4.1 Start Testing…………………………………………………….... 54 3.4.2 Replacement of ATF……………………………………………... 54 3.4.3 Fix Instrumentation……………………………………………..... 56 3.4.4 Data Recording Process………………………………………….. 57 3.4.5 Experiment 1: Standard ATF only………………………………. 57 3.4.2 Experiment 2: Additive No 1 (med grade) + standard ATF……... 58 3.4.3 Experiment 3: Additive No 2 (low grade) + standard ATF……… 58 3.4.4 Experiment 4: Additive No 3 (high grade) + standard ATF…….. 59 3.4.5 Experiment 5: Aluminum Oil Cooler + standard ATF………….. 59 3.4.6 Experiment 6: Steel Oil Cooler + standard ATF………………… 59 3.4.7 Experiment 7: Used ATF (mileage ~ 15000 km)………………... 59 3.5 Cost Analysis………………………………………………………….. 60
CHAPTER 4: RESULTS AND DISCUSSIONS……………………………… 61
4.1 Introduction……..…………………………………………………..… 61 4.2 Experimental Results……………………………………………….…. 62 4.2.1 Experiment 1: Standard ATF only………………………………. 62 4.2.2 Experiment 2: Additive 1 + Standard ATF……………………… 64 4.2.3 Experiment 3: Additive 2 + Standard ATF……………………… 66 4.2.4 Experiment 4: Additive 3 + Standard ATF……………………… 68 4.2.5 Experiment 5: Aluminum Oil Cooler + Standard ATF…………. 70 4.2.6 Experiment 6: Steel Oil Cooler + Standard ATF……………….. 72 4.2.7 Experiment 7: Used ATF (mileage ~ 15000 km)……………….. 74 4.3 Analysis and Discussion………………………………………………. 77 4.3.1 Reducing Line…………………………………………………… 77 4.3.2 Torque Converter Line………………………………………….. 79 4.3.3 Transmission Outflow Line……………………………………… 81 4.3.4 Transmission Inflow Line……………………………………….. 83 4.3.5 Pressure Different at Cooling Line………………………………. 85 4.3.6 Temperature Different at Cooling Line…………………………. 86
4.3.7 Pressure Drop Cooling Line between Standard and Used ATF…. 87 4.3.8 Temperature Difference Cooling Line between Standard and Used ATF………………………………………………...… 88 4.3.9 Summary of Finding…………………………………………… 89
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CHAPTER 5: CONCLUSION AND RECOMMENDATION……………….. 90
3.7 Oil Coolers Specification 52 3.8 Standard Repco ATF specification 54 3.9 Cost analysis 60 4.1 Summary of finding 89
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LIST OF FIGURES
Figure No. Page No.
1.1 Overheated clutch disc B and plate C 4
2.1 Rear wheel drive arrangement 8 2.2 Front wheel drive arrangement 9 2.3 Cut-view of Torque Converter 13 2.4 Side view of Planetary Gear system 14 2.5 Front view of Planetary gear system 14
2.6 Clutch packs 16 2.7 Kick-down Band Brake 18 2.8 Basic components of Hydraulic system 19 2.9 Pro-Blend Trans Cool Automatic Transmission Fluid (ATF) Additive 26 2.10 Auxiliary Oil Cooler 27
2.11 Special Transmission Oil Pan 27 2.12 Effect the temperature on the gearbox life 29
2.13 Standard line pressure for Mitsubishi gearbox (F4A23) 30
2.14 Plate type oil cooler 33
2.15 Makato’s Oil Cooler 35
2.16 Temperature controller for automatic transmission 37
2.17 Temperature effect on the shift quality 39
3.1 Proton Perdana V6 42
3.2 Chassis dynamometer – Communication console and Roller set 43 3.3 ATF Flushing Machine 45
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3.4 AD Scan & Thermo Scan 46 3.5 Thermocouple Type-K 48 3.6 Pressure Sensor 48 3.7 In-series installation of additional oil cooler 52 3.8 The right location of additional oil cooler 52 3.9 Process of Experimental Flowchart 55 3.10 Transmission outflow pressure line(T/M_O) and inflow pressure line (T/M_I) locations 56 3.11 Reducing pressure line (RED) and Torque converter pressure line
(T/C) location 56 4.1 Pressure vs. Shifting Gear (Experiment no 1) 62 4.2 Temperature vs. Shifting Gear (Experiment no 1) 63 4.3 Pressure vs. Shifting Gear (Experiment no 2) 64 4.4 Temperature vs. Shifting Gear (Experiment no 2) 65 4.5 Pressure vs. Shifting Gear (Experiment no 3) 66 4.6 Temperature vs. Shifting Gear (Experiment no 3) 67 4.7 Pressure vs. Shifting Gear (Experiment no 4) 68 4.8 Temperature vs. Shifting Gear graph for Experiment no 4 69 4.9 Pressure vs. Shifting Gear (Experiment no 5) 70 4.10 Temperature vs. Shifting Gear (Experiment no 5) 71 4.11 Pressure vs. Shifting Gear (Experiment no 6) 72 4.12 Temperature vs. Shifting Gear (Experiment no 6) 73 4.13 Pressure vs. Shifting Gear (Experiment no 7) 74 4.14 Temperature vs. Shifting Gear (Experiment no 7) 75 4.15 Comparison Pressure vs. Shifting Gear at reducing line 77 4.16 Comparison Temperature vs. Shifting Gear at reducing line 78
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4.17 Comparison Pressure vs. Shifting Gear at torque converter 79 4.18 Comparison Temperature vs. Shifting Gear at torque converter 80 4.19 Comparison Pressure vs. Shifting Gear at transmission outflow line 81 4.20 Comparison Temperature vs. Shifting Gear at transmission outflow 82
line 4.21 Comparison Pressure vs. Shifting Gear at transmission inflow line 83 4.22 Comparison Temperature vs. Shifting Gear at transmission inflow 84
line 4.23 Comparison Pressure vs. Shifting Gear at cooling system 85 4.24 Comparison Temperature vs. Shifting Gear at cooling system 86 4.24 Comparison Pressure vs. Shifting Gear for used ATF 87 4.24 Comparison Temperature vs. Shifting Gear for used ATF 88
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CHAPTER 1
INTRODUCTION 1.1 INTRODUCTION
The use of automatic transmission in motor vehicles nowadays is increasing
drastically. Automatic transmission is an automobile gearbox that can change gear
ratios automatically as the car moves, thus freeing the driver from having to shift
gears manually. People feel that driving a vehicle with automatic transmission will
give them comfort and make them less fatigued. Therefore, the demand for repairing
automatic gearboxes is also increasing. People who are using automatic transmission
vehicles normally lack the knowledge of how to take care of their cars. Owners of the
vehicles should be aware of preventive maintenance. Those who are engaged in severe
driving need to equip their vehicles with an additional cooling system to reduce the
heat generated during the running of vehicles. Most of the transmission troubles start
from the overheating of its fluid. The transmission can overheat under heavy loads,
such as towing a heavy trailer, rocking the vehicle from the snow, being in severe
traffic jam in hot weather, racing and speeding.
Overheating means the increase in temperature leading to reduced efficiency,
damage or even destruction. At higher temperatures the transmission fluid burns,
losing its lubricating qualities and becomes oxidized leaving deposits all over the
inside of the transmission. Exposed to the heat, the rubber seals and gaskets inside the
transmission become hardened and this causes leaks. The metal parts warp and lose
their strength. All this, sooner or later, results in transmission failure.
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Recently, many research studies and inventions have been carried out to
overcome the problem of transmission overheating. For example, the use of