NAVISTAR MPAPS P-9542-2015 Quality Requirements For Manual Automated Manual Dual Clutch and Automatic Transmissions.pdf

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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. 2015 by Navistar, Inc. OCTOBER 2015 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.: 1510 DATE: OCT 2015 WRITTEN/EDITED BY: T. Glotfelty APPROVED BY: C. Harshbarger SUPERSEDES: Rev. 1506 June 2015 PRINTED COPI

3、ES 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 p

4、ractices and to determine the applicability of regulatory limits prior to use. Change Notice: Updated terminology for Allison 1k/2k and 3k/4k series nomenclature. Addition of input shaft KCC for Eaton Procision DCT. 1.0 APPLICATION This specification covers quality control requirements for purchased

5、 transmission assemblies provided as completed units to Navistar Assembly Plants. 2.0 SCOPE This specification covers the transmission noise requirements, the quality plan, quality control, source approval, suppliers reports, and shipping and identification requirements. 2.1 Restricted Chemical Subs

6、tances Effective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the MPAPS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified the latest issue of all referenced standards shall apply. The following specification

7、s, standards, and regulations are referenced in this specification: Quality System Standard ISO 9001 or TS-16949 CFR Title 29, Part 1910 CFR Title 40, Part 205 (SAE J366) NAVISTAR Manufacturing Std MS-D-13 NAVISTAR MPAPS B-50 NAVISTAR Eng. Design STD. A-16 NAVISTAR MPAPS G-9009 NAVISTAR TMS-9541 NAV

8、ISTAR MPAPS P-9543 SAE J617 SAE J1463 4.0 GENERAL REQUIREMENTS 4.1 Noise Requirement - 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

9、), shall not exceed 72 dBA. In order to verify compliance with this requirement, 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 standar

10、d deviations, shall not exceed 72.0 dBA for each of the gear ratios measured during 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, Du

11、al Clutch, and Automatic Transmissions REVISION: 1510 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. 2015 by Navistar, Inc. OCTOBER 2015 Page 2 of 7 dri

12、ve-by gear ratios shall not exceed 70.0 dBA. The supplier shall submit a report (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 p

13、rocedure for each transmission model. 4.1.2 Cab Interior Noise The contribution 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

14、 is stationary, with engine at idle, transmission in neutral and the clutch engaged. 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

15、interior cab noise will be developed and the test procedures agreed to between the 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 trans

16、mission assembly or test fluids/oils that may remain or leave a residue inside the 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

17、will be established by mutual agreement between Navistar and the supplier. The following 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.

18、1.1 AMT, DCT, Eaton Manual, and Tremec Manual 5.1.1.2 AMT, DCT, Eaton Manual, and 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,

19、DCT, and Manual 5.1.1.11 AMT and Manual 5.1.1 Manual and Automated Manual Transmissions 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 dep

20、ending on the suppler to be delivered to Navistar. Not all ABR features have controlled NUMBER: MPAPS P-9542 Quality Requirements For Manual, Automated Manual, Dual Clutch, and Automatic Transmissions REVISION: 1510 This document is restricted and may not be sent outside Navistar, Inc. or reproduced

21、 without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. OCTOBER 2015 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 inst

22、all the switch, which is supplier controlled, or not install the switch. Dimensions of 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 p

23、ossible ABR features, as well as the Key Critical Characteristics (KCC) within those ABR 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 t

24、ransmissions that share the same basic design and external dimensions. A drawing 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

25、function” such as transmission size impacts or transmission mount changes must be approved 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. A subsection of this ABR will be ap

26、plicable to AMTs and DCTs only. Controls CAN Communication Rate will define the baud rate (250k vs. 500k) at which the J1939 network communicates at. 5.1.1.2 Shift Controls Applicable to manual transmissions only. Some suppliers have the ability to have the shifter tower in a forward, or center/stan

27、dard 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 separately, the shift tower will h

28、ave 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. 5.1.1.3 Output Shaft Speed Sensor This ABR category defines the number

29、 and type of Output Shaft Speed Sensors to be installed by the transmission supplier prior 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

30、 “form, fit, or function” must be approved by Navistar through the SREA Process. 5.1.1.4 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 KC

31、Cs for this ABR category. However, any changes to the Reverse Switch from the supplier 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

32、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 Neutral Start Switch from the supplier affecting “form, fit, or function” must be approved by Navistar through the SREA Process. NUMBER: M

33、PAPS P-9542 Quality Requirements For Manual, Automated Manual, Dual Clutch, and Automatic Transmissions REVISION: 1510 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 pate

34、nt liability. 2015 by Navistar, Inc. OCTOBER 2015 Page 4 of 7 5.1.1.6 Rear Bearing Retainer 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. H

35、owever, any changes to the Rear Bearing Retainer from the supplier affecting “form, fit, 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 prio

36、r to delivery to Navistar. The output shaft dimensions are defined by the supplier in their design and the supplier must approve the yoke / flange possibilities. The yoke / flange selection will be done by the Navistar Driveline Group (Reference TMS-9541) and will be released on the ABR by the Trans

37、mission Group. There are no KCCs for this ABR category. 5.1.1.8 Internal Lube Pump Provision This ABR category 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

38、 of the suppliers assembly. The transmission supplier must inform Navistar what possibilities exist so Navistar 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

39、 transmission supplier prior to delivery to Navistar. The clutch housing is designed and released by the transmission 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

40、ABR codes based on the suppliers design. The KCCs for the Clutch Housing are: 1. Engine Mounting diameter 2. 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

41、the transmission supplier prior to delivery to Navistar. The input spline is designed and released by the transmission 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 G

42、auging is Acceptable) 3. Damper Assembly Disc Hub 5.1.1.11 Thru-Shaft PTO This ABR category defines if a thru shaft PTO provision is installed 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

43、 the suppliers assembly. The transmission supplier must inform Navistar what possibilities NUMBER: MPAPS P-9542 Quality Requirements For Manual, Automated Manual, Dual Clutch, and Automatic Transmissions REVISION: 1510 This document is restricted and may not be sent outside Navistar, Inc. or reprodu

44、ced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2015 by Navistar, Inc. OCTOBER 2015 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 AB

45、R 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 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 transmissio

46、n feature codes. The definition of a family shall be transmissions that share the same basic design and external dimensions. A drawing 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 Tr

47、ansmission from the supplier affecting “form, fit, or function” such as transmission size impacts or transmission mount changes must be 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 suppl

48、ier 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 (1k/2k series) 3. Adapter bolt Torque (3k/4k series = Shipped Installed) 5.1.2.3 Torque Converter Housing This ABR category defines what torque converter housing shall be instal