NAVISTAR TMS 9542-2003 Quality Requirements For Manual Transmissions Automatic Transmissions And Manual Shift Controls (Revision D Includes Appendix).pdf

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1、 INTERNATIONAL TRUCK AND ENGINE CORPORATION TMS (TRUCK MATERIAL SPECIFICATION)NUMBER: TMS-9542 TITLE : Quality Requirements For Manual Transmissions, Automatic Transmissions, And Manual Shift Controls REVISION: D WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering DATE ISSUED

2、: December 2003 PRINTED COPIES 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 app

3、ropriate safety and health practices and to determine the applicability of regulatory limits prior to use. Change Notice: Reduced allowable noise levels in cab interior, and made editorial changes. Reference: File: 13 Keywords: Transmission and Shift Control Quality 1.0 APPLICATION This specificatio

4、n covers quality control requirements for purchased transmission assemblies provided as completed units to International plants. 2.0 SCOPE This specification covers the transmission noise requirements, the quality plan, painting, quality control, source approval, suppliers reports, and shipping and

5、identification requirements. 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: INTERNATIONAL TMS-9009 Quality System Standard QS-9000 (ISO 9000 or

6、 TS-16949) INTERNATIONAL TMS-9541 INTERNATIONAL Eng. Design STD. A-16 INTERNATIONAL TMS-9543 INTERNATIONAL Manufacturing Std D-13 CFR Title 29, Part 1910 CFR Title 40, Part 205/SAE J366 4.0 GENERAL REQUIREMENTS 4.1 Noise Requirement - All Transmissions 4.1.1 Drive-by-Noise The noise level contributi

7、on 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, the transmission shall be tested in all possible drive-by gear ratios a

8、nd 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 during the drive-by test. If a small statistical sample is tested, the aver

9、age transmission contributed noise level measured in each of the possible drive-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,

10、 to the Vehicle Acoustical Group at TDTC as a part of the qualification procedure for each transmission model. This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are require

11、d to assume all patent liability. 2003 by International Truck and Engine Corporation. DECEMBER 2003 Page 1 of 5 NUMBER: TITLE: Quality Requirements For Manual TransmissionsREVISION: TMS-9542 Automatic Transmission, And Manual Shift Controls D 4.1.2 Cab Interior Noise The contribution of an isolated

12、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 52 dBA (Note: effective June 1, 2006 this value is reduced to 49 dBA) when the vehicle is stationary, with engine at i

13、dle, 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 65 dBA (Note: effective June 1, 2006 this value is reduced to 62 dBa). (A test to evaluate the

14、gearshift lever contribution to interior cab noise will be developed and the test procedures agreed to between the Vehicle Acoustics Group at TDTC and the transmission supplier.) 4.2 Painting Transmissions shall be supplied to the plants with a prime paint or corrosion preventive compound meeting th

15、e requirements of Class IV per TMS-9009. All paints or coatings used must be compatible for recoating with chassis paints used in International Assembly Plants. 5.0 QUALITY All transmissions shall be supplied in a clean and dry condition. All transmission assembly or test fluids/oils that may remain

16、 or leave a residue in the transmission must be compatible with International 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 Int

17、ernational and the supplier. The following items, where applicable,* will be included in the control plan as dimensional features for management by statistical process control.* 5.1.1 Manual Transmissions 5.1.1.1 Clutch Housing KCC1. 2. Engine Mounting diameter Alignment of Pedal Shaft Bore 5.1.1.2

18、Input Shaft 1. Pilot Diameter 2. Tooth Thickness and Spacing (Composite Gauging is Acceptable) KCC5.1.1.3 Shift Bar Housing KCC1. 2. Spot Face Depth (Reverse Light Switch Hole) Spot Face Depth (Neutral Switch Hole) 5.1.1.4 Rear Bearing Cap KCC1. 2. 3. 4. 5. Spot Face Depth (Magnetic Speedo Pick Up H

19、ole-threaded) Spot Face Depth (Sensor Speedo Pick Up Hole-plug in) End Yoke or Flange Seal Diameter Run Out (If supplied with transmission, ref. TMS-9541.) Speedometer Rotor Height Parking Brake Pivot Arm - Hole Depth and Diameter (when supplied with Bendix 9X3 Parking Brake) This document is restri

20、cted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2003 by International Truck and Engine Corporation. DECEMBER 2003 Page 2 of 5 NUMBER: TITLE: Quality

21、 Requirements For Manual TransmissionsREVISION: TMS-9542 Automatic Transmission, And Manual Shift Controls D 5.1.1.5 Input Shaft Bearing Cap (Stem Cap Push Type Clutch) KCC1. 2. Stem Outside Diameter Overall Stem Length 5.1.1.6 Output Shaft KCC1. 2. 3. Spline Pitch Diameter (rolled spline) Spline Ou

22、tside Diameter (machined spline) Spline Tooth Thickness (machined spline) 5.1.2 Automatic Transmissions 5.1.2.1 Converter Housing (SAE Mounting Face) KCC1. 2. 3. Bolt Hole Location Pilot Diameter Face Runout 5.1.2.2 Torque Converter KCC1. 2. 3. Pilot Diameter Studs/Lugs/Bolt Holes - Location (1000 t

23、hru 2500 series) Adapter bolt Torque (WT = Shipped Installed) 5.1.2.3 Parking Brake KCC1. 2. 3. Pilot Diameter (At, MT) Brake and Linkage Mounting Bolt Hole Location (1000 thru 2500 series: WT = Shipped Installed) Parking Brake Pivot Arm - Hole Depth and Diameter (when supplied with Bendix 9X3 Parki

24、ng Brake) 5.1.2.4 Output Drive (when shipped without the Output Yoke) KCC1. 2. Output Shaft Spline Tooth Thickness (Composite Gauging is Acceptable) Output Shaft Spline Tooth Spacing (Composite Gauging is Acceptable) 5.1.2.5 Selector Shaft KCC1. Pilot Profile (1000 thru 2500)5.1.2.6 Transmission Mou

25、nts (as applicable MT series is obsolete) KCC1. Hole Location (as applicable) 2. Thread Data (as applicable) This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required

26、to assume all patent liability. 2003 by International Truck and Engine Corporation. DECEMBER 2003 Page 3 of 5 NUMBER: TITLE: Quality Requirements For Manual TransmissionsREVISION: TMS-9542 Automatic Transmission, And Manual Shift Controls D 5.1.3 SHIFT CONTROL 5.1.3.1 Shift Lever Isolator (Two Piece

27、 Design) KCC1. 2. Internal Sleeve Diameter (Attribute Gauging is Acceptable) Crosshole Diameter (Attribute Gauging is Acceptable) 5.1.3.2 Shift Lever Configuration KCC1. Tang Thickness 2. Diameter of the Shaft 3. Tang Spherical Diameter Stub Crosshole (above the ball 5.1.3.3 Shift Tower KCC1. Hole D

28、iameter 2. True Position of the Holes 5.1.3.4 Leak Control KCC1. Hand Valve Leak Integrity 5.1.3.5 Remote Control KCC1. Remote Control Tie Rod Position 2. Remote Hole Diameter 3. Remote Hole Pattern * Additional characteristics for inclusion in the control plan may be specified on the engineering dr

29、awing and/or purchase order. * See International Engineering Design Standard A-16. 6.0 SOURCE APPROVAL AND QUALITY CONTROL 6.1 Supplier Requirements Suppliers must be registered to QS-9000 Quality System Requirements. A mutually acceptable Quality Control Plan as described therein is required for so

30、urce approval to the requirements of this specification. Alternatively, International will accept ISO 9000 or TS-16949 registration, providing the supplier can also fulfill all AIAG PPAP documentation and approval requirements 6.2 Approval Parts supplied against contracts or purchase orders citing t

31、his specification shall be equivalent in all respects to those samples that were approved by the purchaser. No changes in formulation or processing practices are permitted without approval. In the event that changes in material, properties, processing practices, construction, color, or labeling of t

32、he product are required, the supplier shall notify Materials Engineering at TDTC and Purchasing and Logistics of the proposed change(s). Test data indicating conformance to all requirements of this specification, test samples, and new or amended or updated Material Safety Data Sheet(s) (MSDS), in ac

33、cordance with CFR Title 29, Part 1910 shall be submitted with the request for change. This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent li

34、ability. 2003 by International Truck and Engine Corporation. DECEMBER 2003 Page 4 of 5 NUMBER: TMS-9542 TITLE: Quality Requirements For Manual TransmissionsAutomatic Transmission, And Manual Shift Controls REVISION: D This document is restricted and may not be sent outside International Truck and En

35、gine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2003 by International Truck and Engine Corporation. DECEMBER 2003 Page 5 of 5 6.3 Process Control The supplier shall either perform and report results of tests

36、 on specific lots of parts produced or provide statistical evidence of the lot having been produced in a state of statistical control and with a process capable of providing all required properties. The part supplier and the plant metallurgist and/or the quality control manager of the using Internat

37、ional plant may determine testing and reporting requirements on specific products. 7.0 SHIPPING, PACKING AND IDENTIFICATION Loading, packing, and identification shall be in accordance with Manufacturing Std. D-13. 8.0 DESIGNATION ON DRAWINGS The drawing will utilize the KCC symbol with a note that: Completed assemblies will comply with requirements of TMS-9542. A.0 GENERAL INFORMATION A.1 Suppliers Reports Suppliers shall submit a report detailing their drive-by noise test results for each new transmission. Supplier reports shall follow the format described in TMS-9543.